SM PC600 (LC) - 8 30001-Up Sen00128-12

SEN00128-12
HYDRAULIC EXCAVATOR
-8 PC600 PC600LC -8
SERIAL NUMBERS
PC600- 30001 PC600LC- 30001
and up
SEN00130-12
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
Machine model PC600-8 PC600LC-8 Serial number 30001 and up 30001 and up
00 Index and foreword

Index
Composition of shop manual ............................................................................................................................... 2 Table of contents .................................................................................................................................................. 4
PC600-8
SEN00130-12
Composition of shop manual

The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title Shop Manual, contents binder, binder label and tabs 00 Index and foreword Index Foreword and general information 01 Specification Specification and technical data 10 Structure, function and maintenance standard Engine and cooling system Power train Undercarriage and frame Hydraulic system, Part 1 Hydraulic system, Part 2 Work equipment Cab and its attachments Electrical system 20 Standard value table Standard service value table 30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 40 Troubleshooting Failure code table and fuse locations General information on troubleshooting Troubleshooting by failure code (Display of code), Part 1 Troubleshooting by failure code (Display of code), Part 2 Troubleshooting by failure code (Display of code), Part 3 Troubleshooting of electrical system (E-mode) Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of engine (S-mode) Form Number SEN00128-12 SEN00129-12 SEN00130-12 q SEN00131-04 SEN00132-03 SEN00133-03 SEN00134-06 SEN00135-02 q SEN00136-01 q SEN00137-01 SEN00138-01 SEN00139-02 SEN00140-03 SEN00141-00 SEN00142-04 q SEN00394-04 SEN00395-04 q SEN00443-04 SEN00444-04 q SEN00445-03 SEN00446-04 SEN03960-03 q SEN00447-04 q SEN00448-02 SEN00449-02 SEN00450-01 SEN00451-03 q SEN00452-02 SEN00453-02
PC600-8
SEN00130-12
SEN01061-04 SEN01062-04 q SEN01063-02 SEN01064-02 SEN01065-02 q SEN01066-03 q SEN01067-03 SEN01068-02 SEN01069-01 SEN01070-02 SEN00143-04 SEN00144-02 SEN00145-04
50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system, Part 1 Engine and cooling system, Part 2 Power train Undercarriage and frame Hydraulic system Work equipment Cab and its attachments Electrical system 90 Diagrams and drawings Hydraulic diagrams and drawings Electrical diagrams and drawings
PC600-8
SEN00130-12
Table of contents
00 Index and foreword Index SEN00130-12 Composition of shop manual ........................................................................................................ 2 Table of contents........................................................................................................................... 4 Foreword and general information SEN00131-04 Safety notice ................................................................................................................................. 2 How to read the shop manual....................................................................................................... 7 Explanation of terms for maintenance standard ........................................................................... 9 Handling of electric equipment and hydraulic component ............................................................ 11 Handling of connectors newly used for engines ........................................................................... 20 How to read electric wire code...................................................................................................... 23 Precautions when carrying out operation ..................................................................................... 26 Method of disassembling and connecting push-pull type coupler ................................................ 29 Standard tightening torque table ................................................................................................... 32 Conversion table ........................................................................................................................... 36 01 Specification 01 Specification SEN00133-03 Specification and technical data ....................................................................................................... 2 Specification drawings .................................................................................................................. 2 Working range drawings ............................................................................................................... 4 Specifications................................................................................................................................ 6 Weight table .................................................................................................................................. 14 Table of fuel, coolant and lubricants ............................................................................................. 18 10 Structure, function and maintenance standard Engine and cooling system SEN00135-02 Engine and cooling system .............................................................................................................. 2 Parts related to engine.................................................................................................................. 2 PTO .............................................................................................................................................. 4 Fan, control and PTO lubrication pump ........................................................................................ 6 Radiator, oil cooler ........................................................................................................................ 7 Power train SEN00136-01 Power train ....................................................................................................................................... 2 Power train.................................................................................................................................... 2 Final drive ..................................................................................................................................... 5 Sprocket........................................................................................................................................ 8 Swing circle................................................................................................................................... 10 Swing machinery .......................................................................................................................... 12 Undercarriage and frame SEN00137-01 Undercarriage and frame ................................................................................................................. 2 Track frame, recoil spring ............................................................................................................. 2 Idler............................................................................................................................................... 4 Carrier roller.................................................................................................................................. 6 Track roller .................................................................................................................................... 7 Track shoe .................................................................................................................................... 8 Hydraulic system, Part 1 SEN00138-01 Hydraulic system, Part 1 .................................................................................................................. 2 Hydraulic piping drawing............................................................................................................... 2 Hydraulic tank, hydraulic filter ....................................................................................................... 4 Hydraulic pump (piston pump)...................................................................................................... 6 Line oil filter................................................................................................................................... 34 Cooling fan pump.......................................................................................................................... 36 Cooling fan motor ......................................................................................................................... 44
PC600-8
SEN00130-12
Hydraulic system, Part 2 SEN00139-02 Hydraulic system, Part 2 .................................................................................................................. 2 Control valve................................................................................................................................. 2 Swing motor.................................................................................................................................. 21 Swing brake .................................................................................................................................. 24 Safety valve .................................................................................................................................. 25 Reverse prevention valve ............................................................................................................. 27 Center swivel joint ........................................................................................................................ 30 Travel motor.................................................................................................................................. 31 Parking brake ............................................................................................................................... 36 Brake valve ................................................................................................................................... 38 Set pressures varying mechanism ............................................................................................... 41 Valve control ................................................................................................................................. 42 Work equipment, swing PPC valve............................................................................................... 44 Travel PPC valve .......................................................................................................................... 48 Service PPC valve ........................................................................................................................ 50 PPC accumulator.......................................................................................................................... 51 PPC shuttle valve ......................................................................................................................... 52 Solenoid valve .............................................................................................................................. 53 Boom holding valve ...................................................................................................................... 58 Boom LOWER regeneration valve ............................................................................................... 62 Quick return valve......................................................................................................................... 65 Hydraulic cylinder ......................................................................................................................... 68 Work equipment SEN00140-03 Work equipment ............................................................................................................................... 2 Work equipment............................................................................................................................ 2 Dimensions of work equipment .................................................................................................... 6 Cab and its attachments SEN00141-00 Cab and its attachments................................................................................................................... 2 Air conditioner piping .................................................................................................................... 2 Electrical system SEN00142-04 Engine control............................................................................................................................... 2 Machine control system diagram .................................................................................................. 7 Monitor system ............................................................................................................................. 31 Sensors ........................................................................................................................................ 46 KOMTRAX system ....................................................................................................................... 50 20 Standard value table Standard service value table SEN00395-04 Standard value table for engine .................................................................................................... 2 Standard value table for chassis................................................................................................... 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN00444-04 Tools for testing, adjusting and troubleshooting ........................................................................... 4 Measuring engine speed .............................................................................................................. 9 Measuring intake air pressure (boost pressure) ........................................................................... 10 Measuring exhaust gas temperature ............................................................................................ 11 Measuring exhaust gas color........................................................................................................ 12 Adjusting valve clearance ............................................................................................................. 13 Measuring compression pressure ................................................................................................ 14 Measuring blow-by pressure ........................................................................................................ 16 Measuring engine oil pressure ..................................................................................................... 16 Testing EGR valve and bypass valve drive oil pressure ............................................................... 17 Handling equipment in fuel circuit................................................................................................. 18 Releasing remaining pressure in fuel system ............................................................................... 18 Measuring fuel pressure ............................................................................................................... 19
PC600-8
SEN00130-12
Reduced cylinder mode operation ................................................................................................ 20 No-injection cranking .................................................................................................................... 20 Testing leakage from pressure limiter and return rate from injector.............................................. 21 Bleeding air from fuel circuit ......................................................................................................... 23 Testing fuel system for leakage .................................................................................................... 25 Testing and adjusting alternator belt tension ................................................................................ 26 Testing and adjusting air conditioner compressor belt tension ..................................................... 27 Testing clearance of swing circle bearing ..................................................................................... 28 Testing and adjusting track shoe tension...................................................................................... 29 Testing and adjusting work equipment, swing, and travel circuit oil pressures............................. 30 Testing and adjusting control circuit oil pressure .......................................................................... 35 Testing and adjusting piston pump control oil pressure ................................................................ 37 Testing servo piston stroke ........................................................................................................... 43 Measuring PPC valve output pressure ......................................................................................... 44 Measuring outlet pressures of solenoid valve and PPC shuttle valve .......................................... 48 Adjusting work equipment, swing PPC valve................................................................................ 54 Testing and adjusting travel deviation........................................................................................... 55 Measuring fan speed .................................................................................................................... 57 Measuring fan circuit oil pressure ................................................................................................. 57 Inspection of locations of hydraulic drift of work equipment ......................................................... 58 Measuring oil leakage................................................................................................................... 59 Releasing remaining pressure in hydraulic circuit ........................................................................ 63 Bleeding air from each part........................................................................................................... 64 Inspection procedures for diode ................................................................................................... 67 Testing and adjusting, Part 2 SEN00445-03 Special function of machine monitor ............................................................................................. 2 Handling controller voltage circuit ................................................................................................. 36 Procedure for turning on KOMTRAX terminal .............................................................................. 37 KOMTRAX terminal lamp indications ........................................................................................... 40 Preparation work for troubleshooting electrical system ................................................................ 43 Adjusting mirrors........................................................................................................................... 45 Pm-clinic service........................................................................................................................... 46 Undercarriage inspection.............................................................................................................. 52 40 Troubleshooting Failure code table and fuse locations SEN03960-03 Failure codes table ....................................................................................................................... 2 Fuse locations............................................................................................................................... 6 General information on troubleshooting SEN00447-04 Points to remember when troubleshooting ................................................................................... 2 Sequence of events in troubleshooting......................................................................................... 3 Checks before troubleshooting ..................................................................................................... 4 Classification and procedures of troubleshooting ......................................................................... 5 Information contained in troubleshooting table ............................................................................. 6 Failure-looking phenomenon and troubleshooting No. ................................................................. 8 Connection table for connector pin numbers ................................................................................ 12 T- branch box and T- branch adapter table................................................................................... 48 Troubleshooting by failure code (Display of code), Part 1 SEN00448-02 Failure code [A000N1] Eng. Hi Out of Std .................................................................................... 3 Failure code [AA10NX] Aircleaner clogging.................................................................................. 4 Failure code [AB00KE] Charge Voltage Low ................................................................................ 6 Failure code [B@BAZG] Eng. Oil Press. Low............................................................................... 8 Failure code [B@BAZK] Eng. Oil Level Low................................................................................. 10 Failure code [B@BCNS] Eng. Water Overheat ............................................................................ 11 Failure code [B@BCZK] Eng. Water Lvl Low ............................................................................... 12 Failure code [B@HANS] Hydr. Oil Overheat ................................................................................ 14 Failure code [CA111] ECM Critical Internal Failure....................................................................... 15 Failure code [CA115] Eng Ne and Bkup Speed Sens Error.......................................................... 16
PC600-8
SEN00130-12
Failure code [CA122] Chg Air Press Sensor High Error ............................................................... 18 Failure code [CA123] Chg Air Press Sensor Low Error................................................................ 20 Failure code [CA131] Throttle Sensor High Error ......................................................................... 22 Failure code [CA132] Throttle Sensor Low Error.......................................................................... 24 Failure code [CA135] Eng Oil Press Sensor High Error ............................................................... 26 Failure code [CA141] Eng Oil Press Sensor Low Error ................................................................ 28 Failure code [CA144] Coolant Temp Sens High Error .................................................................. 30 Failure code [CA145] Coolant Temp Sens Low Error ................................................................... 32 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................... 34 Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................ 36 Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................... 36 Failure code [CA221] Ambient Press Sens High Error ................................................................. 38 Failure code [CA222] Ambient Press Sens Low Error.................................................................. 40 Failure code [CA227] Sens Supply 2 Volt High Error ................................................................... 42 Failure code [CA234] Eng Overspeed .......................................................................................... 44 Failure code [CA238] Ne Speed Sens Supply Volt Error .............................................................. 45 Failure code [CA263] Fuel Temp Sensor High Error .................................................................... 46 Failure code [CA265] Fuel Temp Sensor Low Error ..................................................................... 48 Failure code [CA271] IMV/PCV1 Short Error ............................................................................... 49 Failure code [CA272] IMV/PCV1 Open Error ............................................................................... 50 Failure code [CA273] PCV2 Short Error ....................................................................................... 51 Failure code [CA274] PCV2 Open Error....................................................................................... 52 Troubleshooting by failure code (Display of code), Part 2 SEN00449-02 Failure code [CA322] Inj #1 (L#1) Open/Short Error .................................................................... 4 Failure code [CA323] Inj #5 (L#5) Open/Short Error .................................................................... 6 Failure code [CA324] Inj #3 (L#3) Open/Short Error .................................................................... 8 Failure code [CA325] Inj #6 (L#6) Open/Short Error .................................................................... 10 Failure code [CA331] Inj #2 (L#2) Open/Short Error .................................................................... 12 Failure code [CA332] Inj #4 (L#4) Open/Short Error .................................................................... 14 Failure code [CA342] Calibration Code Incompatibility ................................................................ 16 Failure code [CA351] Injectors Drive Circuit Error........................................................................ 17 Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................... 19 Failure code [CA386] Sens Supply 1 Volt High Error ................................................................... 20 Failure code [CA441] Battery Voltage Low Error .......................................................................... 22 Failure code [CA442] Battery Voltage High Error ......................................................................... 22 Failure code [CA449] Rail Press Very High Error ......................................................................... 23 Failure code [CA451] Rail Press Sensor High Error..................................................................... 24 Failure code [CA452] Rail Press Sensor Low Error ..................................................................... 26 Failure code [CA553] Rail Press High Error ................................................................................. 26 Failure code [CA554] Rail Press Sensor In Range Error ............................................................. 27 Failure code [CA559] Rail Press Low Error .................................................................................. 28 Failure code [CA689] Eng Ne Speed Sensor Error ...................................................................... 32 Failure code [CA731] Eng Bkup Speed Sens Phase Error........................................................... 34 Failure code [CA757] All Persistent Data Lost Error..................................................................... 35 Failure code [CA778] Engine Bkup Speed Sensor Error .............................................................. 36 Failure code [CA1228] EGR Valve Servo Error 1 ......................................................................... 38 Failure code [CA1625] EGR Valve Servo Error 2 ......................................................................... 39 Failure code [CA1626] BP Valve Sol Current High Error.............................................................. 40 Failure code [CA1627] BP Valve Sol Current Low Error............................................................... 42 Failure code [CA1628] Bypass Valve Servo Error 1 ..................................................................... 43 Failure code [CA1629] Bypass Valve Servo Error 2 ..................................................................... 44 Failure code [CA1631] BP Valve Pos Sens High Error................................................................. 45 Failure code [CA1632] BP Valve Pos Sens Low Error ................................................................. 47 Failure code [CA1633] KOMNET Datalink Timeout Error............................................................. 48 Failure code [CA1642] EGR Inlet Press Sens Low Error ............................................................. 51 Failure code [CA1653] EGR Inlet Press Sens High Error ............................................................ 52 Failure code [CA2185] Throt Sens Sup Volt High Error ............................................................... 54 Failure code [CA2186] Throt Sens Sup Volt Low Error ................................................................ 56 Failure code [CA2249] Rail Press Very Low Error........................................................................ 57
PC600-8
SEN00130-12
Failure code [CA2271] EGR Valve Pos Sens High Error.............................................................. 58 Failure code [CA2272] EGR Valve Pos Sens Low Error............................................................... 60 Failure code [CA2351] EGR Valve Sol Current High Error ........................................................... 62 Failure code [CA2352] EGR Valve Sol Current Low Error............................................................ 64 Failure code [CA2555] Grid Htr Relay Volt Low Error................................................................... 65 Failure code [CA2556] Grid Htr Relay Volt High Error.................................................................. 66 Troubleshooting by failure code (Display of code), Part 3 SEN00450-01 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 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 Troubleshooting of electrical system (E-mode) SEN00451-02 E-1 Engine does not start (Engine does not rotate)...................................................................... 3 E-2 Preheater does not operate ................................................................................................... 6 E-3 Auto engine warm-up device does not work .......................................................................... 8 E-4 Auto-decelerator does not operate......................................................................................... 9 E-5 All work equipment, swing and travel do not move ................................................................ 10 E-6 Power max. function does not operate................................................................................... 12 E-7 Machine push-up function does not operate normally ........................................................... 13 E-8 Any item is not displayed on machine monitor....................................................................... 15 E-9 Part of display on machine monitor is missing ....................................................................... 16 E-10 Machine monitor displays contents irrelevant to the model ................................................. 16 E-11 Fuel level monitor red lamp lights up while engine is running .............................................. 17 E-12 Engine coolant temperature gauge does not display correctly ............................................ 18 E-13 Hydraulic oil temperature gauge does not display correctly................................................. 20 E-14 Fuel gauge does not display correctly.................................................................................. 21 E-15 Swing lock monitor does not display correctly ..................................................................... 22 E-16 When monitor switch is operated, nothing is displayed ....................................................... 24
PC600-8
SEN00130-12
E-17 Wiper and window washer do not work ............................................................................... 26 E-18 "Boom Raise" is not correctly displayed in monitoring function ........................................... 34 E-19 "Boom Lower" is not correctly displayed in monitoring function........................................... 36 E-20 "Arm IN" is not correctly displayed in monitoring function.................................................... 38 E-21 "Arm OUT" is not correctly displayed in monitoring function................................................ 39 E-22 "Bucket CURL" is not correctly displayed in monitoring function ......................................... 40 E-23 "Bucket DUMP" is not correctly displayed in monitoring function ........................................ 41 E-24 "Swing" is not correctly displayed in monitoring function ..................................................... 42 E-25 "Travel" is not correctly displayed in monitoring function ..................................................... 44 E-26 Air conditioner does not work............................................................................................... 46 E-27 Step light does not light up or go off..................................................................................... 48 E-28 Electric grease gun does not operate .................................................................................. 52 E-29 Travel alarm does not sound or does not stop sounding ..................................................... 54 E-30 Horn does not sound............................................................................................................ 56 E-31 Bottom dump does not move ............................................................................................... 58 Troubleshooting of hydraulic and mechanical system (H-mode) SEN00452-02 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.......................................................................................................... 23 H-12 Bottom dump does not move ............................................................................................... 23 H-13 Hydraulic drift of work equipment is large ............................................................................ 24 H-14 Time lag of work equipment is large .................................................................................... 25 H-15 Power max. function does not operate or stop .................................................................... 26 H-16 Machine push-up function does not operate or stop............................................................ 26 H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is low .... 27 H-18 When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel speed is low ............................................................................................................... 27 H-19 When arm and swing are operated simultaneously, swing speed is low ............................. 28 H-20 Machine deviates in one direction ....................................................................................... 29 H-21 Machine deviates largely at start ......................................................................................... 31 H-22 Travel deviation is large during compound operation .......................................................... 32 H-23 Travel speed or power is low ............................................................................................... 33 H-24 Machine does not travel (only one track) ............................................................................. 34 H-25 Travel speed does not change............................................................................................. 35 H-26 Upper structure does not swing ........................................................................................... 36 H-27 Swing speed or acceleration is low...................................................................................... 37 H-28 Upper structure overruns excessively when it stops swinging............................................. 38 H-29 Large shock is made when upper structure stops swinging ................................................ 39 H-30 Large abnormal sound is made when upper structure stops swinging ................................ 40 H-31 Hydraulic drift of swing is large ............................................................................................ 41 Troubleshooting of engine (S-mode) SEN00453-02 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
PC600-8
SEN00130-12
S-7 Exhaust smoke is black (incomplete combustion) ................................................................. S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................... S-9 Oil becomes contaminated quickly......................................................................................... S-10 Fuel consumption is excessive ............................................................................................ S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................... S-12 Oil pressure drops ................................................................................................................ S-13 Oil level rises (Entry of coolant or fuel) ................................................................................ S-14 Coolant temperature becomes too high (overheating) ......................................................... S-15 Abnormal noise is made....................................................................................................... S-16 Vibration is excessive...........................................................................................................
16 17 18 19 20 21 22 24 25 26
50 Disassembly and assembly General information on disassembly and assembly SEN01062-04 How to read this manual ............................................................................................................... 2 Coating materials list .................................................................................................................... 4 Special tools list ............................................................................................................................ 7 Sketches of special tools .............................................................................................................. 13 Engine and cooling system, Part 1 SEN01063-02 Removal and installation of fuel supply pump assembly .............................................................. 2 Removal and installation of cylinder head assembly .................................................................... 8 Removal and installation of fuel injector assembly ....................................................................... 24 Removal and installation of engine front seal ............................................................................... 27 Removal and installation of engine rear seal ................................................................................ 31 Engine and cooling system, Part 2 SEN01064-02 Removal and installation of engine, PTO and hydraulic pump assembly ..................................... 2 Removal and installation of radiator assembly ............................................................................. 9 Removal and installation of hydraulic oil cooler assembly............................................................ 11 Removal and installation of aftercooler assembly......................................................................... 13 Removal and installation of fan motor assembly .......................................................................... 15 Removal and installation of fuel tank assembly ............................................................................ 19 Power train SEN01065-02 Removal and installation of PTO assembly .................................................................................. 2 Disassembly and assembly of PTO assembly.............................................................................. 4 Removal and installation of swing motor and swing machinery assembly ................................... 7 Disassembly and assembly of swing machinery assembly .......................................................... 8 Removal and installation of swing circle assembly ....................................................................... 15 Disassembly and assembly of final drive assembly...................................................................... 16 Undercarriage and frame SEN01066-03 Removal and installation of track shoe assembly ......................................................................... 2 Disassembly and assembly of 1 link in field ................................................................................. 4 Removal and installation of idler, recoil spring assembly ............................................................. 8 Disassembly and assembly of idler assembly .............................................................................. 9 Disassembly and assembly of recoil spring assembly.................................................................. 12 Removal and installation of track roller assembly......................................................................... 14 Disassembly and assembly of track roller assembly .................................................................... 15 Removal and installation of carrier roller assembly ...................................................................... 18 Disassembly and assembly of carrier roller assembly.................................................................. 19 Removal and installation of revolving frame assembly ................................................................. 22 Removal and installation of counterweight assembly ................................................................... 24 Removal and installation of counterweight remover assembly ..................................................... 25 Hydraulic system SEN01067-03 Removal and installation of hydraulic tank assembly ................................................................... 2 Removal and installation of hydraulic pump assembly ................................................................. 4 Removal and installation of control valve and solenoid valve assembly ...................................... 7 Disassembly and assembly of control valve assembly................................................................. 9 Disassembly and assembly of main control valve assembly ........................................................ 10 Removal and installation of swing motor assembly ...................................................................... 14 Removal and installation of center swivel joint assembly ............................................................. 15
10
PC600-8
SEN00130-12
Disassembly and assembly of center swivel joint assembly......................................................... 16 Disassembly and assembly of work equipment PPC valve assembly.......................................... 18 Disassembly and assembly of travel PPC valve assembly .......................................................... 20 Disassembly and assembly of hydraulic cylinder assembly ......................................................... 23 Disassembly and assembly of grease gun assembly ................................................................... 29 Work equipment SEN01068-02 Removal and installation of bucket cylinder assembly (Backhoe specification) ........................... 2 Removal and installation of bucket cylinder assembly (Loading shovel specification) ................. 4 Removal and installation of arm cylinder assembly (Backhoe specification)................................ 6 Removal and installation of arm cylinder assembly (Loading shovel specification) ..................... 8 Removal and installation of boom cylinder assembly (Backhoe specification)............................. 10 Removal and installation of boom cylinder assembly (Loading shovel specification)................... 12 Removal and installation of bottom dump cylinder assembly (Loading shovel specification)....... 14 Removal and installation of bucket assembly (Backhoe specification)......................................... 15 Removal and installation of bucket assembly (Loading shovel specification) .............................. 17 Removal and installation of arm assembly (Backhoe specification) ............................................. 18 Removal and installation of arm assembly (Loading shovel specification)................................... 20 Removal and installation of boom assembly (Backhoe specification) .......................................... 21 Removal and installation of boom assembly (Loading shovel specification) ................................ 23 Removal and installation of work equipment (Backhoe specification) .......................................... 25 Removal and installation of work equipment (Loading shovel specification)................................ 27 Cab and its attachments SEN01069-01 Removal and installation of operators cab................................................................................... 2 Removal and installation of operators cab glass (stuck glass) .................................................... 5 Removal and installation of front window assembly ..................................................................... 15 Electrical system SEN01070-02 Removal and installation of air conditioner unit assembly ............................................................ 2 Removal and installation of engine controller assembly............................................................... 4 Removal and Installation of KOMTRAX terminal assembly.......................................................... 6 Removal and installation of pump controller assembly................................................................. 6 Removal and installation of monitor assembly ............................................................................. 7 90 Diagrams and drawings Hydraulic diagrams and drawings SEN00144-02 Hydraulic circuit diagram (1/3) (Backhoe specification)................................................................ 3 Hydraulic circuit diagram (2/3) (Loading shovel specification)...................................................... 5 Hydraulic circuit diagram (3/3) (Loading shovel specification)...................................................... 7 Electrical diagrams and drawings SEN00145-04 Electrical circuit diagram (1/6) ...................................................................................................... 3 Electrical circuit diagram (2/6) ...................................................................................................... 5 Electrical circuit diagram (3/6) ...................................................................................................... 7 Electrical circuit diagram (4/6) ...................................................................................................... 9 Electrical circuit diagram (5/6) ...................................................................................................... 11 Electrical circuit diagram (6/6) ...................................................................................................... 13 Connector arrangement diagram.................................................................................................. 15 Electrical circuit diagram for air conditioner .................................................................................. 17
PC600-8
11
SEN00130-12
PC600, 600LC-8 Hydraulic excavator Form No. SEN00130-12
2009 KOMATSU All Rights Reserved Printed in Japan 07-09
12
SEN00131-04
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8 PC600LC-8
Machine model PC600-8 PC600LC-8
Serial number 30001 and up 30001 and up

Foreword and general information
Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36
PC600-8
SEN00131-04
Safety notice
(Rev. 2008/08) 1
Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
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Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5 Prohibition of operation and handling by unlicensed workers Wearing protective goggles (for cleaning or grinding work) Wearing shielding goggles and protectors (for welding work) Precautions against work which you are not used to or you are used to too much
6 Safety check before starting work 7 8
9 Good physical condition and preparation 10
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6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
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Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative () terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
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4. Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
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When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
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13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
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Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.
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Wire ropes (Standard Z twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
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8. Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2) Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings. a
Example of O-ring (Fitted to every joint of hoses and tubes)
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
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How to read the shop manual

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Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the engine volume of the engine model mounted on the machine.
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Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The S mode of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
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Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
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Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table.
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Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 ) Revisions Revised brochures are shown in the shop manual composition table.
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Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol k a 4 3 2 5 6 Item Safety Caution Weight Tightening torque Coat Oil, coolant Drain Remarks Special safety precautions are necessary when performing work. Special technical precautions or other precautions for preserving standards are necessary when performing work. Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
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Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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Explanation of terms for maintenance standard
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the standard size and the range of difference from the standard size is called the tolerance. q The tolerance with the symbols of + or is indicated on the right side of the standard size.
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Example: Standard size 120 a
Tolerance 0.022 0.126
The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (0.022/0.126) Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
Example: Standard size 60 Tolerance Shaft Hole 0.030 +0.046 0.076 +0
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2. Standard clearance and standard value The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the standard value, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
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Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the clearance limit. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
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Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the interference. q The range (A B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the standard interference. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the repair limit. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the allowable value or allowable dimension. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the interference limit. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
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Handling of electric equipment and hydraulic component
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
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3) Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
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High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
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Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2]
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When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
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Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
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2) Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
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Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
Disconnection
Connection (Example of incomplete setting of (a))
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4) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter fr om t he c om pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
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4.
Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
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Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
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Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
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Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment. Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal. Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
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Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
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Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
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Handling of connectors newly used for engines

a Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines) Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you. 2.
q
1.
Pull lock type (PACKARD-2) 95 170, 12V140 engines q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
20
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3.
Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow.
q
114 engine
107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04) While pressing lock (D), pull out connector (4) in the direction of the arrow.
3)
107 engine
2)
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
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q
4)
95, 125 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc. Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
1)
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
2)
Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it clicks.
Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
22
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How to read electric wire code

a
The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile Symbol AV Conductor Insulator Conductor Insulator Conductor Insulator Material Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Heat-resistant crosslinked polyethylene Using temperature range (C) Example of use General wiring (Nominal No. 5 and above) 30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely 50 to +110 cold district, wiring at high-temperature place
AVS
Heat-resistant low-voltAEX age wire for automobile
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2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 CovAV Standard 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8 50/0.45 7.95 3.7 5.5 5.3
15 84/0.45 13.36 4.8 7.0 7.0
20 41/0.80 20.61 6.0 8.2 8.2
30 70/0.80 35.19 8.0 10.8 10.8
40 85/0.80 42.73 8.6 11.4 11.4
50
60
85
100
108/0.80 127/0.80 169/0.80 217/0.80 54.29 9.8 13.0 13.0 63.84 10.4 13.6 13.6 84.96 12.0 16.0 16.0 109.1 13.6 17.6 17.6
f of nominal No. denotes flexible.
24
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3.
Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: GW means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch WG

AEX R B R D Y G L

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

YW GL

Gr Br

Others
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Precautions when carrying out operation
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1.
q q q q q q q q q q
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2) Plug (nut end) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234 Sleeve nut (elbow end) 02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05 Flange (hose end) 07379-00400 07379-00500 Sleeve head (tube end) 07378-10400 07378-10500 Split flange 07371-30400 07371-30500
3)
If the part is not under hydraulic pressure, the following corks can be used. Nominal number 06 08 10 12 14 16 18 20 22 24 27 Part Number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734 Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 22.5 34
26
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2.
q q q q q q q q q q q q q
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, Bleeding air. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see Disassembly and assembly. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
a 3.
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4)
5)
Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly and assembly.
28
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Method of disassembling and connecting push-pull type coupler

k k
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1 1. Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.
2.
Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
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Type 2 1. Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
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Type 3 1. Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
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Standard tightening torque table

1. Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a The following table applies to the bolts in Fig. A. Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Tightening torque Nm 11.8 14.7 27 34 59 74 98 123 157 196 245 309 343 427 490 608 662 829 824 1,030 1,180 1,470 1,520 1,910 1,960 2,450 2,450 3,040 2,890 3,630 kgm 1.2 1.5 2.8 3.5 6.0 7.5 10.0 12.5 16 20 25 31.5 35 43.5 50 62 67.5 84.5 84 105 120 150 155 195 200 250 250 310 295 370
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a
The following table applies to the bolts in Fig. B. Width across flats mm 10 12 14 17 Tightening torque Nm kgm 5.9 9.8 0.6 1.0 13.7 23.5 1.4 2.4 34.3 46.1 3.5 4.7 74.5 90.2 7.6 9.2
a Fig. B
Thread diameter of bolt mm 6 8 10 12

a Fig. A
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)
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2.
Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Width across flats mm 14 17 22 Tightening torque Nm 59 74 98 123 235 285 kgm 6.0 7.5 10.0 12.5 23.5 29.5
Thread diameter of bolt mm 10 12 16
3.
Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below. Thread diameter mm 14 20 24 33 42 Tightening torque Nm {kgm} Range Target 35 63 { 3.5 6.5} 44 { 4.5} 84 132 { 8.5 13.5} 103 {10.5} Varies depending on type of connec- 128 186 {13.0 19.0} 157 {16.0} tor. 363 480 {37.0 49.0} 422 {43.0} 746 1,010 {76.0 103} 883 {90.0} Width across flats mm
Nominal No. 02 03,04 05,06 10,12 14
4.
Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52 Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52 Width across flats mm 14 17 19 22 24 27 30 32 32 36 Tightening torque Nm {kgm} Range Target 5.88 8.82 {0.6 0.9} 7.35 {0.75} 9.81 12.74 {1.0 1.3} 11.27 {1.15} 14.7 19.6 {1.5 2.0} 17.64 {1.8} 19.6 24.5 {2.0 2.5} 22.54 {2.3} 24.5 34.3 {2.5 3.5} 29.4 {3.0} 34.3 44.1 {3.5 4.5} 39.2 {4.0} 44.1 53.9 {4.5 5.5} 49.0 {5.0} 58.8 78.4 {6.0 8.0} 68.6 {7.0} 93.1 122.5 { 9.5 12.5} 107.8 {11.0} 107.8 147.0 {11.0 15.0} 127.4 {13.0} 127.4 176.4 {13.0 18.0} 151.9 {15.5} 181.3 240.1 {18.5 24.5} 210.7 {21.5} 274.4 367.5 {28.0 37.5} 323.4 {33.0}
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5.
Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm} Taper seal Thread size (mm) 14 18 22 24 30 33 36 42 Width across flats Face seal Nominal No. Thread Number of diameter (mm) threads, type of (Reference) thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2
Nominal No. of hose
Range 34 54 { 3.5 5.5} 34 63 { 3.5 6.5} 54 93 { 5.5 9.5} 59 98 { 6.0 10.0} 84 132 { 8.5 13.5} 128 186 {13.0 19.0} 177 245 {18.0 25.0} 177 245 {18.0 25.0} 197 294 {20.0 30.0} 246 343 {25.0 35.0}
Target
02 03 04 05 06 (10) (12) (14)
19 22 24 27 32 36 41 46 55
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
6.
Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted). Width across flats (mm) 19 22 24 (27) 30 (32) 36 Tightening torque Nm {kgm} Range 14 16 {1.4 1.6} 24 27 {2.4 2.7} 43 47 {4.4 4.8} 60 68 {6.1 6.8} 90 95 {9.2 9.7} Target 15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4} Face seal Thread diameter Nominal No. (mm) Number of threads, (Reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2
Outer diameter of pipe (mm) 8 10 12 15 (16) 22 (20)
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14 Nm 10 2 24 4 43 6 77 12 Tightening torque Bolts and nuts kgm 1.02 0.20 2.45 0.41 4.38 0.61 7.85 1.22
34
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8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14 Tightening torque Nm 82 10 2 12 2 24 4 36 5 kgm 0.81 0.20 1.02 0.20 1.22 0.20 2.45 0.41 3.67 0.51
9.
Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 2 1.53 0.20 51 0.51 0.10 20 2 2.04 0.20 15 2 1.53 0.20 25 3 2.55 0.31 20 2 2.04 0.20 35 4 3.57 0.41 25 3 2.55 0.31 55 6 5.61 0.61 35 4 3.57 0.41 75 8 7.65 0.82 45 5 4.59 0.51
Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4
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Conversion table
Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1. Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
2.
Millimeters to inches 0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701
(B) 5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819 1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898
0 10 20 30 40 50 60 70 80 90
(A)
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Millimeters to inches 0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701 5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929 2.244 2.638 3.032 3.425 3.819 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898
0 10 20 30 40 50 60 70 80 90
Kilogram to pound 0 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42 1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62 2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83 3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03 4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24 5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44 1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03 123.46 145.51 167.55 189.60 211.64 125.66 147.71 169.76 191.80 213.85 127.87 149.91 171.96 194.01 216.05 130.07 152.12 174.17 196.21 218.26
0 10 20 30 40 50 60 70 80 90
Liters to U.S. Gallons 0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095 13.209 15.850 18.492 21.134 23.775 13.473 16.115 18.756 21.398 24.040 13.737 16.379 19.020 21.662 24.304 3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568 4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832 1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944 14.529 17.171 19.813 22.455 25.096 14.795 17.435 20.077 22.719 25.361 15.058 17.700 20.341 22.983 25.625 15.322 17.964 20.605 23.247 25.889 15.586 18.228 20.870 23.511 26.153
0 10 20 30 40 50 60 70 80 90
PC600-8
37
SEN00131-04
Liters to U.K. Gallons 0 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797 1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017 2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237 3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457 4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677 5 1.100 3.300 5.499 7.699 9.899 12.098 14.298 16.498 18.697 20.897 1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117 12.528 14.738 16.938 19.137 21.337 12.758 14.958 17.158 19.357 21.557 12.978 15.178 17.378 19.577 21.777
0 10 20 30 40 50 60 70 80 90
kgm to ft.lb 0 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4 412.3 484.6 556.9 629.3 701.6 419.5 491.8 564.2 636.5 708.8 426.8 499.1 571.4 643.7 716.1
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7 1084.9 1157.3 1129.6 1301.9 1374.3 1092.2 1164.5 1236.8 1309.2 1381.5 1099.4 1171.7 1244.1 1316.4 1388.7 1106.6 1179.0 1251.3 1323.6 1396.0 1113.9 1186.2 1258.5 1330.9 1403.2 1121.1 1193.4 1265.8 1338.1 1410.4 1128.3 1200.7 1273.0 1345.3 1417.7 1135.6 1207.9 1280.1 1352.6 1424.9 1142.8 1215.1 1287.5 1359.8 1432.1 1150.0 1222.4 1294.7 1367.0 1439.4
38
PC600-8
SEN00131-04
kg/cm2 to lb/in2 0 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1,138 1,280 1,422 1,565 1,707 1,849 1,991 2,134 2,276 2,418 2,560 2,702 2,845 2,987 3,129 3,271 3,414 1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1,010 1,152 1,294 1,437 1,579 1,721 1,863 2,005 2,148 2,290 2,432 2,574 2,717 2,859 3,001 3,143 3,286 3,428 2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1,024 1,166 1,309 1,451 1,593 1,735 1,877 2,020 2,162 2,304 2,446 2,589 2,731 2,873 3,015 3,158 3,300 3,442 3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1,038 1,181 1,323 1,465 1,607 1,749 1,892 2,034 2,176 2,318 2,460 2,603 2,745 2,887 3,030 3,172 3,314 3,456 4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1,053 1,195 1,337 1,479 1,621 1,764 1,906 2,048 2,190 2,333 2,475 2,617 2,759 2,901 3,044 3,186 3,328 3,470 5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1,067 1,209 1,351 1,493 1,636 1,778 1,920 2,062 2,205 2,347 2,489 2,631 2,773 2,916 3,058 3,200 3,343 3,485 6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1,081 1,223 1,365 1,508 1,650 1,792 1,934 2,077 2,219 2,361 2,503 2,646 2,788 2,930 3,072 3,214 3,357 3,499 1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9 810.7 953.0 1,095 1,237 1,380 1,522 1,664 1,806 1,949 2,091 2,233 2,375 2,518 2,660 2,802 2,944 3,086 3,229 3,371 3,513 825.0 967.2 1,109 1,252 1,394 1,536 1,678 1,821 1,963 2,105 2,247 2,389 2,532 2,674 2,816 2,958 3,101 3,243 3,385 3,527 839.2 981.4 1,124 1,266 1,408 1,550 1,693 1,835 1,977 2,119 2,262 2,404 2,546 2,688 2,830 2,973 3,115 3,257 3,399 3,542
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
PC600-8
39
SEN00131-04
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1C = 33.8F F 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
C 40.4 37.2 34.4 31.7 28.9 28.3 27.8 27.2 26.7 26.1 25.6 25.0 24.4 23.9 23.3 22.8 22.2 21.7 21.1 20.6 20.0 19.4 18.9 18.3 17.8 17.2 16.7 16.1 15.6 15.0 14.4 13.9 13.3 12.8 12.2 40 35 30 25 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10
F 40.0 31.0 22.0 13.0 4.0 2.2 0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0
C 11.7 11.1 10.6 10.0 9.4 8.9 8.3 7.8 7.2 6.7 6.1 5.6 5.0 4.4 3.9 3.3 2.8 2.2 1.7 1.1 0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0
C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0
C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4
40
PC600-8
SEN00131-04
PC600-8
41
SEN00131-04
2009 KOMATSU All Rights Reserved Printed in Japan 01-09 (01)
42
SEN00133-03
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
01 Specification
Specification and technical data
Specification and technical data Specification drawings .................................................................................................................................... 2 Working range drawings ................................................................................................................................. 4 Specifications.................................................................................................................................................. 6 Weight table.................................................................................................................................................. 14 Table of fuel, coolant and lubricants ............................................................................................................. 18
PC600-8
SEN00133-03
01 Specification
Specification and technical data

Specification drawings
Backhoe specification
Item A B C D E F G H Overall length Overall height Overall width Track shoe width Height of cab Radius of upper structure Overall length of track Tumbler center distance Min. ground clearance
Unit mm mm mm mm mm mm mm mm mm
PC600-8 12,910 4,300 3,900 600 3,290 3,775 5,340 4,250 780
PC600LC-8 12,910 4,300 3,900 600 3,290 3,775 5,690 4,600 780
PC600-8
01 Specification
SEN00133-03
Loading shovel specification
Item A B C D E F G H Overall length Overall height Overall width Track shoe width Height of cab Radius of upper structure Overall length of track Tumbler center distance Min. ground clearance
Unit mm mm mm mm mm mm mm mm mm
PC600-8 Loading shovel specification 8,915 5,530 3,900 600 3,280 3,900 5,360 4,250 780
PC600LC-8 Loading shovel specification 8,915 5,530 3,900 600 3,280 3,900 5,710 4,600 780
PC600-8
SEN00133-03
01 Specification
Working range drawings

Working ranges A B C D E F Max. digging reach Max. digging depth Max. digging height Max. vertical wall digging depth Max. dumping height Max. digging reach at ground level
Unit mm mm mm mm mm mm
PC600-8 13,020 8,490 11,880 7,510 7,960 12,800
PC600LC-8 13,020 8,490 11,880 7,510 7,960 12,800
PC600-8
01 Specification
SEN00133-03
Working ranges A B C D E F Max. digging reach Max. digging reach at ground level Max. digging height Max. digging depth Min. digging radius at ground level Min. turning radius of work equipment
Unit mm mm mm mm mm mm
PC600-8 Loading shovel specification 9,190 8,850 10,090 3,495 5,135 5,515
PC600LC-8 Loading shovel specification 9,190 8,850 10,090 3,495 5,135 5,515
PC600-8
SEN00133-03
01 Specification
Specifications
Backhoe specification PC600-8
Machine model Serial number Bucket capacity Weight of machine Max. digging depth Working ranges Max. vertical wall depth Max. digging reach Max. reach at ground level Max. digging height Max. dumping height Performance Max. digging force (using power max. function) Swing speed Swing max. slope angle Travel speed rpm deg. km/h m3 kg mm mm mm mm mm mm kN {kg} PC600-8 30001 and up 2.7 57,300 8,490 7,510 13,020 12,800 11,880 7,960 294.3 {30,000} (316.9 {32,300}) 8.3 17 Low speed: 3.0 High speed: 4.9 Gradeability Ground pressure (standard triple grouser shoe width: 600 mm) Overall length (for transport) Overall width Overall width of track Overall height (for transport) Overall height to top of cab Ground clearance of Dimensions counterweight Min. ground clearance Tail swing radius Min. swing radius of work equipment Height of work equipment at min. swing radius Length of track on ground Track gauge Height of machine cab mm mm mm 4,250 3,300 3,070 mm 10,020 mm mm mm 780 3,900 5,370 mm mm mm mm mm mm 12,910 3,195 3,900 4,300 3,435 1,365 deg. kPa {kg/cm }
2
35 102 {1.04}
PC600-8
01 Specification
SEN00133-03
Machine model Serial number Model Type No. of cylinders bore stroke Piston displacement Performance Engine Flywheel horsepower Max. torque Max. speed at no load Min. speed at no load mm l {cc} kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm
PC600-8 30001 and up KOMATSU SAA6D140E-5 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) 6 140 165 15.24 {15,240} 323/1,800 {432/1,800} 1,944/1,400 {198.4/1,400} 1,950 800 24V, 11 kW 24V, 50A 12V, 175 Ah 2 CF68-4 3 on each side 8 on each side Assembly-type triple grouser, 49 on each side
Starting motor Alternator Battery Radiator core type Fan system Undercarriage Carrier roller Track roller Track shoe Fan pump Fan motor Set pressure Hydraulic motor Control valve Hydraulic pump Type No. l /min MPa {kg/cm2} MPa {kg/cm2} Type Type
Variable swash plate type: LPV75 Fixed swash plate type: LMF75 24.5 {250} Variable displacement piston type: HPV95+95 2, piston + gear type: LPV75 + SAL(2)56 + (2)8 Piston type: 410 2, gear type: 137 Piston type: 34.3 {350}, gear type: 2.9 {30} 4-spool + 5-spool type 1 Hydraulic
Delivery Set pressure Type No. Control method
Hydraulic system
Travel motor
KMV335ADT, Piston type (with brake valve, shaft brake): 2 KMF90ABE-3, Piston type (with safety valve, shaft brake, reverse prevention valve): 2 Boom Arm Double-acting piston 200 140 2,045 4,933 2,888 Box-shaped, sealed Tank return side CF42-1 (Air cooled) Bucket Double-acting piston 185 130 1,425 3,577 2,152
Swing motor
Hydraulic cylinder
Type Inside diameter of cylinder Diameter of piston rod Stroke Max. distance between pins Min. distance between pins mm mm mm mm mm
Double-acting piston 185 120 1,725 4,182 2,457
Hydraulic system
Hydraulic tank Hydraulic filter Hydraulic cooler
PC600-8
SEN00133-03 PC600LC-8
Machine model Serial number Bucket capacity Weight of machine Max. digging depth Working ranges Max. vertical wall depth Max. digging reach Max. reach at ground level Max. digging height Max. dumping height Performance Max. digging force (using power max. function) Swing speed Swing max. slope angle Travel speed rpm deg. km/h m3 kg mm mm mm mm mm mm kN {kg} PC600LC-8 30001 and up 2.7 58,300 8,490 7,510 13,020 12,800 11,880 7,960 294.3 {30,000} (316.9 {32,300}) 8.3 17 Low speed: 3.0 High speed: 4.9 Gradeability Ground pressure (standard triple grouser shoe width: 600 mm) Overall length (for transport) Overall width Overall width of track Overall height (for transport) Overall height to top of cab Ground clearance of Dimensions counterweight Min. ground clearance Tail swing radius Min. swing radius of work equipment Height of work equipment at min. swing radius Length of track on ground Track gauge Height of machine cab mm mm mm 4,600 3,300 3,070 mm 10,020 mm mm mm 780 3,900 5,370 mm mm mm mm mm mm 12,910 3,195 3,900 4,300 3,435 1,365 deg. kPa {kg/cm2} 35 96 {0.98}
01 Specification
PC600-8
01 Specification
SEN00133-03
PC600LC-8 30001 and up KOMATSU SAA6D140E-5 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) 6 140 165 15.24 {15,240} 323/1,800 {432/1,800} 1,944/1,400 {198.4/1,400} 1,950 800 24V, 11 kW 24V, 50A 12V, 175 Ah 2 CF68-4 3 on each side 9 on each side Assembly-type triple grouser, 52 on each side
Starting motor Alternator Battery Radiator core type Fan system Undercarriage Carrier roller Track roller Track shoe Fan pump Fan motor Set pressure Hydraulic motor Control valve Hydraulic pump Type No. l /min MPa {kg/cm2} MPa {kg/cm2} Type Type
Variable swash plate type: LPV75 Fixed swash plate type: LMF75 24.5 {250} Variable displacement piston type: HPV95+95 2, piston + gear type: LPV75 + SAL(2)56 + (2)8 Piston type: 410 2, gear type: 137 Piston type: 34.3 {350}, gear type: 2.9 {30} 4-spool + 5-spool type 1 Hydraulic
Delivery Set pressure Type No. Control method
Hydraulic system
Travel motor
KMV335ADT, Piston type (with brake valve, shaft brake): 2 KMF90ABE-3, Piston type (with safety valve, shaft brake, reverse prevention valve): 2 Boom Arm Double-acting piston 200 140 2,045 4,933 2,888 Box-shaped, sealed Tank return side CF42-1 (Air cooled) Bucket Double-acting piston 185 130 1,425 3,577 2,152
Swing motor
Hydraulic cylinder
Double-acting piston 185 120 1,725 4,182 2,457
Hydraulic system
PC600-8
SEN00133-03 Loading shovel specification PC600-8

Machine model Serial number Bucket capacity Weight of machine Max. digging depth Working ranges Max. vertical wall depth Max. digging reach Max. reach at ground level Max. digging height Max. dumping height Max. digging force Swing speed Swing max. slope angle Travel speed Gradeability Ground pressure (standard triple grouser shoe width: 600 mm) Overall length (for transport) Overall width Overall width of track Overall height (for transport) Overall height to top of cab Ground clearance of counterweight Min. ground clearance Tail swing radius Min. swing radius of work equipment Height of work equipment at min. swing radius Length of track on ground Track gauge Height of machine cab m
3
01 Specification
PC600-8 Loading shovel specification 55001 and up 4.0 61,300 3,495 9,190 8,850 10,090 6,705 386 {39,400} 8.3 15.5 Low speed: 3.0 High speed: 4.9 35
2
kg mm mm mm mm mm mm kN {kg} rpm deg. km/h deg. kPa {kg/cm } mm mm mm mm mm mm mm mm mm mm mm mm mm
Performance
109 {1.11} 8,915 3,195 3,900 5,530 3,435 1,365 780 3,900 5,515 6,480 4,250 3,300 3,070
10
Dimensions
PC600-8
01 Specification
SEN00133-03
PC600-8 Loading shovel specification 55001 and up KOMATSU SAA6D140E-5 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) 6 140 165 15.24 {15,240} 323/1,800 {432/1,800} 1,944/1,400 {198.4/1,400} 1,950 800 24V, 11 kW 24V, 50A 12V, 175 Ah 2 CF68-4 3 on each side 8 on each side Assembly-type double grouser, 49 on each side
Starting motor Alternator Battery Radiator core type Fan system Undercarriage Carrier roller Track roller Track shoe Fan pump Fan motor Set pressure Hydraulic motor Control valve Hydraulic pump Type No. l /min MPa {kg/cm2} MPa {kg/cm }
2
Type Type
Variable swash plate type: LPV75 Fixed swash plate type: LMF75 24.5 {250} Variable displacement piston type: HPV95+95 2, piston + gear type: LPV75 + SAL(2)56 + (2)8 Piston type: 410 2, gear type: 137 Piston type: 34.3 {350}, gear type: 2.9 {30} 4-spool + 5-spool type 1 Hydraulic KMV335ADT, Piston type (with brake valve, shaft brake): 2 KMF90ABE-3, Piston type (with safety valve, shaft brake, reverse prevention valve): 2 Boom Arm Bucket Bottom dump
Delivery Set pressure Type No. Control method Travel motor
Hydraulic system
Swing motor
Hydraulic cylinder
Double-acting Double-acting Double-acting Double-acting piston piston piston piston 185 130 1,410 4,147 2,737 200 140 1,500 3,878 2,378 160 110 1,400 3,750 2,350 140 90 335 1,235 900
Hydraulic system
Box-shaped, sealed Tank return side CF42-1 (Air cooled)
PC600-8
11
SEN00133-03 PC600LC-8
Machine model Serial number Bucket capacity Weight of machine Max. digging depth Working ranges Max. vertical wall depth Max. digging reach Max. reach at ground level Max. digging height Max. dumping height Max. digging force Swing speed Swing max. slope angle Travel speed Gradeability Ground pressure (standard triple grouser shoe width: 600 mm) Overall length (for transport) Overall width Overall width of track Overall height (for transport) Overall height to top of cab Ground clearance of counterweight Min. ground clearance Tail swing radius Min. swing radius of work equipment Height of work equipment at min. swing radius Length of track on ground Track gauge Height of machine cab m
3
01 Specification
PC600LC-8 Loading shovel specification 55001 and up 4.0 62,300 3,495 9,190 8,850 10,090 6,705 386 {39,400} 8.3 15.5 Low speed: 3.0 High speed: 4.9 35
2
kg mm mm mm mm mm mm kN {kg} rpm deg. km/h deg. kPa {kg/cm } mm mm mm mm mm mm mm mm mm mm mm mm mm
Performance
102 {1.04} 8,915 3,195 3,900 5,530 3,435 1,365 780 3,900 5,515 6,480 4,600 3,300 3,070
12
Dimensions
PC600-8
01 Specification
SEN00133-03
PC600LC-8 Loading shovel specification 55001 and up KOMATSU SAA6D140E-5 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) 6 140 165 15.24 {15,240} 323/1,800 {432/1,800} 1,944/1,400 {198.4/1,400} 1,950 800 24V, 11 kW 24V, 50A 12V, 175 Ah 2 CF68-4 3 on each side 9 on each side Assembly-type double grouser, 52 on each side
Starting motor Alternator Battery Radiator core type Fan system Undercarriage Carrier roller Track roller Track shoe Fan pump Fan motor Set pressure Hydraulic motor Control valve Hydraulic pump Type No. l /min MPa {kg/cm2} MPa {kg/cm }
2
Type Type
Variable swash plate type: LPV75 Fixed swash plate type: LMF75 24.5 {250} Variable displacement piston type: HPV95+95 2, piston + gear type: LPV75 + SAL(2)56 + (2)8 Piston type: 410 2, gear type: 137 Piston type: 34.3 {350}, gear type: 2.9 {30} 4-spool + 5-spool type 1 Hydraulic KMV335ADT, Piston type (with brake valve, shaft brake): 2 KMF90ABE-3, Piston type (with safety valve, shaft brake, reverse prevention valve): 2 Boom Arm Bucket Bottom dump
Delivery Set pressure Type No. Control method Travel motor
Hydraulic system
Swing motor
Hydraulic cylinder
Double-acting Double-acting Double-acting Double-acting piston piston piston piston 185 130 1,410 4,147 2,737 200 140 1,500 3,878 2,378 160 110 1,400 3,750 2,350 140 90 335 1,235 900
Hydraulic system
Box-shaped, sealed Tank return side CF42-1 (Air cooled)
PC600-8
13
SEN00133-03
01 Specification
Weight table
k This weight table is a guide for use when transporting or handling components.
Unit: kg Machine model Serial number Engine assembly Engine PTO (incl. lubricating piping) Hydraulic pump Fan, control and PTO lubrication pump Radiator, oil cooler assembly Hydraulic tank, filter assembly (excl. hydraulic oil) Fuel tank (excl. fuel) Revolving frame Operator's cab Operator's seat Counterweight Swing machinery Control valve Swing motor Travel motor Fan motor Center swivel joint Track frame assembly (Excluding step, roller guard, shoe assembly, and lower piping) Center frame Track frame Swing circle Idler Idler cushion Carrier roller Track roller Final drive (incl. travel motor) 3,998 2,207 2 1,136 342 2 452 2 50 6 108 16 994 2 3,998 2,355 2 1,136 342 2 452 2 50 6 108 18 994 2 PC600-8 30001 and up 2,610 1,965 285 305 55 268 455 520 4,640 280 35 10,750 743 301 61 2 268 2 25 43 15,152 PC600LC-8 30001 and up 2,610 1,965 285 305 55 268 455 520 4,640 280 35 10,750 743 301 61 2 268 2 25 43 15,664
14
PC600-8
01 Specification
SEN00133-03
Unit: kg Machine model Serial number Track shoe assembly Standard triple grouser shoe (600 mm) Wide triple grouser shoe Boom assembly Arm assembly Bucket assembly Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly Link assembly (large) Link assembly (small) Boom pin Arm pin Bucket pin Link pin (750 mm) 5,930 6,750 4,820 3,250 2,430 496 2 734 482 345 149 + 26 2 + 76 + 104 + 36 32 + 55 55 + 62 45 2 6,290 7,170 4,820 3,250 2,430 496 2 734 482 345 149 + 26 2 + 76 + 104 + 36 32 + 55 55 + 62 45 2 PC600-8 30001 and up PC600LC-8 30001 and up
PC600-8
15
SEN00133-03 Loading shovel specification
01 Specification
Unit: kg Machine model Serial number Engine assembly Engine PTO (incl. lubricating piping) Hydraulic pump Fan, control and PTO lubrication pump Radiator, oil cooler assembly Hydraulic tank, filter assembly (excl. hydraulic oil) Fuel tank (excl. fuel) Revolving frame Operator's cab Operator's seat Counterweight Swing machinery Control valve Swing motor Travel motor Fan motor Center swivel joint Track frame assembly (Excluding step, roller guard, shoe assembly, and lower piping) Center frame Track frame Swing circle Idler Idler cushion Carrier roller Track roller Final drive (incl. travel motor) 3,998 2,207 2 1,136 342 2 452 2 50 6 108 14 994 2 3,998 2,355 2 1,136 342 2 452 2 50 6 108 14 994 2 PC600-8 Loading shovel specification 55001 and up 2,610 1,965 285 305 55 268 455 520 4,640 280 35 10,750 743 301 61 2 268 2 25 43 15,152 PC600LC-8 Loading shovel specification 55001 and up 2,610 1,965 285 305 55 268 455 520 4,640 280 35 10,750 743 301 61 2 268 2 25 43 15,664
16
PC600-8
01 Specification
SEN00133-03
Unit: kg Machine model Serial number Track shoe assembly Standard double grouser shoe (600 mm) Wide triple grouser shoe Boom assembly Arm assembly Bucket assembly Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly Bottom dump cylinder assembly Boom pin Arm pin Bucket pin Bucket connecting pin 5,760 3,880 2,770 6,080 524 2 569 406 2 114 2 149 + 26 2 + 104 + 97 110 + 32 55 2 + 37 2 19 2 + 10 2 + 17 2 6,120 3,880 2,770 6,080 524 2 569 406 2 114 2 149 + 26 2 + 104 + 97 110 + 32 55 2 + 37 2 19 2 + 10 2 + 17 2 PC600-8 Loading shovel specification 55001 and up PC600LC-8 Loading shovel specification 55001 and up
PC600-8
17
SEN00133-03
01 Specification
Table of fuel, coolant and lubricants

a For details of the notes (Note 1, Note 2, ---) in the table, see the Operation and Maintenance Manual.
18
PC600-8
01 Specification
SEN00133-03
Unit: l PC600, PC600LC-8 Supply point Specified capacity Engine oil pan PTO case Swing machinary case Final drive case (each) Hydraulic system Fuel tank Cooling system 48 7.2 13 10.5 520 880 58 Refill capacity 40 7.2 13 10 360
PC600-8
19
SEN00133-03
01 Specification
20
SEN00135-02
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
10 Structure, function and maintenance standard

Engine and cooling system
Engine and cooling system Parts related to engine.................................................................................................................................... 2 PTO ................................................................................................................................................................ 4 Fan, control and PTO lubrication pump .......................................................................................................... 6 Radiator, oil cooler .......................................................................................................................................... 7
PC600-8
SEN00135-02
Engine and cooling system

Parts related to engine
1. Air cleaner 2. Intake connector 3. Muffler
4. Front engine mount 5. Rear engine mount
PC600-8
SEN00135-02
Unit: mm
No. Check item Free height of front mount rubber Free height of rear mount rubber Standard size 126 134 Criteria Repair limit Replace Remedy
PC600-8
SEN00135-02
PTO
1. 2. 3. 4. 5. 6. 7.
Connection plate PTO case Driven gear (No. of teeth: 40) Drive gear (No. of teeth: 36) Oil level gauge Main shaft Breather
a. Center of crankshaft (Center of SAL56 shaft) b. Center of HPV95+95 shaft c. Center of HPV95+95 shaft Specifications Lubricating oil: 7.2 l Reducation ratio: Input shaft (SAL56 shaft) = 1 36 HPV95+95 shaft = = 0.9 40
PC600-8
SEN00135-02
Unit: mm
No. Check item Backlash between drive gear and driven gear Backlash of SAL56 pump input shaft Backlash between main shaft and connecting hub assenbly Standard clearance 0.23 0.74 0.273 0.374 Criteria Clearance limit Adjust Remedy
10
0.074 0.226
PC600-8
SEN00135-02
Fan, control and PTO lubrication pump

LPV75 + SAL56 + 8
Unit: mm
No. Check item Clearance between gear case and side plate Clearance between bearing inner dia. and gear shaft outer dia. Model SAL56 SAL8 SAL56 SAL8 Standard clearance 0.13 0.18 0.10 0.15 0.067 0.125 0.067 0.125 Standard size 3 Pin insertion depth 4 Delivery Oil: EO10-CD Oil temp.: 45 55C 12 12 Speed (rpm) 2,500 SAL8 2,500 Delivery pressure
(MPa {kg/cm2})
Criteria Clearance limit 0.22 0.19 0.20 0.20 Tolerance 0 0.5 0 0.5 Standard delivery (l/min.) 134 19 Repair limit Delivery limit (l/min.) 124 17
Remedy
Replace
SAL56
2.9 {30} 2.9 {30}
PC600-8
SEN00135-02
Radiator, oil cooler
1. 2. 3. 4. 5.
Reservoir tank Radiator inlet hose Radiator Radiator cap Oil cooler
6. Fan 7. Shroud 8. Radiator outlet hose
Specifications Radiator: CF68-4 Oil cooler: CF42-1
PC600-8
SEN00135-02
SEN00136-01
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8

Power train
Power train Power train ..................................................................................................................................................... 2 Final drive ....................................................................................................................................................... 5 Sprocket.......................................................................................................................................................... 8 Swing circle .................................................................................................................................................. 10 Swing machinery .......................................................................................................................................... 12
PC600-8
SEN00136-01
Power train Power train
PC600-8
SEN00136-01
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Idler Center swivel joint Swing motor (KMF90ABE-3) Control valve Final drive, sprocket Travel motor (KMV335ADT) Engine PTO No. 2 pump (HPV95+95) Fan pump (LPV75)
11. 12. 13. 14. 15. 16. 17.
Control pump (SAL56) PTO lubrication pump No. 1 pump (HPV95+95) Swing machinery Swing circle Travel speed solenoid valve Swing brake solenoid valve
A. Control valve B. Swing brake solenoid valve
PC600-8
SEN00136-01
PC600-8
SEN00136-01
Final drive
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Level plug Drain plug No. 1 planetary gear (No. of teeth: 50) No. 1 sun gear (No. of teeth: 12) No. 2 sun gear (No. of teeth: 14) No. 1 planetary carrier No. 2 planetary carrier Cover No. 1 ring gear (No. of teeth: 114) Hub Sprocket Floating seal Travel motor No. 2 planetary gear (No. of teeth: 27) No. 2 ring gear (No. of teeth: 70)
Specifications Reduction ratio: 12+114 x 12 = 62.000 14+70 14 +1
PC600-8
SEN00136-01
PC600-8
SEN00136-01
Unit: mm
No. Check item Backlash between No. 2 planet carrier and motor Backlash between No. 2 planet gear and No. 2 ring gear Backlash between No. 1 planet gear and No. 1 ring gear Backlash between No. 2 sun gear and No. 2 planet gear Backlash between No. 1 sun gear and No. 1 planet gear Backlash between No. 1 planet carrier and No. 2 sun gear End play of sprocket shaft Sprocket tooth width 104 24 Wear of sprocket teeth Repair limit: 6 101.5 Standard clearance 0.06 0.21 0.21 0.69 Criteria Clearance limit 1.10 Remedy
16
17
18
0.18 0.63
1.10 Replace
19 20
0.17 0.62 0.14 0.45
1.00 1.00
21 22 23
0.16 0.56 0.10 0.15 Standard size
1.00 Repair limit Rebuild or replace Replace
PC600-8
SEN00136-01
Sprocket
Unit: mm
No. Check item Standard size 1 2 3 4 Wear of tooth tip 350.1 Thickness of tooth root Width of tooth Wear of tooth shape 24.4 104 338.1 18.4 101.5 Rebuild or replace Criteria Repair limit Remedy
Repair limit: 6 (measure with sprocket tooth shape)
PC600-8
SEN00136-01
Sprocket tooth shape of real dimension
a The above drawing is reduced to 60%. Enlarge it to 168% to return it to the full scale and make a copy on an OHP sheet.
PC600-8
SEN00136-01
Swing circle
STD
1. Swing circle inner race (No. of teeth: 100) 2. Ball 3. Swing circle outer race a. Inner race soft zone "S" position b. Outer rae soft zone "S" position
Specifications Reduction raito: 100 13
= 7.692
Amount of grease: 31 l (G2-LI)
Unit: mm
No. 4 Check item Clearance of bearing in axial direction (when mounted on machine) Standard clearance 0.10 0.25 Criteria Clearance limit Replace 3.2 Remedy
10
PC600-8
SEN00136-01
If equipped
PC600-8
11
SEN00136-01
Swing machinery
12
PC600-8
SEN00136-01
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Swing pinion (No. of teeth: 13) Cover Case Coupling No. 2 planetary gear (No. of teeth: 36) Ring gear (No. of teeth: 95) No. 1 planetary gear (No. of teeth: 39) Cover Swing motor Oil level gauge No. 1 sun gear (No. of teeth: 16) No. 1 planetary carrier No. 2 sun gear (No. of teeth: 21) No. 2 planetary carrier
Specifications Reduction raito: 21+95 16+95 x 21 16 = 38.321
Unit: mm
No. Check item Backlash between swing motor shaft and No. 1 sun gear Backlash between No. 1 planet carrier and No. 2 sun gear Backlash between No. 2 planet gear and ring gear Backlash between No. 2 sun gear and No. 2 planet gear Backlash between No. 2 planet carrier and coupling Clearance between plate and coupling Backlash between No. 1 sun gear and No. 1 planet gear Backlash between swing pinion and swing circle Backlash between coupling and swing pinion Backlash between No. 1 planet gear and ring gear Wear of swing pinion oil seal contact surface Standard clearance 0.15 0.49 0.38 0.66 0.17 0.57 0.15 0.49 0.06 0.25 0.38 0.82 0.15 0.49 0 0.126 0.07 0.23 0.15 0.57 Standard size 140.3 0.100
0
Criteria Clearance limit 1.20 1.00 0.90
Remedy
15
16 17 18 19 20 21 22 23 24
Replace 1.00 2.00 1.10 Repair limit Repair hard chrome plating or replace
25
PC600-8
13
SEN00136-01
14
SEN00137-01
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8

Undercarriage and frame
Undercarriage and frame Track frame, recoil spring ............................................................................................................................... 2 Idler................................................................................................................................................................. 4 Carrier roller.................................................................................................................................................... 6 Track roller ...................................................................................................................................................... 7 Track shoe ...................................................................................................................................................... 8
PC600-8
SEN00137-01

Track frame, recoil spring
1. 2. 3. 4. 5. 6. 7. 8.
Idler Track frame Carrier roller Center frame Final drive Track roller Track shoe Center guard
The dimensions and number of track rollers may differ according to the model, but the basic structure is the same. No. of track rollers. Model
PC600-8 PC600LC-8
No. of rollers (each side)

8 9
PC600-8
SEN00137-01
Unit: mm
No. Check item Standard size 9 Recoil spring
Free length x OD
Criteria Repair limit Installed load

292 kN {29,770 kg}
Remedy
Installed length 715
Free length Tolerance 163.5 0 161 0 329 0

+4 +1 +4
Installed load
233.6 kN {23,816 kg}
Replace
859 x 299
Standard size 10 Top-to-bottom width of idler guide Track frame Idler support Track frame 11 Left-to-right width of idler guide Idler support 324 163.5 161 329
Repair limit 167.5 159 334 322 Rebuild or replace
PC600-8
SEN00137-01
Idler
PC600-8
SEN00137-01
Unit: mm
No. Check item Outside diameter of protruding part Outside diameter of tread surface Height of tread Thickness of tread Overall width Width of tread Standard size 110 Standard size 120 Standard size 761 716 22.5 26 234 56 Tolerance Shaft 0.120 0.207 Hole +0.480 +0.420 Criteria Repair limit 704 28.5 20 62 Standard clearance 0.540 0.687
Standard interference
Remedy
2 3 4 5 6
Rebuild or replace
Clearance between shaft and bushing
Clearance limit Interference limit Replace bushing
Tolerance Shaft +0.087 +0.037 Hole 0.036 0.136
Interference between idler and bushing
0.073 0.223 Clearance limit
Standard clearance 9 Play of axial direction 0.35 0.88
Replace
PC600-8
SEN00137-01
Carrier roller
Unit: mm
No. Check item Standard size 1 2 3 4 5 Outside diameter of flange 210 Outside diameter of tread Width of tread Thickness of tread Width of flange Standard size 68 Standard size 73 180 53 42.5 15 Tolerance Shaft +0.09 +0.07 Hole +0.43 +0.18 170 37.5 Standard clearance 0.09 0.36
Criteria Repair limit
Remedy
Clearance limit Interference limit
Replace
Tolerance Shaft +0.38 +0.33 Hole +0.24 +0.21
Interference between roller and bushing
Standard clearance 8 Play of roller in axial direction 0.62 0.93
PC600-8
SEN00137-01
Track roller
Unit: mm
No. Check item Standard size 1 Outside diameter of flange 260 2 3 4 5 6 Outside diameter of tread surface Thickness of tread Overall width Width of tread Width of flange Standard size 100 Standard size 107.6 220 56.2 325 63 39.5 Tolerance Shaft 0.140 0.207 Hole +0.390 +0.330 208 50.2 Standard clearance 0.470 0.597
Criteria Repair limit
Remedy
Rebuild or replace
Clearance limit 1.5 Interference limit Replace bushing
Tolerance Shaft +0.087 +0.037 Hole +0.020 0.015
Interference between roller and bushing
Standard clearance 9 Play of axial direction 0.5 1.1
Replace
PC600-8
SEN00137-01
Track shoe
a P portion shows the link of buhing press fitting end.
PC600-8
SEN00137-01
Unit: mm
No. Check item Standard size 1 Link pitch 228.9 Standard size 2 Bushing outside diameter 79 Standard size 3 Thickness of bushing metal 14.6 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 *19 Press-fitting force Protrusion of pin Protrusion of regular bushing Overall length of pin Overall length of bushing Thickness of spacer Bushing Regular pin Master pin Link Inside width Overall width Tread width Shoe bolt pitch Link height Thickness of link metal (bushing press-fitting portion) 133 33.75 219.8 169 76.2 122.4 61.4 54.5 3.7 9.6 290 200.6 127.4 343 kN {13 35 ton} 196.1 490 kN {20 50 ton} 156.9 431 kN {16 44 ton} Adjust or replace Repair or replace 9.6 123 23.75 Replace Normal load 74 Impact load Repair limit Adjust or replace Rebuild or replace 231.9 When turned Reverse or replace Criteria Repair limit Remedy
*:Dry type track link

PC600-8
SEN00137-01
Unit: mm
No. Check item Tightening torque (Nm {kgm}) 784.578.5 {808} 20 Shoe bolt b. Master link Tightening torque (Nm {kgm}) Standard size 21 Interference between bushing and link 72.9 22 Interference between regular pin and link 48.8 Shaft +0.050 +0.050 +0.180 +0.080 Tolerance Standard size 23 Clearance between regular pin and bushing 49.6 Shaft 0.62 0.72 Tolerance Standard size *24 Interference between master pin and link 48.8 Shaft +0.030 +0.030 Tolerance Standard size *25 Clearance between master pin and bushing 49.2 Shaft 0.65 0.75 Hole +0.60 +0.60 Hole 0.238 0.300 Hole +0.6 +0.6 Hole 0.326 0.400 0.238 0.300 Additional tightening angle (deg.) Tolerance Lower limit torque (Nm {kgm}) Standard interference 0.326 0.450 0.318 0.480 Standard clearance 0.62 1.32 Standard interference 0.238 0.330 Standard clearance 0.65 1.35 Adjust or replace Criteria Additional tightening angle (deg.) 12010 Retighten Remedy
a. Regular link
*: Dry type track link
10
PC600-8
SEN00137-01
Double shoe
Unit: mm
No. Check item Standard size 1 2 3 4 Length at bottom 5 6 Length at tip 7 Standard size 8 Thickness 65 44 26 Repair limit 34 26 Height 48 Height Thickness 48 17 34 Rebuild or replace 27 Criteria Repair limit Remedy
PC600-8
11
SEN00137-01 Triple grouser shoe
Unit: mm
No. Check item Standard size 1 2 3 Length of bottom 4 5 6 7 Standard size 8 Thickness 55 40 Length at tip 27 25.5 17.5 23.5 Repair limit Rebuild or replace Height 37 Thickness 18 33 22 Criteria Repair limit Remedy
12
PC600-8
SEN00137-01
Standard shoe
Model PC600-8 Item Shoe width (mm) (triple shoe) Link pitch (mm) No. of shoes (each side) 600 228.6 49 600 228.6 52 PC600LC-8
Selection of track shoe Select the most suitable track shoe from the following table
PC600-8 Specifications Standard If equipped If equipped If equipped Category A Use Rocky ground, normal river soil Normal soil, soft land 600 mm triple 700 mm triple 750 mm triple 900 mm triple Category A B B B PC600LC-8 Specifications 600 mm triple 750 mm triple 900 mm triple Category A B B
Precautions when using Travel in Lo speed when traveling on rough ground with obstacles such as large boulders and fallen trees. Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground; when it is impossible to avoid traveling over obstacles, lower the travel speed to approx. half of Lo speed. Use only for ground where A and B sink and are impossible to use. Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees Travel in Hi speed only on flat ground; when it is impossible to avoid traveling over obstacles, lower the travel speed to approx. half of Lo speed. The shoes are flat, so they have low gradeability The shoes are made of rubber, so be careful when traveling on rough ground
Extremely soft ground (swampy ground) Paved surface Paved surface
D E
a Categories B and C are wide shoes, so there are restrictions on their use. Therefore, before using, check the restrictions and consider carefully the conditions of use before recommending a suitable shoe width. If necessary, give the customer guidance in their use.
a When selecting the shoe width, select the narrowest shoe possible within the range that will give no problem with flotation and ground pressure. If a wider shoe than necessary is used, there will be a large load on the shoe, and this may lead to bending of the shoe, cracking of the links, breakage of the pins, loosening of the shoe bolts, or other problems.
PC600-8
13
SEN00137-01
14
SEN00138-01
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8

Hydraulic system, Part 1
Hydraulic system, Part 1 Hydraulic piping drawing ................................................................................................................................ 2 Hydraulic tank, hydraulic filter......................................................................................................................... 4 Hydraulic pump (piston pump)........................................................................................................................ 6 Line oil filter .................................................................................................................................................. 34 Cooling fan pump ......................................................................................................................................... 36 Cooling fan motor ......................................................................................................................................... 44
PC600-8
SEN00138-01

Hydraulic piping drawing
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Bucket cylinder Arm cylinder Boom cylinder Center swivel joint Boom LOWER regeneration valve Swing motor Quick return valve (Arm) Oil cooler Cooling fan motor Control valve PPC shuttle valve Hydraulic filter Cooling fan pump Hydraulic pump L.H. travel motor Hydraulic tank PPC lock valve L.H. PPC valve R.H. PPC valve Travel PPC valve Boom holding valve Accumulator Active solenoid valve (swing) Solenoid valve assembly 24A. Travel speed solenoid valve 24B. Swing brake solenoid valve 24C. Boom Hi 2-stage safety solenoid valve 24D. 2-stage relief solenoid valve 24E. CO cancel solenoid valve
PC600-8
SEN00138-01
PC600-8
SEN00138-01
Hydraulic tank, hydraulic filter
PC600-8
SEN00138-01
1. Hydraulic filter 1A. Bypass valve 1B. Strainer 1C. Element 1D. Cooler check valve 2. Hydraulic tank 3. Suction strainer 4. Sight gauge 5. Oil filler cap 6. Breather Specifications Tank capacity: 500 l Amount of oil inside tank: 380 l (at H level) Cap Relief cracking pressure: 16.7 6.9 kPa {0.17 0.07 kg/cm2} Suction operating pressure: 0 0.49 kPa {0 0.005 kg/cm2} Bypass valve set pressure: 0.15 0.03 MPa {1.5 0.3 kg/cm2} Breather Suction operating pressure: 0 2 kPa {0 0.02 kg/cm2} Relief cracking pressure: 0.1 0.015 MPa {1.0 0.15 kg/cm2}
PC600-8
SEN00138-01
Hydraulic pump (piston pump)

No. 1 main pump
Model: HPV95+95
PA1 PA2 PD11 PD21 PCF PCR PD PS PT PSV PECN
: Front pump discharge port : Rear pump discharge port : Drain port : Drain port : CO selector pilot port : CO selector pilot port : Jet sensor downstream pressure IN port : Pump suction port : Jet sensor upstream pressure IN port : Servo basic pressure IN port : CO+NC valve output pressure output port
1. 2. 3. 4. 5. 6. 7.
Front pump Front servo valve Front CO+NC valve Rear servo valve Rear CO+NC valve TVC valve Rear pump
PC600-8
SEN00138-01
No. 1 main pump
PSV1 PSV2 PSV1A PSV1B PSV2A PSV2B
: Servo valve basic pressure port : Servo valve basic pressure port : Servo piston output port : Servo valve output port : Servo piston output port : Servo valve output port
PC600-8
SEN00138-01
1. 2. 3. 4. 5. 6. 7.
Front shaft Front cradle Front case Rocker cam Piston Cylinder block Valve plate
8. 9. 10. 11. 12. 13. 14.
Front end cap Coupling Impeller Rear end cap Valve plate Cylinder block Piston
15. 16. 17. 18. 19.
Rear case Rocker cam Rear cradle Rear shaft Servo piston
PC600-8
SEN00138-01
Servo valve
1. Servo valve assembly (No. 1 front)
P1 PE
: Main pump pressure IN port : TVC valve output pressure front, rear interconnection port PCO : CO selector pilot port PD : Jet sensor downstream pressure IN port PT : Jet sensor upstream pressure IN port PAC : Servo actuator port PDR : Servo valve drain OUT port PPO : Servo basic pressure IN port PECN : CO+NC valve output pressure output port
1. CO+NC valve 2. Servo valve
PC600-8
SEN00138-01
2. Servo valve (No. 1 front)
P2 : Main pump pressure OUT port PDR : CO+NC valve drain IN port PECN : CO+NC valve output pressure IN port
10
PC600-8
SEN00138-01
3. Servo valve assembly (No. 1 rear)
P1 P2 PCO PAC PDR PPO PD PE PT
: Main pump pressure IN port : Main pump pressure IN port : CO selector pilot port : Servo actuator port : Servo valve drain OUT port : Servo basic pressure IN port : Jet sensor downstream pressure IN port : TVC valve output pressure front, rear interconnection port : Jet sensor upstream pressure IN port
1. 2. 3. 4.
TVC valve CO+NC valve Connector Servo valve
PC600-8
11
SEN00138-01
4. Servo valve (No. 1 rear)
P1 P2 PDR PPO PECN
: : : : :
Main pump pressure OUT port Main pump pressure OUT port CO+NC valve drain IN port Servo basic pressure OUT port CO+NC valve output pressure IN port
12
PC600-8
SEN00138-01
Structure
(The following illustration shows the servo valve for No. 1 rear.)
1. 2. 3. 4. 5. 6.
Locknut Cover Plug Spring Valve body Arm
7. 8. 9. 10. 11. 12.
Pin Piston Locknut Plug Locknut Cover
13. 14. 15. 16. 17. 18.
Sleeve Piston Spring Plug Cover Locknut
Function Discharge amounts Q1 and Q2 of main pumps P1 and P2 are controlled individually by the respective servo valves. The relationship between pump discharge amount Q and input signal PECN to the servo valve is as shown in the graph on the right. Q varies in proportion to PECN.
PC600-8
13
SEN00138-01
1) Operation in direction of increase of pump discharge amount (max. angle)
Operation The control pump pressure PPO is taken to port a. Signal pressure PECN from the NC valve is taken from port b to chamber c. When signal pressure PECN rises, piston (8) is pushed to the right by the pressure in chamber c, and stops at a point where it balances the pressure of springs (4) and (4A). At the same time, arm (6) uses servo piston (19) as a fulcrum and sways to the right in the same way as piston (8). This moves guide spool (13) to the right. When guide spool (13) moves, port a and port d are closed and port d is connected to drain chamber e. As a result, servo piston chamber f is also interconnected with drain chamber e through port g and port d.
At the same time, port a is interconnected with port h, so the pressure oil flows through port i to servo piston chamber j, pushes servo piston (19) to the right, increases the swash plate angle in the main piston pump and increases the pump discharge amount. When servo piston (19) moves, arm (6) rotates counterclockwise with its center at pin (7) and moves guide spool (13) to the left. Port a, port d and port h close, so the discharge increases by an amount that matches signal pressure PECN.
14
PC600-8
SEN00138-01
2) Operation in direction of decrease of pump discharge amount (min. angle)
Operation When signal pressure PECN goes down, piston (8) moves to the left and stops at a point where the pressure in chamber c balances the pressure of springs (4) and (4A). At the same time, arm (6) uses servo piston (19) as a fulcrum and sways to the left in the same way as piston (8). This moves guide spool (13) to the left. When guide spool (13) moves, port a and port h are closed and port h is connected to drain chamber e. As a result, servo piston chamber j is also interconnected with drain chamber e through port i and port h.
At the same time, port a is interconnected with port d, so the oil flows through port g to servo piston chamber f, pushes servo piston (19) to the left, decreases the swash plate angle in the main piston pump and decreases the pump discharge amount. When servo piston (19) moves, arm (6) rotates counterclockwise with its center at pin (7). Guide spool (13) is moved to the right and closes port a, port d and port h, so the discharge decreases by an amount that matches signal pressure PECN.
PC600-8
15
SEN00138-01
TVC valve
PPO P1 P2 PDR PE
: Servo basic pressure IN port : Main pump pressure IN port : Main pump pressure IN port : TVC valve drain OUT port : TVC valve output pressure OUT port
1. 2. 3. 4.
Spring Spool Piston Piston
5. 6. 7. 8.
Sleeve Piston Body Solenoid
16
PC600-8
SEN00138-01
Function When the power mode is P-mode or E-mode, the pump discharge amount is set properly with the command current sent from the controller according to the engine speed.
When the emergency pump drive switch is turned ON, the pump discharge amount is controlled according to the pump discharge pressure (load) by sensing the oil pressure at constant pump absorption torque.
1) When command current value from controller is small in P and E mode
Operation The command current sent from the controller actuates solenoid push pin (9) and spool (2) moves. When this happens, spool (2) stops at a point where it balances the total of the force of spring (1), the force of push pin (9), and the force of TVC output pressure PE acting on piston (3). At this time, since the command current and the force of push pin (9) are small, spool (2) is balanced on the lower side.
As a result, ports "a" and "b" are opened almost fully and almost all the oil from the control pump is output as TVC valve output pressure PE . Then, TVC valve output pressure PE and signal pressure PECN increase, thus the pump discharge amount increases.
PC600-8
17
SEN00138-01
2) When command current value from controller is large in P and E mode
Operation The command current sent from the controller moves push pin (9), which moves spool (2). Spool (2) stops at a position where it is balanced with spring (1). At this time, since the command current and the force of push pin (9) are large, spool (2) is balanced on the upper side.
As a result, the oil flow from the control pump is reduced between ports "a" and "b" and the open areas of port " b" and port "c " (drain port) increase. Then, TVC valve output pressure PE and signal pressure PECN lower, thus the pump discharge amount decreases.
18
PC600-8
SEN00138-01
3) When emergency pump drive switch is turned ON and pump load is small
Operation If the emergency pump drive switch is turned ON, the command current increases and the force of solenoid push pin (9) becomes larger. As a result, spring (1) is kept compressed.
Since main pump discharge pressures P1 and P2 are low, spring (1) keeps pressing spool (2) down. As a result, control pump discharge pressure PPO becomes equal to TVC valve output pressure PE. At this time, TVC valve output pressure PE and the pump discharge amount increase.
PC600-8
19
SEN00138-01
4) When emergency pump drive switch is turned ON and pump load is large
Operation When main pump discharge pressure P1 (or P2) increases, spool (2) is moved up by piston (4) or piston (6). As a result, the flow of oil from port a to port b is throttled by the notch in the spool. At the same time, the area of the opening at port b and port c (drain port) becomes larger. In this way, TVC valve output pressure PE goes down, and the pump discharge amount decreases.
20
PC600-8
SEN00138-01
CO+NC valve
1. CO+NC valve (No. 1 front)
P : Main pump pressure IN port PEFR : TVC valve output pressure front, rear interconnection port PE : TVC valve output pressure detection port PCO : CO selector pilot port
PC600-8
PD PT PDR PECN
: Jet sensor downstream pressure IN port : Jet sensor upstream pressure IN port : CO+NC valve drain OUT port : CO+NC valve output pressure OUT port
21
SEN00138-01
2. CO+NC valve (No. 1 rear)
P1I P1O P2I P2O PEFR
Main pump pressure IN port (front) Main pump pressure OUT port Main pump pressure IN port (rear) Main pump pressure OUT port TVC valve output pressure front, rear interconnection port PEI : TVC valve output pressure IN port PCO : CO selector pilot port
: : : : :
PD : Jet sensor downstream pressure IN port PT : Jet sensor upstream pressure IN port PDRI : TVC valve drain IN port PDRO : CO+NC valve drain OUT port PPOI : Servo basic pressure IN port PPOO : Servo basic pressure OUT port PECN : CO+NC valve output pressure OUT port
22
PC600-8
SEN00138-01
CO valve 1. Plug 2. Piston 3. Spring 4. Spool 5. Piston 6. Plug
NC valve 7. Plug 8. Sleeve 9. Piston 10. Spool 11. Spring 12. Plug
PC600-8
23
SEN00138-01
3. CO valve
Function When the load becomes large during operations and the main pump discharge pressure rises to a point close to relief pressure, the cut-off function of the CO valve acts to reduce the pump discharge in order to reduce relief loss.
At the same time, it has a cut-off cancel function actuated by the pilot pressure from the heavy-lift solenoid valve. The CO valve is controlled by balancing the spring with the total of main pump discharge pressure P and CO valve output pressure PEC.
1) When main pump discharge pressure is lower than relief pressure
Operation Spool (4) is pressed down by spring (3). As a result, ports "a" and "b" are opened fully, and TVC valve output pressure PE is equal to CO valve output pressure PEC. Accordingly, CO valve output pressure PEC, signal pressure PECN , and pump discharge amount become maximum.
24
PC600-8
SEN00138-01
2) When main pump discharge pressure becomes close to relief pressure
Operation If the load increases and main pump discharge pressure P increases near to the relief pressure, main pump discharge pressure P presses piston (5). At the same time, CO valve output pressure PEC presses piston (5) and spool (4) moves up. As a result, oil flow from port "a" to port "b" is reduced by the notch of the spool and the open areas of port "b" and port "c" (drain port) increase. Accordingly, CO valve output pressure PEC and signal pressure PECN lower and the pump discharge amount becomes minimum.
PC600-8
25
SEN00138-01
3) When cut-off function is canceled by 2-stage relief solenoid valve
Operation If the 2-stage relief solenoid valve is turned ON, its pilot pressure PCO is lead in the port and piston (2) is pressed down. Accordingly, seat (6) touches seat (7) and locks spool (4). As a result, even if main pump discharge pressure P increases to the relief pressure, spool (4) does not operate. Accordingly, CO valve output pressure PEC keeps maximum and the pump discharge amount does not decrease.
26
PC600-8
SEN00138-01
4. NC valve
Function The NC valve controls the main pump discharge amount to reduce the neutral loss and fine control loss according to the moving distance of the control valve spool. The main pump discharge amount is controlled by balance of the sum of jet sensor upstream pressure PT and NC valve output pressure PECN and the sum of the force of NC valve spring (12) and jet sensor downstream pressure PD. The jet sensor senses the flow of the oil returning through the control valve to the tank and use it as PT and PD of the NC valve.
1) When control valve is at neutral
Operation When the control valve is at neutral, jet sensor differential pressure ( PT PD ) becomes the maximum, and the force of jet sensor output pressure PT pushing piston (10) becomes larger than the total of the force of spring (12) and the force of jet sensor output pressure PD pushing the bottom of spool (11).
As a result, spool (11) is pushed down, so the flow from port c to port b is throttled, and the area of the opening of port b and port a (drain port) becomes larger. In this way, NC valve output pressure PECN becomes the minimum, and the main pump discharge amount also becomes the minimum.
PC600-8
27
SEN00138-01
2) When control lever is operated
Operation When the control lever is moved, the jet sensor differential pressure (PT PD) goes down in accordance with the movement of the control lever. Spool (11) is pushed up, and the area of the opening of port c and port b becomes larger. In this way, NC valve output pressure PECN becomes larger and the discharge amount from the main pump increases. In other words, the pump discharge amount increases according to the amount that the control lever is operated.
28
PC600-8
SEN00138-01
No. 2 main pump

Model: HPV95+95
PA1 PA2 PD12 PD22 PS PSV PECN
: Front pump discharge port : Rear pump discharge port : Drain port : Drain port : Pump suction port : Servo basic pressure IN port : CO+NC valve output pressure port
1. 2. 3. 4.
Front pump Front servo valve Rear servo valve Rear pump
PC600-8
29
SEN00138-01
No. 2 main pump
PSV1 PSV2 PSV1A PSV1B PSV2A PSV2B
: Servo valve basic pressure port : Servo valve basic pressure port : Servo piston output port : Servo valve output port : Servo piston output port : Servo valve output port
PC600-8
30
SEN00138-01
1. 2. 3. 4. 5. 6. 7.
Front shaft Front cradle Front case Rocker cam Piston Cylinder block Valve plate
8. 9. 10. 11. 12. 13. 14.
Front end cap Coupling Impeller Rear end cap Valve plate Cylinder block Piston
15. 16. 17. 18. 19.
Rear case Rocker cam Rear cradle Rear shaft Servo piston
PC600-8
31
SEN00138-01
Servo valve
1. Servo valve (No. 2 front)
P1 P2 PAC PDR PPO PECN
: : : : : :
Main pump pressure IN port Main pump pressure IN port Servo actuator port Servo valve drain OUT port Servo basic pressure IN port CO+NC valve output pressure IN port
1. Servo valve
32
PC600-8
SEN00138-01
2. Servo valve (No. 2 rear)
P2 PAC PDR PPO PECN
: Main pump pressure IN port : Servo actuator port : Servo valve drain OUT port : Servo basic pressure IN port : CO+NC valve output pressure IN port
1. Servo valve
PC600-8
33
SEN00138-01
Line oil filter
1. Cover 2. Element 3. Case A: From main pump B: To control valve
Outline There are two line oil filters installed to the discharge side of the main pump. They protect the circuit and equipment by removing all dirt and dust from the oil.
34
PC600-8
SEN00138-01
PC600-8
35
SEN00138-01
Cooling fan pump

LPV75
P1 PS Pa Pe P1C Pen
: : : : : :
Pump discharge port Pump suction port Pump control basic pressure Pump control pressure Pump pressure detection port Pump control pressure detection port
PD2 : Pump drain port PD3 : Pump drain port PD4 : Pump drain port
36
PC600-8
SEN00138-01
1. 2. 3. 4. 5. 6.
Shaft Oil seal Case Rocker cam Shoe Piston
7. 8. 9. 10. 11. 12.
Cylinder block Valve plate Spring Servo piston Ball End cap
PC600-8
37
SEN00138-01
Function The rotation and torque of the engine are transmitted to the shaft of this pump and converted into hydraulic energy in this pump. This pump discharges the pressurized oil according to the load. The discharge of this pump can be changed by changing the swash plate angle in it.
Structure Cylinder block (7) is supported on shaft (1) through spline a. Shaft (1) is supported by the front and rear bearings. The end of piston (6) has a spherical hollow which is combined with shoe (5). Piston (6) and shoe (5) form a spherical bearing. Rocker cam (4) has plane A. Shoe (5) is kept pressed against plane A and slid circularly. Rocker cam (4) slides around ball (11). Piston (6) in each cylinder of cylinder block (7) moves relatively in the axial direction. Cylinder block (7) rotates relatively against valve plate (8), sealing the pressurized oil, and the hydraulic balance is maintained properly. The oil in each cylinder of cylinder block (7) can be sucked and discharged through valve plate (8).
38
PC600-8
SEN00138-01
Operation 1. Operation of pump Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane A. At this time, rocker cam (4) tilts around ball (11). As a result, angle between center line X of rocker cam (4) and the axis of cylinder block (7) changes. Angle is called the swash plate angle. If angle is made between center line X of rocker cam (7) and the axis of cylinder block (7), plane A works as a cam for shoe (5). Accordingly, piston (6) slides inside cylinder block (7) and a difference is made between volumes E and F in cylinder block (7). As a resurlt, each piston (6) sucks and discharges oil by F E. In other words, if cylinder block (7) rotates and the volume of chamber E is decreased, the oil is discharged from chamber E. On the other hand, the volume of chamber F is increased and the oil is sucked in chamber F. (In the figure, chamber F is at the end of the suction stroke and chamber E is at the end of the discharge stroke.) If center line X of rocker cam (4) is equal to the axis of cylinder block (7) (the swash plate angle is 0), there is not a difference between volumes E and F in cylinder block (7) and oil is not sucked or discharged. (The swash plate angle is not set to 0 actually, however.) In short, swash plate angle is in proportion to the pump discharge.
PC600-8
39
SEN00138-01
2. Control of discharge If swash plate angle is increased, the difference between volumes E and F is increased, and so discharge Q is increased. Swash plate angle is changed with servo piston (10). Servo piston (10) reciprocates straight according to the signal pressure of the servo valve. This straight motion is transmitted to rocker cam (4). Then, rocker cam (4) supported on ball (11) slides around ball (11).
40
PC600-8
SEN00138-01
Servo valve
P : EPC valve basic pressure T : Drain PE : Control piston pressure PH : Pump discharge pressure 1. 2. 3. 4. 5. 6. 7. Plug Lever Retainer Seat Spool Piston Sleeve
PC600-8
41
SEN00138-01
Function The servo valve controls the current input to the EPC valve and the swash plate angle of the pump so that they will be related as shown in the figure below.
The relationship between the input current to the EPC valve and the output pressure of EPC valve F is as follows.
42
PC600-8
SEN00138-01
Operation The output pressure of the EPC valve is applied to the piston chamber to push piston (6). Piston (6) pushes spool (5) until it is balanced with the spring. Then, the land of the servo piston pressure passage is connected to the pump discharge passages by the cut of spool (5) and the discharge pressure is led to the servo piston. The servo piston is raised by the rocker cam. The position feedback is applied and the lever moves to compress the spring. If spool (5) is pushed back, the pump discharge circuit and the servo piston circuit are shut off. The pressure in the servo piston chamber lowers and the rocker cam returns toward the maximum swash plate angle. These processes are repeated until the swash plate is fixed to a position where the EPC output pressure is balanced with the spring force. Accordingly as the EPC output pressure is heightened, the swash plate angle is decreased. As the EPC output pressure is lowered, the swash plate angle is increased.
PC600-8
43
SEN00138-01
Cooling fan motor

Type: LMF75
P : From fan pump TC : To tank T : From oil cooler to tank
Specifications Type: LMF75 Capacity: 75 cm3/rev Rated speed: 1,430 rpm Rated flow rate: 112 l/min Cracking pressure of check valve: 78.5 kPa {0.8 kg/cm2}
44
PC600-8
SEN00138-01
1. 2. 3. 4. 5. 6. 7. 8.
Output shaft Case Thrust plate Shoe Piston Cylinder block Valve plate End cover
9. 10. 11. 12. 13. 14. 15.
Center spring Check valve spring Check valve Pilot valve Reversible valve spool Safety valve Reversible valve spring
PC600-8
45
SEN00138-01
1. Hydraulic motor unit
Function This hydraulic motor is called a swash plate type axial piston motor. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion. Principle of operation The oil sent from the hydraulic pump flows through valve plate (7) into cylinder block (5). This oil can flow on supply side of the Y-Y line connecting the top dead center and bottom dead center of the stroke of piston (4). The oil sent to supply side of cylinder block (5) presses pistons (4) (4 or 5 pieces) and generates force F1(F1 kg = P kg/cm2 x x/4D2 cm2). This force is applied to thrust plate (2). Since thrust plate (2) is fixed to the angle of degrees to output shaft (1), the force is divided into components F2 and F3. The radial component F3 generates torque against the Y-Y line connecting the top dead center and bottom dead center (T = F3 x ri). The resultant of this torque [T = ( F3 x ri)] rotates cylinder block (5) through the piston. Since cylinder block (5) is coupled with the output shaft by means of spline, the output shaft revolves to transmit the torque.
46
PC600-8
SEN00138-01
2. Suction valve
Function If the fan pump stops, the hydraulic oil does not flow into the motor. Since the motor continues revolution because of the force of inertia, however, the pressure on the outlet side of the motor rises. When the oil stops flowing in from inlet port P, the suction valve sucks in the oil on the outlet side and supplies it to the port MA where there is not sufficient oil to prevent cavitation. Operation 1) When pump is started If the hydraulic oil from the pump is supplied to port P and the pressure on MA side rises and starting torque is generated in the motor, the motor starts revolution. The oil on outlet MB side of the motor returns through port T to the tank.
2) When pump is stopped If the engine is stopped and the input revolution of the fan pump lowers to 0 rpm, the hydraulic oil from the pump is not supplied to port P anymore. As the hydraulic oil is not supplied to MA side of the motor, the motor speed lowers gradually to stop. If the motor shaft is revolved by the force of inertia while the oil flow in port P is reducing, the oil in port T on the outlet side is sent by the suction valve to MA side to prevent cavitation.
PC600-8
47
SEN00138-01
3. Operation of reversible valve
1) When ON-OFF solenoid for reversible valve is turned OFF If ON-OFF solenoid (1) for reversible valve is turned "OFF", the hydraulic oil from the pump is blocked by ON-OFF reversible valve (2) and port C is connected to the tank circuit. Accordingly, reversible valve spool (3) is pushed by reversible valve spool spring (4) to the right to open motor port MA and then the hydraulic oil flows in to revolve the motor forward (clockwise).
2) When ON-OFF solenoid for reversible valve is turned ON If ON-OFF solenoid (1) for reversible valve is turned "ON", ON-OFF reversible valve (2) changes to let the hydraulic oil from the pump flow through port C into spool chamber D. The hydraulic oil in chamber D pushes reversible valve spool (3) to the left against reversible valve spool spring (4). As a result, motor port MB opens and the hydraulic oil flows in to revolve the motor in reverse (counterclockwise).
48
PC600-8
SEN00138-01
4. Safety valve
Function When the engine is started, the pressure in port P of the fan motor is heightened in some cases. Safety valve (1) is installed to protect the fan system circuit. Operation If the pressure in port P rises above the cracking pressure of safety valve (1), valve (2) of safety valve (1) opens to release the hydraulic oil into port T. By this operation, generation of abnormal pressure in port P is prevented.
PC600-8
49
SEN00138-01
50
SEN00139-02
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8

Hydraulic system, Part 2 Control valve................................................................................................................................................... 2 Swing motor.................................................................................................................................................. 21 Center swivel joint ........................................................................................................................................ 30 Travel motor.................................................................................................................................................. 31 Valve control ................................................................................................................................................. 42 Work equipment, swing PPC valve............................................................................................................... 44 Travel PPC valve .......................................................................................................................................... 48 Service PPC valve ........................................................................................................................................ 50 PPC accumulator.......................................................................................................................................... 51 PPC shuttle valve ......................................................................................................................................... 52 Solenoid valve .............................................................................................................................................. 53 Boom holding valve ...................................................................................................................................... 58 Boom LOWER regeneration valve ............................................................................................................... 62 Quick return valve......................................................................................................................................... 65 Hydraulic cylinder ......................................................................................................................................... 68
PC600-8
SEN00139-02

Control valve
Outline This control valve consists of a 4-spool valve and a 5-spool valve, and a travel shuttle valve is also installed to it. Furthermore, a straight-travel valve, arm throttle valve, and swing priority valve are built in. The 4-spool and 5-spool valves are connected by bolts to form one unit, and internal merging of the oil flow makes it even more compact and easy to maintain. A1L : To L.H. travel motor PB port A2L : To boom cylinder bottom A3L : To bucket cylinder head A1R : To swing motor MA port A3R : Service A4R : To arm cylinder head A5R : To R.H. travel motor PA port B1L : To L.H. travel motor PA port B2L : To boom cylinder head B3L : To bucket cylinder bottom B1R : To swing motor MB port B3R : Service B4R : To arm cylinder bottom B5R : To R.H. travel motor PB port NCAL : To rear NC valve NCBL : To rear NC valve NCAR : To front NC valve NCBR : To front NC valve P3 : From arm PPC shuttle valve P4 : From boom, bucket PPC shuttle valve P5 : From swing PPC shuttle valve P6 : Work equipment oil pressure switch P1AL P2AL P3AL P4AL P1AR P3AR P4AR P5AR P1BL P2BL P3BL P1BR P3BR P4BR P5BR PL PR PRL PRR T TS : From L.H. travel PPC valve : From boom PPC valve : From bucket PPC valve : From arm PPC valve : From swing PPC valve : Service : From arm PPC valve : From R.H. travel PPC valve : From L.H. travel PPC valve : From boom PPC valve : From bucket PPC valve : From swing PPC valve : Service : From arm PPC valve : From R.H. travel PPC valve : From rear main pump : From front main pump : From 2-stage relief solenoid valve : From 2-stage relief solenoid valve : To tank : To tank
1. Travel shuttle valve 2. 4-spool valve (straight-travel valve, arm throttle valve built in) 3. 5-spool valve (swing priority valve built in)
PC600-8
SEN00139-02
4-spool valve + 5-spool valve (with travel shuttle valve)
PC600-8
SEN00139-02
Cross-sectional diagram
(1/4)
1. 2. 3. 4. 5.
Spool return spring Spool (L.H. travel) Spool (boom Lo) Spool (bucket Lo) Spool (arm Hi)
6. 7. 8. 9. 10.
Jet sensor orifice Jet sensor relief valve Main relief valve Spool (straight-travel) Spool (arm throttle)
PC600-8
SEN00139-02
Unit: mm
No. Check item Standard size 11 Spool return spring
Free length x OD
Criteria Repair limit Installed load 192 N {19.6 kg} 324 N {33.0 kg} Free length Installed load 154 N {15.7 kg} 259 N {26.4 kg}
Remedy
Installed length 54.5 52.5
87.6 x 21.2 12 Spool return spring 58.1 x 26.5
Replace spring if damaged or deformed
PC600-8
SEN00139-02
(2/4)
1. 2. 3. 4. 5.
Spool return spring Spool (swing) Spool (boom Hi) Spool (service / bucket Hi) Spool (arm Lo)
6. 7. 8. 9. 10.
Spool (R.H. travel) Jet sensor relief valve Jet sensor orifice Main relief valve Spool (swing priority)
PC600-8
SEN00139-02
Unit: mm
Free length x OD
Criteria Repair limit Installed load 104 N {10.6 kg} Free length Installed load 83.4 N {8.50 kg}
Remedy
Installed length 52.5
53.8 x 26.5
PC600-8
SEN00139-02
(3/4)
1. 2. 3. 4. 5. 6. 7.
Check valve Check valve spring Spool (L.H. travel) Spool (straight-travel) Spool (swing priority) Spool (swing) Suction valve
8. 9. 10. 11. 12. 13.
Spool (boom Lo) Check valve Spool (boom Hi) Suction valve Suction valve Suction valve
PC600-8
SEN00139-02
Unit: mm
No. Check item Standard size 14 Check valve spring
Free length x OD
Criteria Repair limit Installed load 12.7 N {1.3 kg} 0.98 N {0.10 kg} 255 N {26.0 kg} 255 N {26.0 kg} 125 N {12.7 kg} 207 N {21.1 kg} 125 N {12.7 kg} 7.85 N {0.80 kg} Free length Installed load 10.2 N {1.04 kg} 0.78 N {0.08 kg} 204 N {20.8 kg} 204 N {20.8 kg} 100 N {10.2 kg} 100 N {10.2 kg} 6.28 N {0.64 kg}
Remedy
Installed length 13.5 26.5 26.5 52.0 53.5 18.2 53.5 29.0
20.8 x 12.2 15 16 17 18 19 20 21 Check valve spring Spool return spring Spool return spring Spool return spring Spool return spring Spool return spring Check valve spring 31.8 x 7.6 30.7 x 32.5 54.0 x 34.2 54.8 x 34.0 21.0 x 16.9 54.9 x 34.0 55.9 x 30.2
PC600-8
SEN00139-02
(4/4)
1. 2. 3. 4. 5. 6.
Suction-safety valve Spool (bucket Lo) Spool (arm throttle) Spool (service / bucket Hi) Spool (arm Hi) Check valve
7. 8. 9. 10. 11. 12.
Spool (arm Lo) Suction-safety valve Check valve Spool (R.H. travel) Suction-safety valve Suction valve
PC600-8
10
SEN00139-02
Unit: mm
Free length x OD
Criteria Repair limit Installed load 125 N {12.7 kg} 255 N {26.0 kg} 255 N {26.0 kg} 125 N {12.7 kg} 125 N {12.7 kg} 7.85 N {0.80 kg} Free length Installed load 100 N {10.2 kg} 204 N {20.8 kg} 204 N {20.8 kg} 100 N {10.2 kg} 100 N {10.2 kg} 6.28 N {0.64 kg}
Remedy
Installed length 53.5 26.5 52.0 53.5 53.5 29.0
54.8 x 34.0 14 15 16 17 18 Spool return spring Spool return spring Spool return spring Spool return spring Check valve spring 30.7 x 32.5 54.0 x 34.2 54.8 x 34.0 54.9 x 34.0 55.9 x 30.2
PC600-8
11
SEN00139-02 Travel shuttle valve
P0 P1 P2 P3 P4 P5 P4A P5A T
: To straight-travel valve : From L.H. travel valve A1L port : From L.H. travel valve B1L port : From arm shuttle valve : From boom, bucket shuttle valve : From swing shuttle valve : To arm throttle valve : To swing priority valve : To tank
1. 2. 3. 4. 5.
Cover Spool return spring Body Spool Orifice
12
PC600-8
SEN00139-02
Function The travel shuttle valve is installed to the top of the 4-spool valve control valve. It brings the PPC valve pressures from the L.H. travel, work equipment, and swing. It also sends pilot pressure to the straight-travel valve when the travel and work equipment or travel and swing are operated at the same time. 1. When travel is operated independently
Operation When the travel FORWARD is operated, pilot pressure oil flows from the L.H. travel circuit to port P1 and pushes the spool to the right. Ports P3, P4, and P5 are interconnected with port P0 through the groove in the spool to the straighttravel valve. However, when the work equipment and swing control levers are at NEUTRAL, the pilot pressure oil from the PPC valve does not flow, so it also does not flow to the straight-travel valve.
When the travel REVERSE is operated, the pressure oil is sent to port P2 and pushes the spool to the left.
PC600-8
13
SEN00139-02
2. During simultaneous operation
Operation When the arm and travel FORWARD are operated at the same time, pilot pressure oil flows from the L.H. travel circuit to port P1 and pushes the spool to the right. When the arm is operated, pilot pressure oil also flows to port P3 from the arm PPC shuttle valve. This passes through the groove in the spool and port P0, and flows to the straight-travel valve.
The pilot pressure oil from the swing PPC shuttle valve flows from port P5 port P0 straighttravel valve, and the pilot pressure oil from the boom and bucket PPC shuttle valves flows from port P4 port P0 straight-travel valve.
14
PC600-8
SEN00139-02
Straight-travel valve
Function When the travel is operated at the same time as the swing, boom, arm, or bucket, the pressure oil flowing to the left and right travel circuits is divided and sent to the boom, arm, or bucket circuit. If the oil in one travel circuit is divided off, the amount of oil supplied to the travel motor will be less than in the travel circuit which is not divided, so the drop in the supply of oil to the travel motor will cause the machine to deviate. 1. When travel is operated independently To prevent this, the straight-travel valve is switched to interconnect the left and right travel circuits. This ensures that the amount of oil supplied to the left and right travel motors is equal. As a result, the left and right travel motors both rotate at the same speed, and there is little travel deviation.
Operation No pilot pressure flows from the travel shuttle valve, so the straight-travel valve is not actuated. Because of this, port PL (L.H. travel circuit) and port PR (R.H. travel circuit) are not interconnected, and each circuit remains independent.
PC600-8
15
SEN00139-02
2. When travel and work equipment are operated at same time
Operation The pilot oil from the travel shuttle valve presses the spool of straight travel valve (1). Accordingly, port PL is connected to the right and left travel motors and oil of the same quantity is fed to the right and left travel motors. Since the right and left travel motors rotate at the same speed, the machine deviates less.
16
PC600-8
SEN00139-02
Swing priority valve

Function When the swing and arm are operated at the same time, a large amount of the pressure oil flows to the arm circuit where the load is small, so little pressure oil flows to the swing circuit. This makes the arm speed too fast for the swing speed, and causes poor combination in simultaneous operation. 1. When swing is at HOLD To overcome this, the swing priority valve is actuated to throttle the pressure oil flowing to the arm Lo control valve in order to restrict the arm speed and improve the simultaneous operation performance.
Operation No pilot pressure oil flows from the travel shuttle valve, so the swing priority valve is not actuated. For this reason, all the pressure oil from the front main pump passes through port PR and flows to the arm Lo control valve.
PC600-8
17
SEN00139-02
2. When swing is operated
Operation When the swing is operated, the pilot pressure oil from the travel shuttle valve pushes spool (1) of the swing priority valve to the left. As a result, the pressure oil flowing from the front main pump through port PR to the arm Lo control valve is throttled, and the arm speed is restricted to improve the simultaneous operation performance.
18
PC600-8
SEN00139-02
Arm throttle valve

Function When arm and boom are operated at same time When the arm and boom are operated at the same time, a large amount of the pressure oil flows to the arm circuit where the load is small, so little pressure oil flows to the boom circuit. This makes the arm speed too fast for the boom speed, and causes poor combination in simultaneous operation. This is a particular problem when the arm OUT and boom RAISE are operated at the same time. To overcome this, the arm throttle valve is actuated to throttle the pressure oil flowing to the arm Hi control valve in order to restrict the arm speed and improve the simultaneous operation performance. When arm and bucket are operated at same time The arm is actuated by the merged flow from two pumps and the bucket is actuated by the oil from one pump. In this condition, if the arm and bucket are operated at the same time, a large amount of the pressure oil flows to the arm circuit, so little pressure oil flows to the bucket circuit. This makes the arm speed too fast for the bucket speed, and causes poor combination in simultaneous operation. This is a particular problem when the arm OUT and bucket CURL are operated at the same time. To overcome this, the arm throttle valve is actuated to throttle the pressure oil flowing to the arm Hi control valve in order to restrict the arm speed and improve the simultaneous operation performance.
1. When arm is operated independently
Operation No pilot pressure oil flows from the travel shuttle valve, so the arm throttle valve is not actuated.
For this reason, all the pressure oil from the rear main pump passes through port PL and flows to the arm Hi control valve.
PC600-8
19
SEN00139-02
2. When arm and boom or bucket are operated at same time
Operation When the arm and boom or bucket are operated at the same time, the pilot pressure oil from the travel shuttle valve pushes spool (1) of the arm throttle valve to the right. As a result, the pressure oil flowing from the rear main pump to the arm Hi control valve is throttled, and the arm speed is restricted to improve the simultaneous operation performance.
20
PC600-8
SEN00139-02
Swing motor
Model: KMF90ABE-3 (with reverse prevention valve)
T1 S MA MB B
: To tank : From control valve : From control valve : From control valve : From swing brake solenoid valve
Specifications Model: KMF90ABE-3 Theoretical delivery: 87.8 cc/rev Safety valve set pressure: 25.5 MPa {260 kg/cm2} Rated speed: 2,320 rpm Brake release pressure: 2.06 MPa {21.0 kg/cm2}
PC600-8
21
SEN00139-02
1. 2. 3. 4. 5. 6. 7.
Drive shaft Spacer Case Disc Plate Brake ring Brake piston
8. 9. 10. 11. 12. 13. 14.
Housing Reverse prevention valve Center spring Cylinder block Valve plate Piston Center shaft
15. 16. 17. 18. 19. 20.
Safety valve Check valve Check valve spring Shuttle valve Shuttle valve spring Brake spring
22
PC600-8
SEN00139-02
Unit: mm
No. Check item Standard size 21 Check valve spring
Free length x OD
Criteria Repair limit Installed load 3.04 N {0.31 kg} 13.7 N {1.4 kg} Free length Installed load 2.45 N {0.25 kg} 11 N {1.12 kg}
Remedy
Installed length 39 11.5
62.5 x 20.0 22 Shuttle valve spring 16.4 x 8.9
PC600-8
23
SEN00139-02
Swing brake
Operation 1. When swing brake solenoid valve is de-energized If the swing brake solenoid valve is de-energized, the flow of pressurized oil from the control pump is shut off, and port B is connected to the tank circuit. As a result, brake piston (7) is pushed down by brake spring (8), pushes disc (4) and plate (5) together, and the brake is applied.
2. When swing brake solenoid valve is energized When the swing brake solenoid valve is energized, the valve is switched, and pressurized oil from the control pump enters port B and flows to brake chamber A. The pressurized oil entering chamber A overcomes brake spring (8) and brake piston (7) moves up. As a result, disc (4) and plate (5) are separated and the brake is released.
24
PC600-8
SEN00139-02
Safety valve
Outline The safety valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). Function When the swing is stopped, the outlet port circuit of the motor is closed by the control valve, but the motor continues to be turned by the inertia of the swing. As a result, the pressure at the outlet port of the motor becomes abnormally high and there is danger that the motor will be damaged. The safety valve is installed to prevent this problem. It acts to release the abnormally high pressure oil from the outlet port (high-pressure side) of the motor and send it to the back pressure valve and prevent damage to the motor. Operation 1. When starting swing If the swing control lever is operated to swing to the right, the pressurized oil from the pump passes through the control valve and is supplied to port MA. When this happens, the pressure at port MA rises and starting force is generated in the motor, so the motor starts to turn. The oil from the outlet port of the motor flows from port MB through the control valve and returns to the tank.
PC600-8
25
SEN00139-02
2. When stopping swing When the swing control lever is returned to the neutral position, no more pressurized oil is supplied from the pump to port MA . At the same time, the oil from the outlet port of the motor returns from the control valve to the tank, and the circuit is closed. The pressure at port MB rises, and rotating resistance to the motor is generated, so the brake starts to take effect. If the pressure at port MB rises higher than the pressure at port MA, shuttle valve (4) is pushed and chamber C becomes the same pressure as port MB. The pressure then rises to the set pressure of relief valve (1). In this way, a high brake torque is generated in the motor, and the motor stops. When relief valve (1) is being actuated, the relieved oil and oil from back pressure valve is supplied to port MA through check valve (3) to prevent cavitation at port MA.
26
PC600-8
SEN00139-02
Reverse prevention valve
MA T1 MB T2
: Port : Port : Port : Port
1. 2. 3. 4. 5. 6. 7.
Valve body Spool (MA side) Spring (MA side) Plug (MA side) Spool (MB side) Spring (MB side) Plug (MB side)
PC600-8
27
SEN00139-02
Explanation of effect
28
PC600-8
SEN00139-02
Function When the swing is stopped, this valve reduces the rocking motion of the swing body due to the inertia of the swing body, backlash of the machinery system, the compressibility of the hydraulic oil, etc. This valve is effective to prevent the cargo from being spilled when the swing is stopped as well as to shorten recycle time (excellent in the positioning accuracy and the next operation can be started quickly).
Operation 1. When the braking pressure is present at port MB MB pressure is introduced to chamber d via the notch and spool (5) makes a stroke motion to the left, pressing spring (6) due to the difference in area (D1>D2) and the interconnection of MB to e is established. On this occasion, MA pressure is less than the set pressure of spring (3), so that spool (2) does not make a stoke motion and the pressure oil is closed by spool (2), and the braking force is secured.
2. When the motor stopped temporarily The motor is reversed by the shutoff pressure that occurred at port MB. (First reversal) On this occasion, the reverse pressure is generated at port MA side. This pressure at port MA is introduced to chamber a, and spool (2) makes a stroke motion to the right, pressing spring (3), and the interconnection of MA to b is established. Also, the interconnection of b to f is established through the drill hole of spool (5) and the reverse pressure at port MA is bypassed to port T, thereby preventing the second reversal.
PC600-8
29
SEN00139-02
Center swivel joint
1. 2. 3. 4. 5.
Cover Body Slipper seal O-ring Shaft
A1. A2. B1. B2. C1. C2.
From control valve port A5R To R.H. travel motor port PB From control valve port A1L To L.H. travel motor port PA From control valve port B5R To R.H. travel motor port PA
D1. D2. E1. E2. T1. T2.
From control valve port B1L To L.H. travel motor port PB From travel speed EPC valve To L.H. and R.H. travel motors port P To tank From L.H. and R.H. travel motors port T Unit: mm
No.
Check item Clearance between rotor and shaft Standard size 90
Criteria Standard clearance 0.056 0.105 Clearance limit
Remedy
Replace 0.111
30
PC600-8
SEN00139-02
Travel motor
Model: KMV335ADT
P T PA PB
: : : :
From travel speed solenoid valve To tank From control valve From control valve
Specifications Model: KMV335ADT Theoretical delivery: Minimum 217 cc/rev Maximum 336 cc/rev Brake release pressure: 1.27 0.39 MPa {13.0 4.0 kg/cm2} Travel speed selector pressure: 0.93 0.25 MPa {9.50 2.50 kg/cm2}
PC600-8
31
SEN00139-02
1. 2. 3. 4. 5. 6. 7.
Output shaft Motor case Piston Cylinder block Valve plate End cover Slow return valve
8. 9. 10. 11. 12. 13. 14.
Plug Regulator piston Plate Disc Check valve spring Check valve Counterbalance valve
15. 16. 17. 18. 19. 20.
Spool return spring Safety valve Regulator valve Spring Brake spring Brake piston
32
PC600-8
SEN00139-02
Unit: mm
Free length x OD
Criteria Repair limit Installed load 427 N {43.5 kg} 3.04 N {0.31 kg} 98.1 N {10.0 kg} Free length Installed load 341 N {34.8 kg} 2.45 N {0.25 kg} 78.5 N {8.0 kg}
Remedy
Installed length 42.0 39.0 50.0
62.5 x 32 22 23 Check valve spring Regulator piston spring 62.5 x 20.0 55.0 x 9.0
PC600-8
33
SEN00139-02
1. At low speed (motor swash plate angle at maximum)
Operation When the solenoid valve is de-energized, the pilot pressure oil from the control pump does not flow to port P. For this reason, regulator valve (17) is pushed upward in the direction of the arrow by spring (18). The main pressure oil from the control valve pushes shuttle valve (7), goes through end cover (6), and acts on chamber a of regulator piston (9). At the same time, the main pressure passes through passage c and acts on chamber b through regulator valve (17).
Because of this, propulsion force equal to the difference in area of chambers a and b (Ab Aa) of regulator piston (9) acts in a downward direction. As a result, valve plate (5) and cylinder block (4) move in the maximum swash plate angle direction, the motor capacity becomes the maximum, and the system is set to low speed.
34
PC600-8
SEN00139-02
2. At high speed (motor swash plate angle at minimum)
Operation When the solenoid valve is energized, the pilot pressure oil from the control pump flows to port P, and pushes regulator valve (17) down. Because of this, the main pressure oil and the oil in chamber d is shut off by regulator valve (17), and the oil in chamber b is drained inside the case. A propulsion force generated by the pressure oil in chamber a of regulator piston (9) then acts upward.
As a result, valve plate (5) and cylinder block (4) move in the minimum swash plate angle direction, the motor capacity becomes the minimum, and the system is set to high speed.
PC600-8
35
SEN00139-02
Parking brake
1. When starting to travel
Operation When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (14), opens the circuit to the parking brake, and flows into chamber e of brake piston (20). It overcomes the force of spring (19), and pushes piston (20) to the right. When this happens, the force pushing plate (10) and disc (11) together is lost, so plate (10) and disc (11) separate and the brake is released.
36
PC600-8
SEN00139-02
2. When stopping travel
Operation When the travel lever is placed in neutral, counterbalance valve spool (14) returns to the neutral position and the circuit to the parking brake is closed. The pressurized oil in chamber e of brake piston (20) passes through the throttle of slow return valve (7) until spool (14) of the counterbalance valve returns to neutral. When spool (14) of the counterbalance valve returns to the neutral position, the oil is drained inside the case from throttle f of brake piston (20) and brake piston (20) is pushed fully to the left by spring (19).
PC600-8
As a result, plate (10) and disc (11) are pushed together, and the brake is applied. A time delay is provided by having the pressurized oil pass through a throttle in slow return valve (7) when the brake piston returns, and this ensures that the brake is applied after the machine stops.
37
SEN00139-02
Brake valve
Operation of brake valve The brake valve consists of a check valve, counterbalance valve, and safety valve in a circuit as shown in the diagram on the right. The function and operation of each component is as given below.
1. Counterbalance valve, check valve Function When traveling downhill, the weight of the machine makes it try to travel faster than the speed of the motor. As a result, if the machine travels with the engine at low speed, the motor will rotate without load and the machine will run away, which is extremely dangerous. To prevent this, these valves act to make the machine travel according to the engine speed (pump discharge amount).
Operation when pressurized oil is supplied When the travel lever is operated, the pressurized oil from the control valve is supplied to port PA. It pushes open check valve (13A) and flows from motor inlet port MA to motor outlet port MB. However, the motor outlet port is closed by check valve (13B) and spool (14), so the pressure at the supply side rises.
The pressurized oil at the supply side flows from orifice E1 in spool (14) and orifice E2 in the piston to chamber S1. When the pressure in chamber S1 goes above the spool switching pressure, spool (14) is pushed to the right. As a result, port MB and port PB are connected, the outlet port side of the motor is opened, and the motor starts to rotate.
38
PC600-8
SEN00139-02
Operation of brake when traveling downhill If the machine tries to run away when traveling downhill, the motor will turn under no load, so the pressure at the motor inlet port will drop, and the pressure in chamber S1 through orifices E1 and E2 will also drop. When the pressure in chamber S1 drops below the spool switching pressure, spool (14) is returned to the left by spring (15), and outlet port MB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor, and this prevents the machine from running away. In other words, the spool moves to a position where the pressure at outlet port MB balances the pressure at the inlet port and the force generated by the weight of the machine. It throttles the outlet port circuit and controls the travel speed according to the amount of oil discharged from the pump. 2. Safety valve (2-direction operation, 2-stage set safety valve) Function When travel is stopped (or when traveling downhill), the circuits at the inlet and outlet ports of the motor are closed by the counterbalance valve. However, the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and will damage the motor or piping. The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent damage to the equipment. Operation in both directions 1) When pressure in chamber MB has become high (when rotating clockwise) When the travel is stopped (or when traveling downhill), chamber MB in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia. If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D2 [ x/4( D1 2 D2 2 ) x pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MA in the circuit on the opposite side.
PC600-8
39
SEN00139-02
2) When pressure in chamber MA has become high (when rotating counterclockwise) When the travel is stopped (or when traveling downhill), chamber MA in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia.
If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D3 [x /4( D3 2 D1 2 ) x pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MB in the circuit on the opposite side.
40
PC600-8
SEN00139-02
Set pressures varying mechanism

Function 1. When starting travel (high-pressure setting) When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (14), and opens the pilot circuit to the safety valve. The oil passes from chamber G to passage H and flows into chamber J, pushes the piston to the right, and compresses the spring to make the set load larger. Because of this, the set pressure of the safety valve is switched to the high pressure setting, and a large drawbar pull is made available.
2. When stopping travel (low-pressure setting) When the travel lever is placed at neutral, the pressure in chamber PA drops and counterbalance valve spool (14) returns to the neutral position. While the counterbalance valve spool is returning to the neutral position, the pressurized oil in chamber J passes through passage H, and escapes to chamber PA from chamber G. The piston moves to the left, and the set load becomes smaller. Because of this, the set pressure of the safety valve is switched to the low-pressure setting and relieves the shock when reducing speed. Set pressure of safety valve High-pressure setting : 37.8 MPa {385 kg/cm2} (at starting and traveling) Low-pressure setting (at stopping) : 27.5 MPa {280 kg/cm2}
PC600-8
41
SEN00139-02
Valve control
1. 2. 3. 4. 5. 6. 7.
Travel PPC valve Service PPC valve Service pedal L.H. travel lever R.H. travel lever Right PPC valve Right work equipment lever 8. Solenoid valve 9. Accumulator
10. 11. 12. 13. 14.
Solenoid valve Control valve Hydraulic pump Shuttle valve PPC safety lock solenoid valve 15. Left work equipment lever 16. Left PPC valve
Lever positions A. NEUTRAL B. Boom RAISE C. Boom LOWER D. Bucket DUMP E. Bucket CURL F. NEUTRAL G. Arm IN H. Arm OUT
J. K. L. M. N.
Swing RIGHT Swing LEFT NEUTRAL Travel REVERSE Travel FORWARD
42
PC600-8
SEN00139-02
PC600-8
43
SEN00139-02
Work equipment, swing PPC valve
P : From safety lock solenoid valve T : To tank
P1 P2 P3 P4
: L.H. PPC: Arm OUT/R.H. PPC: Boom LOWER : L.H. PPC: Arm IN/R.H. PPC: Boom RAISE : L.H. PPC: Right swing/R.H. PPC: Bucket CURL : L.H. PPC: Left swing/R.H. PPC: Bucket DUMP
44
PC600-8
SEN00139-02
1. 2. 3. 4. 5. 6.
Spool Metering spring Centering spring Piston Disc Nut (for connecting lever)
7. 8. 9. 10. 11.
Joint Plate Retainer Body Filter Unit: mm
No.
Check item Standard size
Criteria Repair limit Installed load 9.81 N {1.0 kg} 17.7 N {1.8 kg} 16.7 N {1.7 kg} Free length Installed load 7.85 N {0.8 kg} 14.1 N {1.44 kg} 13.3 N {1.36 kg}
Remedy
12
Centering spring (for P3, P4)
Free length x OD
Installed length 34.0 34.0 24.9
38.7 x 15.5 13 14 Centering spring (for P1, P2) Metering spring 42.5 x 15.5 26.5 x 8.2
PC600-8
45
SEN00139-02
Operation 1. At neutral Ports A and B of the control valve and ports P1 (P3) and P2 (P4) of the PPC valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1)
2. Fine control (neutral fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed. Spool (1) is also pushed by metering spring (2) and moves down. When this happens, fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure of the control pump is sent from port A through fine control hole f to port P1. When the pressure at port P1 rises, spool (1) is pushed back. Fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D, so the pressure at port P1 escapes. As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the pressure of port P1. The relationship of the positions of spool (1) and body (10) (fine control hole f is in the middle between drain chamber D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. In this way, the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port P1) and the force of the return spring of the control valve spool are balanced. (Fig. 2)
5 4 9 D 2 f P T
1 P1 P2
PP 10
Control valve (Fig. 2)
SBP00276
46
PC600-8
SEN00139-02
3. Fine control (control lever returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port P1 is released. If the pressure at port P1 drops too much, spool (1) is pushed down by metering spring (2), so fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port P1 supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve spool returns, oil in drain chamber D flows in from fine control hole f of the valve on the side that is not moving. It passes through port P2 and goes to chamber B to charge the oil. (Fig. 3)
5 4 3 D 2 f P f' 1 PP P1 P2 T
SBP00277
4. At full stroke Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1). Fine control hole f is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from the control pump passes through fine control hole f and flows to chamber A from port P1 to push the control valve spool. The return oil from chamber B passes from port P2 through fine control hole f and flows to drain chamber D. (Fig. 4)
5 4 9 D
f P
T f'
1 Pp P1 P2
SBP00278
PC600-8
47
SEN00139-02
Travel PPC valve
P : From main pump T : To tank
P1 P2 P3 P4
: L.H. travel REVERSE : L.H. travel FORWARD : R.H. travel REVERSE : R.H. travel FORWARD
a The travel PPC valve operates similarly to the work equipment and swing PPC valves.
48
PC600-8
SEN00139-02
1. Plate 2. Body 3. Piston
4. Collar 5. Valve Unit: mm
No.
Criteria Repair limit Installed load 108 N {11.0 kg} 16.7 N {1.7 kg} Free length Installed load 86.3 N {8.8 kg} 13.7 N {1.4 kg}
Remedy
Centering spring
Free length x OD
Installed length 32.5 24.9
48.6 x 15.5 7 Metering spring 26.5 x 8.15
PC600-8
49
SEN00139-02
Service PPC valve

1. 2. 3. 4. 5. 6. 7. 8. Spool Metering spring Centering spring Piston Lever Plate Retainer Body
T : To tank P : From main pump P1 : Port P2 : Port
a The service PPC valve operates similarly to the work equipment and swing PPC valves. Unit: mm
No. Check item Standard size 9 Centering spring
Free length x OD
Criteria Repair limit Installed load 124.5 N {12.7 kg} 16.7 N {1.7 kg} Free length Installed load 100 N {10.2 kg} 13.7 N {1.4 kg}
Remedy
Installed length 28.4 22
33.9 x 15.3 10 Metering spring 22.7 x 8.1
50
PC600-8
SEN00139-02
PPC accumulator
SBP00290
1. 2. 3. 4. 5. 6.
Gas plug Shell Poppet Holder Bladder Oil port
Specifications Actual gas volume: 500 cc
PC600-8
51
SEN00139-02
PPC shuttle valve

For arm, swing
1. Plug 2. Body 3. Ball a. b. c. d. e. f. g. h. i. j. Port P1B (right swing) Port P5 (travel shuttle valve) Port P2B (left swing) Port P4B (arm OUT) Port P6 (travel shuttle valve) Port P3B (arm IN) Port P2A (left swing) Port P1A (right swing) Port P3A (arm IN) Port P4A (arm OUT)
For boom, bucket

1. 2. 3. 4. a. b. c. d. e. f. g. h. i. Plug assembly Plug Ball Body Port P1A (bucket DUMP) Port P3A (bucket CURL) Port P4A (boom LOWER) Port P2A (boom RAISE) Port P5 (travel shuttle valve) Port P3B (bucket CURL) Port P1B (bucket DUMP) Port P2B (boom RAISE) Port P4B (boom LOWER)
52
PC600-8
SEN00139-02
Solenoid valve
For CO cancel, 2-stage relief, boom Hi 2-stage safety valve, swing brake, travel speed solenoid valve
1. 2. 3. 4. 5.
CO cancel solenoid valve 2-stage relief solenoid valve Boom Hi 2-stage safety valve solenoid valve Swing brake solenoid valve Travel speed solenoid valve
T A1 A2 A3 A4 A5 P1 ACC PPC
: To tank : To No. 1 pump (NC valve) : To left and right travel motors : To boom LOWER 2-stage safety valve : To main valve (relief valve) : To swing motor : From control pump : To accumulator : To PPC valve
PC600-8
53
SEN00139-02
1. 2. 3. 4. 5. 6. 7.
Connector Moving core Solenoid Cage Spool Block Spring
Operation When solenoid is de-energized When the signal current does not flow from the connector, solenoid (3) is de-energized. For this reason, spool (5) is pushed fully to the left by spring (6). As a result, the circuit between ports P and A closes and the pressurized oil from the control pump does not flow to the actuator. At the same time, the pressurized oil from the actuator flows from port A to port T, and is then drained to the tank.
When solenoid is energized When the signal current flows from the connector to solenoid (3), solenoid (3) is energized. For this reason, spool (5) is pushed to the right in the direction of the arrow. As a result, the pressurized oil from the control pump flows from port P through the inside of spool (5) to port A, and then flows to the actuator. At the same time, port T is closed, and this stops the oil from flowing to the tank.
54
PC600-8
SEN00139-02
Bucket curl Hi cancel

1. 2. 3. 4. 5. 6. 7. Connector Moving core Solenoid Spool Body Spring Plug
Operation When solenoid is de-energized The signal current does not flow from the connector, so solenoid (3) is de-energized. For this reason, spool (4) is returned to the neutral position by spring (6). As a result, the circuit between ports P and A is connected, and the pressurized oil from the PPC valve flows to the control valve.
When solenoid is energized When the signal current flows from the connector to solenoid (3), solenoid (3) is energized and moving core (2) is pushed to the right in the direction of the arrow. For this reason, spool (4) is also pushed to the right in the direction of the arrow. As a result, port P is closed, and the pressurized oil from the PPC valve does not flow to the control valve. At the same time, port A and port T are interconnected, and the oil from the control valve is drained to the tank.
PC600-8
55
SEN00139-02
For safety lock (under cab)
1. Safety lock solenoid valve
T : To tank A : To port P of work equipment PPC valve To port P of travel PPC valve P : From control pump
56
PC600-8
SEN00139-02
1. 2. 3. 4. 5. 6.
Connector Solenoid Moving core Body Plug Spring
7. 8. 9. 10. 11.
Spool Body Plug Spring Spool
Operation When solenoid is de-energized No signal current flows from the PPC hydraulic lock switch, so solenoid (2) is de-energized. Accordingly, spool (11) is pushed up by spring (10) and spool (7) is pushed to the left by spring (6). As a result, port P is closed, so pressurized oil from the control pump does not flow to the actuator. At the same time, the oil from the actuator flows from port A2 to port T and is drained to the tank. When solenoid is energized When the signal current flows from the PPC hydraulic lock switch to solenoid (2), solenoid (2) is energized. Accordingly, spool (11) is pushed down and the pressurized oil from the control pump flows through port P to port A1 and spool (7) is pushed to the right. As a result, pressurized oil from the control pump flows from port P to port A2, and then flows to the actuator. At the same time, port T is closed, so the oil does not flow to the tank.
PC600-8
57
SEN00139-02
Boom holding valve
T V CY PI
: To tank : From control valve : To boom cylinder bottom : From PPC valve (pilot pressure)
1. 2. 3. 4. 5.
Safety-suction valve Pilot spring Pilot spool Poppet spring Poppet

PC600-8
58
SEN00139-02
1. Boom at RAISE
Operation When the boom is raised, the main pressure from the control valve pushes poppet (5) up. Because of this, the main pressurized oil from the control valve passes through the valve and flows to the bottom end of the boom cylinder.
PC600-8
59
SEN00139-02
2. Boom at HOLD
Operation When the boom is raised and the control lever is returned to NEUTRAL, the circuit for the holding pressure at the bottom end of the boom cylinder is closed by poppet (5). At the same time, the oil flowing into poppet (5) through orifice a of poppet (5) is closed by pilot spool (3). As a result, the boom is held in position.
60
PC600-8
SEN00139-02
3. Boom at LOWER
Operation When the boom is lowered, the pilot pressure flows to port PI from the PPC valve pushes pilot spool (3) and the pressurized oil in chamber b inside the poppet is drained. When the pressure at port CY rises because of the pressurized oil from the bottom end of the boom cylinder, the pressure of the pressurized oil in chamber b is lowered by orifice a. If the pressure in chamber b drops below the pressure at port CY, poppet (5) opens, the pressurized oil flows from port CY to port V, and then flows to the control valve. If any abnormal pressure is generated in the circuit at the bottom end of the boom cylinder, safety valve (1) is actuated to drain oil from port CY to port T.
PC600-8
61
SEN00139-02
Boom LOWER regeneration valve
T PB PM PI
: To tank : From boom cylinder bottom : From boom cylinder head : From boom LOWER PPC valve
PC600-8
62
SEN00139-02
1. 2. 3. 4.
Body Spool Check valve Spring Unit: mm
No.
Criteria Repair limit Installed load 29.4 N {3.0 kg} 58.8 N {6.0 kg} 207 N {21.1 kg} Free length Installed load 23.5 N {2.4 kg} 47.1 N {4.8 kg} 166 N {16.9 kg}
Remedy
Spring (check valve)
Free length x OD
Installed length 22 35 47
83.5 x 25.5 6 7 Spool return spring (small) Spool return spring (large) 41.1 x 9.6 49.4 x 25.7
PC600-8
63
SEN00139-02
Function When the boom is lowered, some of the oil drained from the bottom end of the boom cylinder is circulated to the cylinder head to increase the lowering speed of the boom. Operation When control lever (1) is operated to the LOWER position, PPC pressure flows and boom Lo spool (2) moves to the LOWER position. At the same time, regeneration valve spool (3) is moved by the PPC pressure from port Pi. As a result, the head and bottom ends of boom cylinder (4) are interconnected through ports PB and PM. When this happens, the oil from the cylinder bottom passes through the control valve and returns to tank (5). Some of the oil enters port PB of the regeneration valve and flows from port PM to the cylinder head to increase the lowering speed of the boom. The boom cylinder has a large volume, and during compound operations, the oil flow from the pump to the cylinder head is insufficient, so this action prevents any vacuum from forming inside the circuit.
64
PC600-8
SEN00139-02
Quick return valve

Function When arm OUT is operated, this valve reduces the pressure loss of the large amount of oil returning from the cylinder bottom. Operation 1. Arm at OUT When arm OUT is operated, the pilot pressure from the PPC valve pushes pilot spool (1), and the pressure oil from chamber b inside the poppet is drained through orifice c. The oil at the bottom end of the arm flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber b drops. When the pressure in chamber b drops below the pressure at port A, the pressure at port A and acts on ring -shaped area C (= Area of d1 Area of d2) because of the difference in the outside diameter d1 of valve (2) and seat diameter d2. Valve (2) moves to the top and the pressure oil from port A goes to port B. From port B, the oil is drained directly to the tank.
PC600-8
65
SEN00139-02
2. Arm at HOLD The oil that has flowed through orifice a in valve (2) is closed by pilot piston (1). At the same time, the hold pressure at the bottom end of the arm acts in the bottom direction on ring-shaped area C (= Area of d1 Area of d2) because of the difference in the outside diameter d1 of valve (2) and seat diameter d2 . Valve (2) is closed by the total of this force and the force of spring (3), so port A and port B are shut off.
66
PC600-8
SEN00139-02
PC600-8
67
SEN00139-02
Hydraulic cylinder
Backhoe specification Boom cylinder
Arm cylinder
Bucket cylinder
68
PC600-8
SEN00139-02
Unit: mm
No. Check item Name of cylinder Clearance between piston rod and bushing Boom Arm Bucket Boom Arm Bucket Boom Arm Bucket Standard size 120 140 130 125 125 110 110 120 110 Criteria Tolerance Shaft 0.036 0.090 0.043 0.106 0.043 0.106 0.043 0.106 0.043 0.106 0.036 0.090 0.036 0.090 0.036 0.090 0.036 0.090 Hole +0.263 +0.048 +0.256 +0.039 +0.256 +0.040 +0.495 +0.395 +0.495 +0.395 +0.457 +0.370 +0.151 +0.074 +0.457 +0.370 +0.457 +0.370 Standard clearance 0.084 0.353 0.082 0.362 0.083 0.362 0.438 0.601 0.438 0.601 0.406 0.547 0.110 0.241 0.406 0.547 0.406 0.547 Clearance limit 0.453 0.662 0.462 1.5 1.5 1.5 Replace pin, bushing 1.5 1.5 1.5 Remedy
Replace bushing
Clearance between piston rod support shaft and bushing
Clearance between cylinder bottom support shaft and bushing
PC600-8
69
SEN00139-02 Loading shovel specification Boom cylinder
Arm cylinder
Bucket cylinder
Bottom dump cylinder
70
PC600-8
SEN00139-02
Unit: mm
No. Check item Name of cylinder Boom 1 Clearance between piston rod and bushing Arm Bucket Bottom dump Boom Clearance between piston rod support shaft and bushing Arm Bucket Bottom dump Boom Clearance between cylinder bottom support shaft and bushing Arm Bucket Bottom dump Standard size 130 140 110 90 125 125 125 90 110 125 115 90 Criteria Tolerance Shaft 0.043 0.106 0.043 0.106 0.036 0.090 0.036 0.090 0.043 0.083 0.043 0.106 0.043 0.083 0.036 0.090 0.036 0.090 0.043 0.106 0.036 0.090 0.036 0.090 Hole +0.256 +0.040 +0.263 +0.047 +0.261 +0.047 +0.257 +0.048 +0.495 +0.395 +0.495 +0.395 +0.495 +0.395 +0.457 +0.370 +0.161 +0.074 +0.495 +0.395 0 0.020 +0.457 +0.370 Standard clearance 0.083 0.362 0.090 0.369 0.083 0.351 0.084 0.347 0.438 0.578 0.438 0.601 0.438 0.578 0.406 0.547 0.110 0.251 0.438 0.601 0.016 0.090 0.406 0.547 Clearance limit 0.662 0.662 0.662 0.647 1.5 1.5 1.5 1.5 Replace pin, bushing 1.5 1.5 1.5 1.5 Replace bushing Remedy
PC600-8
71
SEN00139-02
72
SEN00140-03
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8

Work equipment
Work equipment Work equipment.............................................................................................................................................. 2 Dimensions of work equipment ...................................................................................................................... 6
PC600-8
SEN00140-03
Work equipment
Work equipment
PC600-8
SEN00140-03
Unit: mm
No. Check item Standard size 140 Criteria Tolerance Shaft 0.043 0.106 0.043 0.106 0.036 0.090 0.036 0.090 0.036 0.090 0.036 0.090 Hole +0.148 +0.057 +0.407 +0.325 +0.360 +0.284 +0.326 +0.223 +0.354 +0.275 +0.382 +0.279 0.5 1.0 Standard clearance 0.100 0.254 0.368 0.513 0.320 0.450 0.259 0.416 0.311 0.444 0.315 0.472 Clearance limit 1.5 Remedy
Clearance between bushing and mounting pin of boom and revolving frame Clearance between bushing and mounting pin of boom and arm Clearance between bushing and mounting pin of arm and link Clearance between bushing and mounting pin of arm and bucket Clearance between bushing and mounting pin of link and link Clearance between bushing and mounting pin of link and bucket Bucket clearance
130
1.5
110
1.5
Replace
115
1.5
110
1.5
115
1.5 Adjust shims
PC600-8
SEN00140-03
PC600-8
SEN00140-03
Unit: mm
No. Check item Standard size 140 Criteria Tolerance Shaft 0.043 0.106 0.043 0.106 0.043 0.106 0.036 0.090 Hole +0.148 +0.057 +0.542 +0.442 +0.523 +0.460 +0.457 +0.370 Standard clearance 0.100 0.254 0.485 0.648 0.503 0.629 0.406 0.547 Clearance limit 1.5 Remedy
Clearance between bushing and mounting pin of boom and revolving frame Clearance between bushing and mounting pin of boom and arm Clearance between bushing and mounting pin of arm and bucket Clearance between bushing and mounting pin of front bucket and rear bucket
140
1.5
Replace
140
1.5
95
1.5
PC600-8
SEN00140-03
Dimensions of work equipment

1. Arm
PC600-8
SEN00140-03
Unit: mm Model No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Arm as individual part 18 When pressfitting bushing Min. 19 Max. 3,990 3,577 3,577 3,577 464 2,380 464 2,152 464 2,152 464 2,152
PC600, PC600LC-8 2.9 m Arm

125 148 458 130 499 460.6 1,188.9 2,863.2 3,624 471.3 910 700 678 2,197 115 456 0.5 115 448
0 -0.5
3.5 m Arm
125 148 458 130 582 321.7 1,187.2 3,465.2 3,324.2 497.6 810 700 608 2,166 115 456 0.5 115 448
0 -0.5
4.3m Arm
125 148 458 130 627.7 338 1,182.7 4,256.6 3,315.9 497.6 810 700 608 2,166 115 456 0.5 115 448
0 -0.5
5.2m Arm
125 148 458 130 666.9 352 1,178.6 5,188.1 3,308.2 497.6 810 700 608 2,166 115 456 0.5 115 448
0 -0.5
PC600-8
SEN00140-03
2. Bucket
PC600-8
SEN00140-03
Unit: mm Model No.

1 2 3 4 5 6 7 8 9 10 11 12 Press fit hole for bushing 15 16 17 18 19 20 21 22 23 24 13 14
PC600, PC600LC-8 2.0 m3, 2.3m3, 2.7m3 Bucket

599.7 0.5 100.1 0.5 2,148 280 115 +0.1 0 457 +2 0 84.5 80.5 135 +0.063 0 75.5 488.5 +2 0 79 115 +0.1 0
3.5 m3 Bucket
665 0.5 132.5 0.5 2,179 280 115 +0.1 0 457 +2 0 84.5 80.5 135 +0.063 0 75.5 488.5 +2 0 79 115 +0.1 0
PC600-8
SEN00140-03
10
SEN00141-00
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8

Cab and its attachments
Cab and its attachments Air conditioner piping ...................................................................................................................................... 2
PC600-8
SEN00141-00

Air conditioner piping
For the electric circuit diagram of the air conditioner, see Others.
1. 2. 3. 4. 5. 6. 7. 8.
Air conditioner unit Duct Refrigerant piping Air conditioner compressor Condenser Receiver tank Hot water return piping Hot water pickup piping
A : Fresh air B : Recirculated air C : Hot air/cold air
SEN00141-00
SEN00142-04
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8

Electrical system
Engine control ...................................................................................................................................................... 2 Machine control system diagram ......................................................................................................................... 7 Monitor system................................................................................................................................................... 31 Sensors .............................................................................................................................................................. 46 KOMTRAX system ............................................................................................................................................. 50
PC600-8
SEN00142-04
Engine control
1. Operation of system Starting engine When the starting switch is turned to the START position, the starting signal flows to the starting motor, and the starting motor turns to start the engine. When this happens, the engine controller checks the signal from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.
Engine speed control The fuel control dial sends signal voltages to the engine controller according to its angle. The engine controller sends drive signals to the supply pump according to the signal voltages received from the fuel control dial and controls the fuel injection pump to control the engine speed.
Stopping engine When the engine controller detects that the starting switch is at the STOP position, it cuts the signal to the supply pump drive solenoid to stop the engine.
PC600-8
SEN00142-04
2. Components of system Fuel control dial 1. 2. 3. 4. 5. 6. Knob Dial Spring Ball Potentiometer Connector
Function The fuel control dial is installed at the bottom of the machine monitor. A potentiometer is installed under the knob, and when the knob is turned, it rotates the potentiometer shaft. When the shaft rotates, the resistance of the variable resistor inside the potentiometer changes, and the desired throttle signal is sent to the engine controller. The hatched area in the graph on the right is the abnormality detection area and the engine speed is set at low idling.
PC600-8
SEN00142-04
Engine controller
PC600-8
SEN00142-04
Input and output signals

CN-CE01 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 NC NC Ambient press. sensor Supply pump #1 (+) Supply pump #1 () CAN () NC CAN (+) Supply pump #2 (+) Supply pump #2 () EGR valve () NC Engine oil press. sensor NC Water temp. sensor Sensor power (+5V) NC NC EGR position sensor EGR in press. sensor NC EGR valve (+) Boost temp. sensor NC Common rail press. sensor G sensor (+) NE sensor (+) NC Bypass valve position sensor Fuel temp. sensor Bypass valve (+) NC Sensor power (+5V) NC NC NC Sensor power (+5V) GND NC NC NC NC NC Boost press. sensor Injector #1 (+) Injector #5 (+) G sensor () Signal name Input/ Output Input Output Output Input/ Output Input/ Output Output Output Output Input Input Output Input Input Output Input Input Input Input Input Input Output Output Output Input Output Output Pin No. 48 49 50 51 52 53 54 55 56 57 58 59 60 Signal name NE sensor () NC NC Injector #2 () Injector #3 () Injector #1 () Injector #2 (+) Injector #3 (+) Injector #4 (+) Injector #6 (+) Injector #4 () Injector #6 () Injector #5 () Input/ Output Output Output Output Output Output Output Output Output Output Output
CN-CE02 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 NC NC NC NC NC NC NC NC Fuel dial (+) NC NC NC NC NC NC NC NC NC NC NC NC Fuel dial (+5V) Fuel dial () NC NC NC NC NC NC NC NC NC Signal name Input/ Output Input Output
PC600-8
SEN00142-04
Input/ Output Input Output Output Input/ Output Input/ Output
Pin No. 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 NC NC NC NC
Signal name
NC NC Key switch (ACC) Electrical intake air heater sub relay (output) NC Electrical intake air heater sub relay (return) NC NC NC CAN (+) CAN () NC NC NC
CN-CE03 Pin No. 1 2 3 4 Signal name GND NC Power (+24V) NC Input/ Output
PC600-8
SEN00142-04
Machine control system diagram

OFF (Cancel) Auto deceleration function ON P 3-mode selector type torque control Electronic OLSS function Cut-off control Flow control OFF Power max. function ON ON (low pressure) (Digging improvement mode) 2-stage boom pushing force selector function OFF (high pressure) (Machine push-up mode) (Machine push-up) Machine control system E L E2 E3 E0 E1
Swing control function
Engine automatic warming-up, Overheat prevention function, Turbo protect function
Travel control function Travel speed selection function Travel pressure increasing function Fixed to Lo (Low speed) Automatic travel speed shifting between Hi (High speed) and Lo (Low speed) Normal rotation Fan rotation control Reverse rotation
PC600-8
SEN00142-04
Machine control system diagram
PC600-8
SEN00142-04
PC600-8
SEN00142-04
1. Auto deceleration system
Function If all the control levers are at neutral when waiting for work or waiting for a dump truck, the engine speed is automatically reduced to a midrange speed to reduce fuel consumption and noise. If any lever is operated, the engine speed returns immediately to the set speed.
10
PC600-8
SEN00142-04
Operation 1. When auto-deceleration switch is turned ON Control levers at neutral If the engine is running at above the deceleration actuation speed (approx. 1,400 rpm), and all the control levers are returned to neutral, the engine speed drops immediately to approx. 100 rpm below the set speed to the No. 1 deceleration position. If another 4 seconds passes, the engine speed is reduced to the No. 2 deceleration position (approx. 1,400 rpm), and is kept at that speed until a lever is operated. When control lever is operated If any control lever is operated when the engine speed is at No. 2 deceleration, the engine speed will immediately rise to the speed set by the fuel control dial.
2. When auto-deceleration switch is turned OFF
Control lever at neutral If the engine is running at a speed above 1,750 rpm and all the control levers are returned to neutral, the engine speed drops to approx. 1,750 rpm after 4 seconds and is kept at that speed until a lever is operated.
When control lever is operated If any control lever is operated under the condition shown at left (after the engine speed drops to approx. 1,750 rpm), the engine speed will immediately rise to the speed set by the fuel control dial.
PC600-8
11
SEN00142-04
2. Electronic OLSS function
Pump control system
Interconnected control of all pumps is carried out by one TVC valve. P mode: Total horsepower control by engine speed sensing E mode: Total horsepower control by engine speed sensing Emergency pump drive circuit: Constant torque control
12
PC600-8
SEN00142-04
1) Control method in each mode P, E, L mode
Matching point in P, E and L mode: Rated output point

Model Mode P E0 E1 E2 E3 L PC600-8R PC600LC-8R 1,800 rpm 1,720 rpm 1,680 rpm 1,640 rpm 1,580 rpm 1,730 rpm Cut-off 2-stage relief Relief pressure 31.9 MPa {325 kg/cm2}
Q Q
31.9 MPa {325 kg/cm2}
37.3 MPa {380 kg/cm2}
When the load on the pump rises and the pressure rises, the engine speed goes down. At this time, by reducing the pump discharge, set the engine speed at about the rated output point. If the pressure lowers, by increasing the pump discharge, set the engine speed at about the rated output point. By repeating this control, the engine can always be used at near the rated output point. Compared with the P mode, which provides the maximum output, the E mode lowers the engine output to provide matching at a point which gives better fuel consumption efficiency than the P mode.
PC600-8
13
SEN00142-04
2) Cut-off function If the load during operation increases and the pump discharge pressure rises to near the relief pressure, the main pump cut-off valve is actuated to reduce the relief loss.
3) Cut-off cancel function The cut-off cancel function acts to stop the operation of the cut-off function in order to ensure the pump flow close to the relief pressure, thereby preventing any drop in speed. The actuation and cancellation of the cut-off function is set automatically by operating the power max. switch, or travel lever.
Cut-off function and actuation of each switch

Switch Function Cut-off function P Working mode switch E L Cancel Travel lever ON Cancel OFF Actuated Power max. switch ON Cancel OFF Actuated Swing lock switch ON Cancel OFF Actuated
Actuated Actuated
4) 2-stage relief function When L mode switch is ON, the pilot pressure of the 2-stage relief valve raises the set pressure of the main relief valve from 31.9 MPa {325 kg/ cm2} to 37.2 MPa {380 kg/cm2} to increase the hydraulic power.
14
PC600-8
SEN00142-04
3. Power max. function
Function This is a function to increase the power for a fixed period when the L.H. knob switch is oprerated. It makes it possible to obtain a sudden burst of power to match the working conditions. If knob switch on the work equipment control lever is turned ON, the following functions are actuated.
Power max. switch Mode, function CO function Main relief valve set pressure
OFF
ON
Actuated 31.9 MPa {325 kg/cm2}
Canceled 34.3 MPa {350 kg/cm2} Canceled after 8.5 sec even when kept pressed
Operating time
PC600-8
15
SEN00142-04
4. 2-stage boom pushing force selector function
Outline This function switches the pushing force of the boom. It is aimed to provide both increased digging efficiency by reducing the digging resistance of the boom, and increased ease of operation by increasing the thrusting force for excavation, digging square holes, carrying out twist turns, or escaping from soft ground.
16
PC600-8
SEN00142-04
Operation This function acts to change the set pressure of the safety valve at the boom cylinder end of the R.H. 4-spool control valve boom Lo in 2 ways: to low pressure (14.7 MPa {150 kg/cm2}) and high pressure (33.3 MPa {340 kg/cm2}.
Mode Machine push-up switch Machine push-up solenoid valve Safety valve set pressure Effect By reducing the boom pushing force, it is made easier for the boom to escape automatically in the RAISE direction and to reduce the number of times that the boom is operated. At the same time it also makes the digging operation smoother. By increasing the thrust force for boom LOWER, the ease of operation is improved for excavation, digging square holes, carrying out twist turns, or escaping from soft ground.
Boom pushing force (low mode)
Energized
14.7 MPa {150 kg/cm2}
Boom pushing force (high mode)
De-energized
28.4 MPa {290 kg/cm2}
PC600-8
17
SEN00142-04
5. Swing control function
Function The system is provided with a swing lock and swing holding brake function.
18
PC600-8
SEN00142-04
Swing lock, swing holding brake function The swing lock (manual) can be locked at any desired position, and the swing lock and swing holding brake (automatic) are interconnected with the swing, so they prevent any hydraulic drift after the swing is stopped.
a Swing brake solenoid valve For details of the structure and function, see Solenoid valve. a Swing motor For details of the structure and function, see Swing motor.
Actuation
Mode Swing lock switch Swing lock monitor Swing brake solenoid valve Actuation When swing and work equipment levers are placed at neutral, swing brake is applied after approx. 10 sec; when any swing or work equipment lever is operated, brake is canceled and swing can be operated freely.
Swing holding brake
OFF
OFF
See diagram on right
Swing brake
ON
ON
De-energized
Swing lock is actuated and swing is held in position. Even when swing lever is operated, swing lock is not canceled and swing does not move.
Operation of swing lock prolix switch If any abnormality should occur in the controller, and the swing holding brake is not actuated normally and the swing cannot be operated, the swing lock prolix switch can be operated to cancel the swing lock and allow the swing to be operated. a Even when the swing lock prolix switch is turned ON, the swing lock switch stays ON and the swing brake is not canceled. a When the swing brake is canceled, the swing has only a hydraulic brake operated by the safety valve, so if the swing is stopped on a slope, there may be hydraulic drift.
Swing lock prolix switch Swing lock switch Swing brake
ON (when controller is abnormal) ON Swing lock applied OFF Swing lock canceled
OFF (when controller is normal) ON Swing lock applied OFF Swing holding brake applied
PC600-8
19
SEN00142-04
6. Engine automatic warming-up, overheat prevention function, turbo protect function
Function If the coolant temperature is low, this automatically raises the engine speed to warm up the engine after it is started. In addition, if the coolant temperature rises too high during operations, it reduces the load of the pump to prevent overheating. To protect the turbocharger bearing during cold weather, the engine speed is kept below the fixed speed when the engine is started. In addition, to improve the starting ability, a small amount of fuel is injected two or more times before the main injection.
20
PC600-8
SEN00142-04
1) Engine automatic warming-up function After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm up the engine.
2) Engine overheat prevention function This function protects the engine by lowering the pump load and engine speed to prevent overheating when the engine coolant temperature has risen too high. This system is actuated at 105C and above.
PC600-8
21
SEN00142-04
3) Turbo protection function Function to protect turbocharger bearing during cold weather by keeping engine speed below fixed speed when engine is started. Actuation condition
Engine coolant temperature More than +10C +10C to 10C Less than 10C Turbo protect time (sec) 0 Gradually changes between 0 and 20 20
Engine speed: 1,000 rpm Even if the fuel control dial is operated during the above time, the engine speed will not change. After the set time passes, the operation moves to the automatic warming up function in Step 1).
22
PC600-8
SEN00142-04
7. Travel control function
Outline The pump absorption torque is increased when traveling to increase the drawbar pull. Switching between manual and automatic travel speed selection is used to improve the travel performance.
PC600-8
23
SEN00142-04
Travel speed selection function 1) Manual selection using travel speed switch If the travel speed switch is set to Lo, Hi, the pump controller controls the pump flow and motor volume at each speed range as shown on the right to switch the travel speed. 2) Automatic selection according to engine speed If the engine speed is reduced to below 1,200 rpm by the fuel control dial: If the machine is traveling in Lo, it will not shift even if Hi is selected. If the machine is traveling in Hi, it will automatically shift to Lo. 3) Automatic selection according to pump discharge pressure If the machine is traveling with the travel speed switch at Hi, and the load increases, such as when traveling up a steep hill, if the travel pressure continues at 31.4 MPa {320 kg/cm 2 } for more than 2.0 sec, the pump volume is automatically switched and the travel speed changes to Lo. (The travel speed switch stays at Hi.) The machine continues to travel in Lo, and when the load is reduced, such as when the machine travels again on flat ground or goes downhill, and the travel pressure stays at 22.6 MPa {230 kg/cm2} or less for more than 1.0 sec, the pump volume is automatically switched and the travel speed returns to Hi. Travel pressure increasing function Outline To maintain the drawbar pull when traveling, the cut-off is canceled and the pressure is raised from 31.9 MPa {325 kg/cm2} to 34.3 MPa {350 kg/cm2}. Operation
Pressure increase solenoid valve When traveling When not traveling De-energized De-energized Main relief valve set pressure 31.9 MPa {325 kg/cm2} 31.9 MPa {325 kg/cm2}
Travel speed switch Motor volume Travel speed (km/h)
Lo (Low speed) Max. 3.0
Hi (High speed) Min 4.9
Cut-off cancel solenoid valve Energized De-energized
CO valve Canceled Actuated
24
PC600-8
SEN00142-04
Components of system
Engine speed sensor
1. 2. 3. 4. 5.
Wire Magnet Terminal Housing Connector
Function The engine speed sensor is installed to the ring gear portion of the engine flywheel. It counts electrically the number of gear teeth that pass in front of the sensor, and sends the results to the engine controller and pump controller. This detection is carried out by a magnet, and an electric current is generated every time the gear tooth passes in front of the magnet.
PPC hydraulic switch 1. Plug 2. Switch 3. Connector Specifications Composition of points: N. O. points Actuation (ON) pressure: 0.5 0.1 MPa {5.0 1.0 kg/cm2} Reset (OFF) pressure: 0.3 0.5 MPa {3.0 0.5 kg/cm2}
Function There are 12 switches installed to the PPC block. The operating condition of each actuator is detected from the PPC pressure, and this is sent to the engine controller and pump controller.
PC600-8
25
SEN00142-04
TVC resistor
1. Resistor 2. Connector Specification Resistance: 20 z
Function This resistor acts to allow a suitable current to flow to the TVC solenoid when the TVC emergency pump drive switch is ON. No current flows when the TVC emergency pump drive switch is OFF.
Fuel control dial, engine controller a See Engine control. Monitor panel a See Monitor system. TVC valve a See Hydraulic pump.
26
PC600-8
SEN00142-04
Pump controller
PC600-8
27
SEN00142-04
CN-CP01 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Signal name NC R pump pressure sensor NC Signal GND (Auto grease-up error) NC NC F pump pressure sensor Air temp sensor Signal GND Knob switch NC NC NC NC NC Starting switch (C) NC NC NC Analog GND Power supply (+5V) Starting switch (ACC) Step light switch Input/ Output Input Input Input Input Input Input Input Input Input Input Input Input Input Output Input Input Input Input Output Input Input
CN-CP02 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Signal name NC Swing prolix switch NC 232C_RD (Overload sensor) (Overload caution enable switch) Machine select 4 NC NC NC NC CAN shield Machine select 5 232C_TxD NC NC Machine select 3 NC Step light drive relay NC NC CAN0_L NC Flash memory write enable signal Horn switch NC Machine select 2 NC NC NC NC CAN0_H NC GND (232C GND) Service pressure switch NC Machine select 1 Swing lock switch NC NC Input/ Output Output Input Input Input Input Input Input Output Output Input Output Input Output Input Input Input Output Output Input Input/ Output Input/ Output Input/ Output Input Input Input Input Input Input Input/ Output Input/ Output Input Input Input Input Input
28
PC600-8
SEN00142-04
CN-CP03 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Signal name Controller power supply Solenoid power supply SOL_COM Battery relay drive NC NC NC Travel alarm Bucket digging pressure switch Boom raise switch Controller power supply Solenoid power supply SOL_COM Key signal NC TVC solenoid 2-stage relief solenoid Flash light drive relay Bucket dump pressure switch Boom lower pressure switch GND Solenoid power supply SOL_COM Key signal Fan reverse solenoid NC Travel speed solenoid Cut-off cancel solenoid Swing pressure switch Arm digging pressure switch GND GND GND NC Fan pump EPC NC Swing parking brake solenoid Bucket Hi cancel solenoid Travel pressure switch Arm dump pressure switch Input/ Output Input Input Output Output Output Output Output Input Input Input Input Input Output Output Output Output Input Input Input Input Output Output Output Output Input Input Output Output Output Output Input Input
PC600-8
29
SEN00142-04
30
PC600-8
SEN00142-04
Monitor system
The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It processes and immediately displays the obtained information on the panel notifying the operator of the condition of the machine. The panel is roughly divided as follows. 1. Monitor section to output alarms when the machine has troubles 2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.) The monitor panel also has various mode selector switches and functions to operate the machine control system.
PC600-8
31
SEN00142-04
Monitor panel
Outline The monitor panel has the functions to display various items and the functions to select modes and electric parts. The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information. The monitor display unit consists of LCD (Liquid Crystal Display). The switches are flat sheet switches.
32
PC600-8
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CN1 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 CN2 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Signal name (Coolant temp.) Fuel level Coolant level (Hydraulic oil level) Air filter NC (Engine oil press.) Engine oil level N/W signal N/W signal Charge Hydraulic oil temp. (a) GND Buzzer drive Limit switch (window) Buzzer cancel Swing lock Pre-heating Light GND Input/ Output Input Input Input Input Input Input Input Input Input/ Output Input/ Output Input Input Input Input Input Input Input Input Key ON Key ON Washer Start Limit switch (W) GND GND VB+ Wiper (+) Wiper () Buzzer on input Limit switch (P) Signal name Input/ Output Input Input Output Input Input Input Output Output Input Input CN3 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 NC NC NC NC NC NC RS230C CTS RS232C RD RS232C RD RS232C RD Boot switch NC GND CAN (shield) CAN (+) CAN () Signal name Input/ Output Input Input Input Input Input Input Input Input Input/ Output Input/ Output Input Input Input Input Input
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Monitor control, display portion
Monitor portion
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Wiper monitor Preheating monitor Swing lock monitor Engine coolant temperature monitor Hydraulic oil temperature gauge Engine coolant temperature gauge Working mode monitor Service monitor Travel speed meter Fuel gauge
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Fuel level monitor Hydraulic oil temperature monitor Power Max. monitor Auto-deceleration monitor Radiator coolant level caution Battery charge caution Engine oil pressure caution Engine oil level caution Air cleaner clogging Maintenance time warning caution
34
PC600-8
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Monitor items and display

Display category Symbol Display item Display range Display method
Wiper
ON
INT
OFF
Displays set condition
Working mode
Displays set mode
Monitor
Travel speed
Displays set speed
Auto-deceleration
ON
OFF
Displays actuation status
Service meter
Service meter indicator
When service meter is working
Lights up when service meter is working
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Symbol
Display item
Display method
Swing lock switch OFF Swing lock

SAT00098
Swing holding brake release switch OFF OFF ON ON
Swing lock monitor OFF ON Flashes ON
ON OFF ON
Continuous set time Up to 30 sec. Preheating From 30 sec. to 40 sec. More than 40 sec.
Preheating monitor status ON Flashes OFF
Power Max. switch status Power Max. Being pressed Not being pressed
Power Max. monitor status Lights up but goes out after approx. 9 sec. when kept pressed Flashes
Engine coolant temperature
Hydraulic oil temperature
See gauge display on the next page
Fuel level
36
PC600-8
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Gauge display
Gauge
Range A1 A2
Temperature, volume 105 102 100 80 60 30 105 102 100 80 40 20 524 382 249 138 101 84
Indicator (Symbol) Red Red Green Green Green White Red Red Green Green Green White Green Green Green Green Green Red
Buzzer sound
Engine coolant temperature (C)
A3 A4 A5 A6 B1 B2
Hydraulic oil temperature (C)
B3 B4 B5 B6 C1 C2
Fuel level (l)
C3 C4 C5 C6
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Cautions displayed during checks before starting (caution lamps all light up) When any of the following items is abnormal or its maintenance interval is reached or exceeded, the monitor corresponding to it lights up at the center of the screen.
Check before starting item When engine is stopped When engine is running When abnormal, lights up and buzzer sounds
Symbol
Display item
Engine oil pressure

SAP00519
Battery charge
SAP00522
Lights up when abnormal
Radiator coolant level

SAP00520
When abnormal, lights up and buzzer sounds
Engine oil level

SAP00523
Air cleaner clogging

SAP00521
Maintenance
Lights up when there is a warning. Lights up for only 30 sec. after key is turned ON, then goes out.
The above cautions are displayed at the display positions of the hydraulic oil temperature gauge and hydraulic oil temperature monitor. Accordingly, if the hydraulic oil temperature is abnormally high or low at this time, only the hydraulic oil temperature monitor symbol is displayed.
Condition of hydraulic oil Low temperature (below B6 or equivalent) Normal (B6 B2) High temperature (above B2) Color of symbol Black on white background No display White on red background
38
PC600-8
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Switches
1. 2. 3. 4. 5. 6. 7. 8. 9.
Working mode selector switch Buzzer cancel switch Display brightness, contrast adjustment switch Control switch Window washer switch Wiper switch Maintenance switch Travel speed selector switch Auto-deceleration switch
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Working mode selector switch The condition of the machine changes according to the switch that is pressed (Shown in the figure at right). It is possible to check the condition on the working mode monitor display. The relationship between each working mode and the monitor display is shown in the table on the right. Maintenance switch Check the condition of the maintenance items. (For details, see Maintenance function.) Auto-deceleration switch Each time the auto-deceleration switch is pressed, the auto-deceleration function is switched ON/OFF. Use the auto-deceleration monitor display to check the present condition. When the working mode selector switch is operated to switch the working mode, it is automatically set to ON. Travel speed selector switch Each time the travel speed selector switch is pressed, the travel speed changes. Lo o Hi o Lo Use the travel speed monitor display to check the present condition. The relationship between the set speed and the monitor display is shown in the table on the right. Wiper switch Each time the wiper switch is pressed, the wiper setting changes OFF o INT o ON o OFF o Use the wiper monitor display to check the present condition. The relationship between the wiper setting and the monitor display is shown in the table on the right. Window washer switch While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts. Control switch This is used for control when using the maintenance function or select function. (For details, see each function.) Display brightness, contrast adjustment switch Use this switch when adjusting the display brightness and contrast. (For details, see each function.) Buzzer cancel switch Pressing this switch when the alarm buzzer is making sound stops the alarm buzzer. If a new abnormality is detected, the alarm buzzer sounds. Depending on the alarm buzzer type, it does not stop even if you press the buzzer cancel switch.
Switch that is pressed [P] [E] [L]
Display P E L
Working mode status after setting P mode (default) E mode L mode
Display Crawler symbol + Lo Crawler symbol + Hi
Setting Low speed (default) High speed
Display None Wiper symbol + INT Wiper symbol + ON
Setting OFF INT ON
Wiper actuation status Stowing stopped or now stowing Intermittent actuation Continuous actuation
40
PC600-8
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Maintenance function
When the maintenance time for replacement, inspection, or filling has approached for the 11 maintenance items, press maintenance switch (1) and the caution display (yellow or red) appears on the monitor display for 30 seconds after the key is turned ON to remind the operator to carry out lubrication maintenance.
a Maintenance items
No. 01 02 03 41 04 05 06 07 08 09 10 Engine oil Engine oil filter Fuel filter Fuel pre-filter Hydraulic filter Hydraulic tank breather Corrosion resistor PTO case oil Final case oil Machinery case oil Hydraulic oil Item Replacement interval (hours) 500 500 1,000 500 1,000 1,000 1,000 1,000 2,000 1,000 5,000
a The above replacement intervals are set for each item, and the time remaining to maintenance is reduced as the machine is operated. The content of the caution display differs according to the remaining time. The relationship is as shown in the table below.
Display None Condition Remaining time for maintenance for all items is more than 30 hours There is one or more items with less than 30 hours remaining time for maintenance There is one or more items with less than 0 hours remaining time for maintenance
Notice display (black symbol displayed on yellow background) Warning display (white symbol displayed on red background)
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Method of checking status
Maintenance items a Operate as follows when on the operator screen. 1. Press maintenance switch (1) and switch to the maintenance list display screen. a The maintenance items are displayed as symbols on the screen. 2. Press control switch (2), or use the 10-key pad to input the number (01 to 10, 30, 31) of the maintenance item to select the item. a The cursor moves and the item is highlighted. a The display method is the same as described on the previous page (relationship between remaining time and caution display). If the remaining time is less than 30 hours, the item is displayed in yellow, and if it is less than 0 hours, it is displayed in red.
Maintenance operation 1. After completing the selection, press input confirmation switch (3). The screen will change to the maintenance reset screen. 2. Use the maintenance reset screen to check the content, and if there is any problem, press input confirmation switch (3) to move to the check screen. If the wrong item is selected, press return switch (4) to return to the maintenance list screen. 3. Check the content on the check screen, and if there is no problem, press input confirmation switch (3) to reset the maintenance time. After the reset is completed, the screen returns to the maintenance list display screen. To check the remaining time, or if the wrong item is selected, press return switch (4) to return to the maintenance list screen. a The check screen shows the symbol for the maintenance item and the set time in large letters. a The background color of the symbol for the item where the maintenance hour was reset is the same as the background of the screen, so it is possible to check that it has been reset.
42
PC600-8
SEN00142-04
Brightness, contrast adjustment function

This function is used to adjust the brightness and contrast of the display.
Adjustment method a Operate as follows when on the operator screen. 1. Press display brightness, contrast adjustment switch (1) and switch to the adjustment screen. a Relationship between menu symbol and content.
No. 00 Symbol Return mark Content Return
01
Contrast
02
Brightness
2. Press control switch (2), or use the 10-key pad to input the number (00 to 02) to select either contrast or brightness. After completing the selection, press input confirmation switch (3) and return to the adjustment screen. Then press return switch (4) or use the 10-key pad to set to [00] and press input confirmation switch (3) to return to the normal screen. 3. Press control switch (2) and adjust the brightness and contrast as desired.
Control switch Actuation Flow level bar graph extends to the right
Flow level bar graph retracts to the left
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Service meter check function When the starting switch is at the OFF position, keep return switch (1) and control switch (2) of the monitor pressed at the same time, and the service meter is shown on the display. This display is shown only while the two switches are being pressed. When the switches are released, the display goes out. Note that it takes 3 5 seconds after the switches are pressed for the service meter display to appear.
Display LCD check function On the password input screen or on the normal screen, if monitor return switch (1) and working mode (A) switch are kept pressed at the same time, all the LCD display will light up and the whole screen will become white, so the display can be checked. If any part of the display is black, the LCD is broken.
User code display function If there is any problem in operating the machine, the user code is displayed on the monitor to advise the operator of the steps to take. This code display appears on the operator screen. On the operator screen, the user code is displayed on the portion for the hydraulic oil temperature gauge.
If more than one user code is generated at the same time, the user codes are displayed in turn for 2 seconds each to display all the user codes.
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PC600-8
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While the user code is being displayed, if the input confirmation switch is pressed, the service code and failure code can be displayed.
If there is mode than one service code or failure code, the display switches every 2 seconds and displays all the service codes/failure codes that caused the user code to be displayed. Even if service codes/failure codes have occurred, if they did not cause the user code to be displayed, this function does not display them.
If the telephone number has been set using the telephone number input on the service menu, it is possible to switch on the service code/failure code and display the telephone symbol and telephone number. For details of inputting and setting the telephone number, see Special functions of monitor panel in the Testing and adjusting section.
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Sensors
The signals from the sensors are input directly to the engine controller and the pump controller monitor.
Name of sensor Coolant level Engine oil level Engine oil pressure Coolant temperature Fuel level Air cleaner clogging Hydraulic oil temperature Main pump oil pressure Type of sensor Contact type Contact type Contact type Resistance type Resistance type Contact type Resistance type Analog
The contact type sensors are always connected at one end to the chassis GND.
When normal ON (closed) ON (closed) ON (closed) OFF (open)
When abnormal OFF (open) OFF (open) OFF (open) ON (closed)
Input controller Monitor Monitor Engine controller Engine controller Monitor Monitor Monitor Pump controller
Coolant level sensor
1. 2. 3. 4.
Sub-tank Float Sensor Connector
46
PC600-8
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Engine oil level sensor
1. 2. 3. 4.
Connector Bracket Float Switch
Engine oil pressure sensor
1. 2. 3. 4. 5. 6.
Plug Contact ring Contact Diaphragm Spring Terminal
Air cleaner clogging sensor
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Fuel level sensor
1. 2. 3. 4.
Float Connector Cover Variable resistor
Coolant temperature sensor Hydraulic oil temperature sensor
1. Thermistor 2. Body 3. Tube
4. Tube 5. Wire 6. Connector
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PC600-8
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Main pump oil pressure sensor (0 49.0 MPa {0 500 kg/cm2})
1. 2. 3. 4.
Sensor Nut Case Connector
Function The pump pressure sensor is installed to the inlet circuit of the control valve. It converts the pump discharge pressure into a voltage and transmits it to the pump controller. Operation The oil pressure applied from the pressure intake part presses the diaphragm of the oil pressure sensor, the diaphragm is deformed. The gauge layer facing the diaphragm measures the deformation of the diaphragm by the change of its resistance, then converts the change of the resistance into a voltage and transmits it to the amplifier (voltage amplifier). The amplifier amplifies the received voltage and transmits it to the pump controller. Relationship between pressure P (MPa {kg/cm2}) and output voltage (V) is as follows. V = 0.08 {0.008} x P + 0.5
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KOMTRAX system
(if equipped)
The KOMTRAX terminal sends various information on the machine by a wireless communication.The KOMTRAX operator refers to this information in the office, and various services can be provided for the customer. a To be provided with the KOMTRAX service, it is necessary to sign up separately. Information that can be sent from the KOMTRAX terminal is as follows: 1. Traveling map 2. Service meter 3. Location information 4. Error history
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PC600-8
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KOMTRAX terminal
Model name: TC301 The KOMTRAX system uses satellite communication technology.
1. 2. 3.
Communication antenna connector GPS antenna connector Machine harness connector (DEUTSCH-40P)

DEUTSCH-40P [CN-G01]
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Signal name NC NC NC NC NC NC CAN signal (L) CAN signal (H) NC NC NC NC NC NC NC NC NC NC NC Relay output Input/Output signal Input/Output Input/Output Output Pin No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Signal name Operation mode selection 1 Operation mode selection 2 NC NC NC NC Starting switch (C) Alternator (R) NC NC NC NC NC NC NC Starting switch (ACC) Power source GND Power source GND Constant power source (24V) Constant power source (24V) Input/Output signal Input Input Input Input Input Input Input
Outline The KOMTRAX terminal can send information via wireless communication antenna, acquiring various information of the machine from the network signal in the machine and the input signal. Also, the controller incorporates CPU (Central Processing Unit) and provide the wireless communication function and the GPS function. Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
There are the LED lamp and the 7-segment indicator lamp in the display area, and these lamps are used for the testing and the troubleshooting. When using TC301 in other countries, the satellite communication company to contract is different. So, part numbers of TC301 are different in other countries. Also, when using TC301 in other countries, you must notify the name of the country.
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HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
20 Standard value table

Standard service value table
Standard value table for engine ........................................................................................................................... 2 Standard value table for chassis .......................................................................................................................... 3
PC600-8
SEN00395-04
Standard value table for engine

Machine model Engine Item Measurement condition High idle Engine speed Low idle Rated speed Intake air pressure Exhaust gas pressure Exhaust gas color At rated output All speed range (intake air temp: 20C) At sudden acceleration (low o high idle) At high idle Intake valve mm Exhaust valve MPa {kg/cm2} MPa {kg/cm2} kPa {mmH2O} 0.57 Min. 1.18 {Min. 12} Min. 1.43 {Min. 14.6} Min. 4.1 {Min. 42} Min. 1.18 {Min. 12} Min. 1.43 {Min. 14.6} 2.8 {29} kPa {mmHg} C % Bosch index rpm Unit PC600, 600LC-8 SAA6D140E-5 Standard value 1,950 50 800 25 1,800 Min 147 {Min. 1,100} Max. 650 Max. 25 (Max. 2.5) (Max. 1.0) 0.35 Permissible value 1,950 50 800 25 1,800 125 {940} 700 35 (3.5) (2.0)
Valve clearance (at cold)
EGR valve and bypass High idle valve drive oil pressure Low idle Compression pressure Blow-by pressure At rated output Oil temperature: Min. 80C Rated output (At high idle) Oil pressure Oil temperature: Min. 80C Rated output (At low idle) EGR valve and bypass High idle valve drive oil presLow idle sure Oil temperature Alternator belt tension Air conditioner compressor belt tension All speed range (inside oil pan) Deflection when pressed with finger force of approx. 58.8 N {6 kg} Deflection when pressed with finger force of approx. 58.8 N {6 kg} Oil temperature: 40 60C Engine speed: 200 250 rpm (Coolant temperature: Min. 70C)
Max. 2.94 {Max. 300}
3.92 {400}
SAE0W30E0S SAE5W40E0S SAE10W30DH SAE15W40DH SAE30DH
Min. 0.34 {Min. 3.5} MPa {kg/cm2} Min. 0.10 {Min. 1.0}
0.21 {2.1}
0.08 {0.8}
MPa {kg/cm2} C mm
Min. 1.43 {Min. 14.6} Min. 1.18 {Min. 12} 90 110 13 16
Min. 1.43 {Min. 14.6} Min. 1.18 {Min. 12} 120 13 16
mm
10 15
10 15
PC600-8
SEN00395-04
Standard value table for chassis

Applicable model Category Item Measurement conditions Engine coolant temperature: Within operating range Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P Boom RAISE relief Engine coolant temperature: Within operating range Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P Boom RAISE relief + power max. switch ON Engine at high idle Auto-deceleration switch OFF All control levers at neutral Engine at high idle Auto-deceleration switch ON All control levers at neutral Unit PC600, 600LC-8 Standard value Permissible value
All pumps at relief
Min. 1,780
Min. 1,780
Engine speed
Power max. ON + All pumps at relief
rpm
Min. 1,730
Min. 1,730
High idle-cut ON
1,750 100
1,750 100
Auto-deceleration ON Boom Lo control valve Boom Hi control valve Spool stroke Arm Lo control valve Arm Hi control valve
1,400 100
1,400 100
Stroke of each side Bucket Lo control valve Bucket Hi control valve Swing control valve Travel control valve Boom control lever
N o RAISE, LOWER
16 0.5
16 0.5
mm
85 10 85 10 85 10 85 10 115 12 Max. 10
85 10 85 10 85 10 85 10 115 12 Max. 15
Travel of control levers
Arm control lever Bucket control lever Swing control lever Travel control lever Play of control levers
Center of lever knob Read max. value to end of travel (Exclude play at neutral.) Engine stopped
N o IN, OUT N o CURL, DUMP N o R.H., L.H. N o F, R (L.H., R.H.) Work equipment, swing, travel
PC600-8
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Applicable model Category Item Boom control lever Operating effort of control levers Arm control lever Bucket control lever Swing control lever Lever Travel control lever, pedal Pedal Engine at high idle Hydraulic oil temperature: Within operating range Center of lever knob Measure max. value to end of travel Measurement conditions Unit
PC600, 600LC-8 Standard value 15.7 3.9 {1.6 0.4} 15.7 3.9 {1.6 0.4} 12.7 2.9 {1.3 0.3} N {kg} 12.7 2.9 {1.3 0.3} 24.5 5.9 {2.5 0.6} 74.5 18.6 {7.6 1.9} 31.87 +1.47 Normal RAISE At power max. L mode
0.98 +15 {325 10 } 34.32 +1.47 0.98 +15 {350 10 } 37.2 +1.5 2.0 +15 {380 20 }
Permissible value Max. 24.5 {Max. 2.5} Max. 24.5 {Max. 2.5} Max. 21.6 {Max. 2.2} Max. 21.6 {Max. 2.2} Max. 39.2 {Max. 4.0} Max. 107.6 {Max. 11} 31.87 +1.47 {325 10 }
0.98 +15
34.32 +1.47 {350 10 } 37.2 +1.5 {380 20 } 15.69 1.96 {160 20} 27.95 1.96 {285 20} 31.87 +1.47 {325 10 } 34.32 +1.47 {350 10 } 31.87 +1.47 {325 10 } 34.32 +1.47 {350 10 } 29.91 0.98 {305 10} 35.30 1.47 {360 15} 3.14 +0.39 {32 +0 }
+0 +4 0.98 +15 0.98 +15 0.98 +15 0.98 +15 2.0 +15 0.98 +15
Boom relief pressure
Arm relief pressure
Hydraulic oil temperature: Normal Within operating range At machine Engine at high push-up idle Working Normal mode: P Pump outlet pressure when meaAt power max. sured circuit is relieved Relieve either Normal travel circuit. LOWER
15.69 1.96 {160 20} 27.95 1.96 {285 20} 31.87 +1.47 MPa {kg/cm2}
0.98 +15 {325 10 } 34.32 +1.47 0.98 +15 {350 10 } 31.87 +1.47 0.98 +15 {325 10 } 34.32 +1.47 0.98 +15 {350 10 }
Hydraulic pressure
Bucket relief pressure At power max.
Swing relief pressure Travel relief pressure Hydraulic oil temperature: Within operating range Engine at high idle
29.91 0.98 {305 10} 35.30 1.47 {360 15} 3.14 +0.39
+0 +4 {32 +0 }
Control pressure
PC600-8
SEN00395-04
Applicable model Category Item Measurement conditions All control levers at neutral Boom RAISE relief (Normal) Power max. + Boom RAISE relief All control levers at neutral Boom RAISE relief (Normal) Travel under no load (Lever at stroke end) Power max. + Boom RAISE relief All control levers at neutral Travel under no load (Lever at stroke end) Unit
PC600, 600LC-8 Standard value 2.25 0.2 {23 2}

0.53 +2.0 {11.2 5.4 }
Permissible value Min. 1.76 {Min. 18} 1.05 +0.20 {10.7 5.4 } 0.97 0.2 {9.9 2.0} Max. 0.55 {Max. 5.5} 1.05 +0.20 {10.7 5.4 } Min. 1.7 {Min. 17} 0.97 0.2 {9.9 2.0} Min. 1.5 {Min. 15}
0.53 +2.0 0.53 +2.0
TVC valve output pressure
Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P
1.10 +0.20
1.02 0.2 {10.4 2.0} Max. 0.4 {Max. 4}

0.53 +2.0 {11.2 5.4 }
Hydraulic pressure
CO-NC valve output pressure
Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P When track runs idle, measure oil pressure on idle side. Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P
1.10 +0.20
Min. 1.7 {Min. 17} MPa {kg/cm2} 1.02 0.2 {10.4 2.0} 1.76 0.2 {18 2}
Jet sensor output differential pressure
Max. 0.2 {Max. 2}
Max. 0.2 {Max. 2}
PPC valve output pressure
Hydraulic oil temperature: Within operating range Engine at high idle Control lever at stroke end Hydraulic oil temperature: Within operating range Difference between relief pressure at high idle and that at low idle
2.9 +0.54
0.15 +5.5 {30 1.5 }
2.9 +0.54 {30 1.5 }

0.15 +5.5
Oil pressure drop
Max. 2.0 {Max. 20}
Max. 2.9 {Max. 30}
Swing
Overrun when stopping Hydraulic oil temperature: Within operating range swing Bucket: No load Engine at high idle Working mode: P Stop after swinging one turn and measure distance that swing circle moves
deg. (mm)
Max. 45 (Max. 775)
Max. 60 (Max. 1,040)
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Applicable model Category Item Measurement conditions Unit
PC600, 600LC-8 Standard value Permissible value
90
4.0 0.5
Max. 4.9
Time taken to start swing
Hydraulic oil temperature: Within operating range Bucket: No load Engine at high idle Working mode: P Time taken to swing 90 and 180 from starting position
sec.
180
5.8 0.7
Max. 7.2
Time taken to swing
Hydraulic oil temperature: Within operating range Bucket: No load Engine at high idle Working mode: P Swing one turn, then measure time taken to swing next 5 turns
sec.
34 38
Max. 40
Swing
Hydraulic oil temperature: Within operating range Hydraulic drift of swing Engine stopped Set machine on 15 slope, and set upper structure at 90 to the side. Make match marks on inner race and outer race of circle. Measure distance that match marks move apart after 5 minutes. Hydraulic oil temperature: Within operating range Engine at high idle Swing lock switch: ON Leakage in 1 minute during swing relief
mm
Leakage from swing motor
l/min
Max. 5
Max. 10
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Lo
STD: 54 66 LC: 57 70
STD: 54 66 LC: 57 70
Travel speed (Free rotation)
Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns with no load.
sec.
Hi
STD: 35 43 LC: 37 46
STD: 35 43 LC: 37 46
Lo
23 31
23 31
Travel speed (Actual travel) Travel
Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P On flat place Run up for at least 10 m, and measure time taken to travel next 20 m on flat ground.
sec.
Hi
15 19
15 19
Travel deviation
Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P Travel speed: Lo On hard and flat place Measure travel deviation (x) in travel of 20 m after running up 10 m.
mm
Max. 200
Max. 220
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Hydraulic drift of travel Travel
Hydraulic oil temperature: Within operating range Engine stopped Stop machine on 12 slope with sprocket at uphill end of machine. Measure the distance the machine moves in 5 minutes. Hydraulic oil temperature: Within operating range Engine at high idle Travel: Lock sprocket. Measure leakage in 1 minute during travel relief.
mm
Leakage of travel motor
l/min
Max. 10
Max. 20
Total work equipment (hydraulic drift at tip of bucket teeth) Hydraulic drift of work equipment
Max. 1,200
Max. 1,800
Work equipment
Boom cylinder (amout of retraction of cylinder)
Arm cylinder (amount of extension of cylinder)
Hydraulic oil temperature: Within operating range On level and flat place Work equipment: In above measuring posture with rated load 44 kN {4,500 kg} Engine: Stopped Work equipment control lever: Neutral Start measuring just after setting machine and measure every 5 minutes for 15 minutes.
Max. 60
Max. 90
mm
Max. 165
Max. 250
Bucket cylinder (amount of retraction of cylinder)
Max. 50
Max. 75
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RAISE
5.1 0.5
Max. 5.9
Boom speed
Hydraulic oil temperature: Within operating range Engine: High idle Working mode: P Measure time taken to move bucket between RAISE stroke end and ground touch point of bucket (including operating time of cylinder cushion).
LOWER
3.6 0.4
Max. 4.4
IN
5.3 0.5
Max. 6.3
Work equipment speed
Work equipment
Arm speed
Hydraulic oil temperature: Within operating range Engine: High idle Working mode: P Measure time taken to move arm between OUT stroke end and IN stroke end (including operating time of cylinder cushion).
sec.
OUT
3.9 0.4
Max. 4.7
CURL
3.2 0.4
Max. 4.0
Bucket speed
Hydraulic oil temperature: Within operating range Engine: High idle Working mode: P Measure time taken to move bucket between DUMP stroke end and CURL stroke end (including operating time of cylinder cushion).
DUMP
3.2 0.4
Max. 4.1
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Boom time lag
Hydraulic oil temperature: Within operating range Engine: Low idle Working mode: P Lower boom from RAISE stroke end and measure time taken to lift up front side of machine after bucket touches ground.
Max. 3
Max. 3
Time lag
Arm time lag
Hydraulic oil temperature: Within operating range Engine: Low idle Working mode: P Move in arm from OUT stroke end and measure time taken to start moving arm again after it is stopped.
sec.
Max. 3
Max. 3
Work equipment
Bucket time lag
Hydraulic oil temperature: Within operating range Engine: Low idle Working mode: P Curl bucket from DUMP stroke end and measure time taken to start moving bucket again after it is stopped.
Max. 3
Max. 3
Oil leakage
Cylinder
Hydraulic oil temperature: Within operating range Engine: High idle Relieve cylinder to be measured or travel circuit and meaCenter swivel joint sure leakage in 1 minute.
Max. 5 cc/min Max. 10
Max. 20
Max. 100
Pump performance
Hydraulic pump discharge amount
See following page.
l/min
See following page.
10
PC600-8
SEN00395-04
Applicable model Category Item Measurement conditions Hydraulic oil temperature: 45 55C Engine: High idle Fan: 100% speed mode Unit
Fan speed
rpm
1,450 50
1,450 50
Hydraulic oil temperature: 45 55C Fan circuit oil pressure Engine: High idle Fan: 100% speed mode Hydraulic oil temperature: 45 55C Fan pump EPC current Engine: High idle Fan: 100% speed mode
MPa {kg/cm2}
13.2 18.1 {135 185}
13.2 18.1 {135 185}
Fan
mA
490 50
490 50
PC600-8
11
SEN00395-04
Discharge amount of one hydraulic pump
Performance of hydraulic pump TVC current : 400 mA Pump speed: At 2,000 rpm (Engine rated speed at 1,800 rpm) Test pump discharge pressure (MPa {kg/cm2} P1 Discharge pressure of other pump (MPa {kg/cm2}) P2 Average pressure (MPa {kg/cm2}) P= P1 + P2 2 Standard value for discharge amount Q (l/min) See graph Judgement standard lower limit Q (l/min) See graph Check point As desired a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring. The error is large near the point where the graph curves, so avoid measuring at this point. a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
12
PC600-8
SEN00395-04

Applicable model Category Item Measurement conditions Engine coolant temperature: Within operating range Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P Boom RAISE relief Engine at high idle Auto-deceleration switch OFF All control levers at neutral Engine at high idle Auto-deceleration switch ON All control levers at neutral Unit PC600, 600LC-8 Standard value Permissible value
All pumps at relief Engine speed
Min. 1,780
Min. 1,780
rpm 1,750 100 1,750 100
High idle-cut ON
Auto-deceleration ON Boom Lo control valve Boom Hi control valve Spool stroke Arm Lo control valve Arm Hi control valve
1,400 100
1,400 100
Stroke of each side Bucket Lo control valve Bucket Hi control valve Swing control valve Travel control valve Boom control lever
N o RAISE, LOWER
16 0.5
16 0.5
mm
79 10 79 10 79 10 79 10 115 12 Max. 10 16.7 3.9 {1.7 0.4}
85 10 85 10 85 10 85 10 115 12 Max. 15 Max. 25.5 {Max. 2.6} Max. 25.5 {Max. 2.6} Max. 22.6 {Max. 2.3} Max. 22.6 {Max. 2.3} Max. 39.2 {Max. 4.0} Max. 107.6 {Max. 11}
Travel of control levers
Arm control lever Bucket control lever Swing control lever Travel control lever Play of control levers Boom control lever
Center of lever knob Read max. value to end of travel (Exclude play at neutral.) Engine stopped
N o IN, OUT N o CURL, DUMP N o R.H., L.H. N o F, R (L.H., R.H.) Work equipment, swing, travel
Operating effort of control levers
Arm control lever Bucket control lever Swing control lever
Engine at high idle Hydraulic oil temperature: Within operating range Center of lever knob Measure max. value to end of travel
16.7 3.9 {1.7 0.4} 13.7 2.9 {1.4 0.3} N {kg} 13.7 2.9 {1.4 0.3}
Lever Travel control lever, pedal Pedal
24.5 5.9 {2.5 0.6} 74.5 18.6 {7.6 1.9}
PC600-8
13
SEN00395-04
PC600, 600LC-8 Standard value 29.42 +1.47 0.98 {300 +15 10 } 34.32 +1.47 0.98 Permissible value 29.42 +1.47 0.98 {300 +15 10 } 34.32 +1.47 0.98
Normal RAISE At power max.
Boom relief pressure
L mode
{350 +15 10 } (When Boom Raise is single) 15.69 1.96 {160 20} 27.95 1.96 {285 20} 29.42 +1.47 0.98 {300 +15 10 } MPa {kg/cm2} 29.42 +1.47 0.98 {300 +15 10 } 28.42 +1.47 0.98 {290 +15 10 } 24.52 0.98 {250 +15 10 } 29.91 0.98 {305 10} 35.3 1.47 {360 15}
+1.47
{350 +15 10 } (When Boom Raise is single) 15.69 1.96 {160 20} 27.95 1.96 {285 20} 29.42 +1.47 0.98 {300 +15 10 } 29.42 +1.47 0.98 {300 +15 10 } 28.42 +1.47 0.98 {290 +15 10 } 24.52 +1.47 0.98 {250 +15 10 } 29.91 0.98 {305 10} 35.3 1.47 {360 15} 3.14 0 {32 +4 0}
+0.39
Arm relief pressure
Bucket relief pressure
Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P Pump outlet pressure when measured circuit is relieved Relieve either travel circuit.
LOWER Open Close
Normal At machine push-up
Normal
Hydraulic pressure
At power max.
Normal
At power max.
Normal
Bottom dump relief pressure
Normal
Swing relief pressure Travel relief pressure Hydraulic oil temperature: Within operating range Engine at high idle
Control pressure
3.14 0 {32 +4 0}
+0.39
14
PC600-8
SEN00395-04
Applicable model Category Item Measurement conditions Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P When track runs idle, measure oil pressure on idle side. Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P All control levers at neutral Boom RAISE relief (Normal) Unit
PC600, 600LC-8 Standard value 2.25 0.2 {23 2}

+0.20 +2.0
Permissible value Min. 1.76 {Min. 18}

+0.20 +2.0
TVC valve output pressure
1.10 0.53
1.05 0.53
{11.2 5.4 }
{10.7 5.4 }
All control levers at neutral
Max. 0.4 {Max. 4}
Max. 0.55 {Max. 5.5}
CO-NC valve output pressure Hydraulic pressure
Boom RAISE relief (Normal)
1.10 0.53
+2.0
+0.20
1.05 0.53
+2.0
+0.20
{11.2 5.4 }
{10.7 5.4 }
Travel under no load (Lever at stroke end) All control levers at neutral Travel under no load (Lever at stroke end)
MPa {kg/cm2}
Min. 1.7 {Min. 17}
Min. 1.7 {Min. 17}
1.76 0.2 {18 2}
Min. 1.5 {Min. 15}
Jet sensor output differential pressure
Max. 0.2 {Max. 2}
Max. 0.2 {Max. 2}
PPC valve output pressure
Hydraulic oil temperature: Within operating range Engine at high idle Control lever at stroke end Hydraulic oil temperature: Within operating range Difference between relief pressure at high idle and that at low idle
2.9 0.15
+5.5
+0.54
2.9 0.15
+5.5
+0.54
{30 1.5 }
{30 1.5 }
Oil pressure drop
Max. 2.0 {Max. 20}
Max. 2.9 {Max. 30}
Swing
Overrun when stopping Hydraulic oil temperature: Within operating range swing Bucket: No load Engine at high idle Working mode: P Stop after swinging one turn and measure distance that swing circle moves
deg. (mm)
Max. 45 (Max. 775)
Max. 60 (Max. 1,040)
PC600-8
15
SEN00395-04
90
4.0 0.5
Max. 4.9
Time taken to start swing
Hydraulic oil temperature: Within operating range Bucket: No load Engine at high idle Working mode: P Time taken to swing 90 and 180 from starting position
sec.
180
5.8 0.7
Max. 7.2
Time taken to swing
Swing
Hydraulic oil temperature: Within operating range Bucket: No load Engine at high idle Working mode: P Swing one turn, then measure time taken to swing next 5 turns
sec.
34 38
Max. 40
Hydraulic oil temperature: Within operating range Hydraulic drift of swing Engine stopped Set machine on 15 slope, and set upper structure at 90 to the side. Make match marks on inner race and outer race of circle. Measure distance that match marks move apart after 5 minutes. Hydraulic oil temperature: Within operating range Engine at high idle Swing lock switch: ON Leakage in 1 minute during swing relief
mm
Leakage from swing motor
l/min
Max. 5
Max. 10
16
PC600-8
SEN00395-04
Lo Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns with no load.
STD: 54 66 LC: 57 70
STD: 54 66 LC: 57 70
Travel speed (Free rotation)
sec.
Hi
STD: 35 43 LC: 37 46
STD: 35 43 LC: 37 46
Lo
23 31
23 31
Travel speed (Actual travel) Travel
Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P On flat place Run up for at least 10 m, and measure time taken to travel next 20 m on flat ground.
sec.
Hi
15 19
15 19
Travel deviation
Hydraulic oil temperature: Within operating range Engine at high idle Working mode: P Travel speed: Lo On hard and flat place Measure travel deviation (x) in travel of 20 m after running up 10 m.
mm
Max. 200
Max. 220
PC600-8
17
SEN00395-04
Hydraulic drift of travel Travel
Hydraulic oil temperature: Within operating range Engine stopped Stop machine on 12 slope with sprocket at uphill end of machine. Measure the distance the machine moves in 5 minutes. Hydraulic oil temperature: Within operating range Engine at high idle Travel: Lock sprocket. Measure leakage in 1 minute during travel relief.
mm
Leakage of travel motor
l/min
Max. 10
Max. 20
Total work equipment (hydraulic drift at tip of bucket teeth) Hydraulic drift of work equipment Hydraulic oil temperature: Within operating range On level and flat place Work equipment: In above measuring posture with rated load 70 kN {7,200 kg} Engine: Stopped Work equipment control lever: Neutral Start measuring just after setting machine and measure every 5 minutes for 15 minutes.
Max. 1,500
Max. 1,800
Work equipment
Boom cylinder (amout of retraction of cylinder)
Max. 150 mm Max. 30
Max. 230
Arm cylinder (amount of extension of cylinder)
Max. 45
Bucket cylinder (amount of retraction of cylinder)
Max. 8
Max. 12
18
PC600-8
SEN00395-04
RAISE
5.5 0.6
Max. 6.8
Boom speed
Hydraulic oil temperature: Within operating range Engine: High idle Working mode: P Measure time taken to move bucket between RAISE stroke end and ground touch point of bucket (including operating time of cylinder cushion).
LOWER
4.0 0.4
Max. 5.2
IN
4.5 0.5
Max. 5.9
Arm speed Work equipment speed Work equipment
Hydraulic oil temperature: Within operating range Engine: High idle Working mode: P Measure time taken to move arm between OUT stroke end and IN stroke end (including operating time of cylinder cushion).
OUT
2.7 0.3 sec.
Max. 3.6
OPEN
2.2 0.2
Max. 2.8
Bottom speed Engine: High idle Hydraulic oil temperature: Within operating range CLOSE 2.5 0.3 Max. 3.4
CURL
4.0 0.4
Max. 5.0
Bucket speed
Hydraulic oil temperature: Within operating range Engine: High idle Working mode: P Measure time taken to move bucket between DUMP stroke end and CURL stroke end (including operating time of cylinder cushion).
DUMP
4.0 0.4
Max. 2.8
PC600-8
19
SEN00395-04
Boom time lag Hydraulic oil temperature: Within operating range Engine: Low idle Working mode: P Lower boom from RAISE stroke end and measure time taken to lift up front side of machine after bucket touches ground.
Max. 3
Max. 3
Work equipment
Time lag
Arm time lag
Hydraulic oil temperature: Within operating range Engine: Low idle Working mode: P Move in arm from OUT stroke end and measure time taken to start moving arm again after it is stopped.
sec.
Max. 3
Max. 3
Bucket time lag Hydraulic oil temperature: Within operating range Engine: Low idle Working mode: P Curl bucket from DUMP stroke end and measure time taken to start moving bucket again after it is stopped.
Max. 3
Max. 3
20
PC600-8
SEN00395-04
Time lag
Work equipment
Bottom time lag Hydraulic oil temperature: Within operating range Engine: Low idle Close bottom in full open state and measure time taken to start moving bottom again after it is stopped. Cylinder Hydraulic oil temperature: Within operating range Engine: High idle Relieve cylinder to be measured or travel circuit and meaCenter swivel joint sure leakage in 1 minute.
sec.
Max. 3
Max. 3
Oil leakage
Max. 5 cc/min Max. 10
Max. 20
Max. 100
Pump performance
Hydraulic pump discharge amount
See following page.
l/min
See following page.
Fan speed
Hydraulic oil temperature: 45 55C Engine: High idle Fan: 100% speed mode
rpm
1,450 50
1,450 50
Hydraulic oil temperature: 45 55C Fan circuit oil pressure Engine: High idle Fan: 100% speed mode Hydraulic oil temperature: 45 55C Fan pump EPC current Engine: High idle Fan: 100% speed mode
MPa {kg/cm2}
13.2 18.1 {135 185}
13.2 18.1 {135 185}
Fan
mA
490 50
490 50
PC600-8
21
SEN00395-04
Discharge amount of one hydraulic pump
Performance of hydraulic pump TVC current : 400 mA Pump speed: At 2,000 rpm (Engine rated speed at 1,800 rpm) Test pump discharge pressure (MPa {kg/cm2} P1 Discharge pressure of other pump (MPa {kg/cm2}) P2 Average pressure (MPa {kg/cm2}) P= P1 + P2 2 Standard value for discharge amount Q (l/min) See graph Judgement standard lower limit Q (l/min) See graph Check point As desired a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring. The error is large near the point where the graph curves, so avoid measuring at this point. a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
22
PC600-8
SEN00395-04
PC600-8
23
SEN00395-04
24
SEN00444-04
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
30 Testing and adjusting

Testing and adjusting, Part 1
Tools for testing, adjusting and troubleshooting ................................................................................................... 4 Measuring engine speed...................................................................................................................................... 9 Measuring intake air pressure (boost pressure)................................................................................................. 10 Measuring exhaust gas temperature ..................................................................................................................11 Measuring exhaust gas color ............................................................................................................................. 12 Adjusting valve clearance .................................................................................................................................. 13 Measuring compression pressure ...................................................................................................................... 14 Measuring blow-by pressure .............................................................................................................................. 16 Measuring engine oil pressure ........................................................................................................................... 16 Testing EGR valve and bypass valve drive oil pressure .................................................................................... 17 Handling equipment in fuel circuit ...................................................................................................................... 18 Releasing remaining pressure in fuel system .................................................................................................... 18 Measuring fuel pressure .................................................................................................................................... 19 Reduced cylinder mode operation ..................................................................................................................... 20 No-injection cranking ......................................................................................................................................... 20 Testing leakage from pressure limiter and return rate from injector ................................................................... 21 Bleeding air from fuel circuit............................................................................................................................... 23 Testing fuel system for leakage.......................................................................................................................... 25 Testing and adjusting alternator belt tension...................................................................................................... 26 Testing and adjusting air conditioner compressor belt tension .......................................................................... 27 Testing clearance of swing circle bearing .......................................................................................................... 28 Testing and adjusting track shoe tension ........................................................................................................... 29
PC600-8
SEN00444-04
Testing and adjusting work equipment, swing, and travel circuit oil pressures .................................................. 30 Testing and adjusting control circuit oil pressure................................................................................................ 35 Testing and adjusting piston pump control oil pressure ..................................................................................... 37 Testing servo piston stroke................................................................................................................................. 43 Measuring PPC valve output pressure............................................................................................................... 44 Measuring outlet pressures of solenoid valve and PPC shuttle valve................................................................ 48 Adjusting work equipment, swing PPC valve ..................................................................................................... 54 Testing and adjusting travel deviation ................................................................................................................ 55 Measuring fan speed.......................................................................................................................................... 57 Measuring fan circuit oil pressure ...................................................................................................................... 57 Inspection of locations of hydraulic drift of work equipment ............................................................................... 58 Measuring oil leakage ........................................................................................................................................ 59 Releasing remaining pressure in hydraulic circuit.............................................................................................. 63 Bleeding air from each part ................................................................................................................................ 64 Inspection procedures for diode......................................................................................................................... 67
PC600-8
SEN00444-04
PC600-8
SEN00444-04
Tools for testing, adjusting and troubleshooting

Test, measurement item Measuring intake air pressure (boost pressure) Measuring exhaust temperature Measuring exhaust gas color Adjusting valve clearance Measuring compression pressure Measuring blow-by pressure Measuring engine oil pressure Testing EGR valve and bypass valve drive oil pressure C 2 D 1 E 2 6261-71-615A F 799-201-1504 799-101-5002 1 G 2 790-261-1204 799-401-2320 799-101-5002 1 790-261-1204 Measuring fuel pressure H 2 3 07005-00812 1 2 3 Testing leakage from pressure limiter and return rate from injector J 4 5 6 Measuring clearance of swing circle bearing Testing and adjusting in work equipment, swing, and travel circuit oil pressures Testing and adjusting control circuit oil pressure K 6151-51-8490 6206-71-1770 Commercially available Commercially available Commercially available Commercially available Commercially available 799-101-5002 L 790-261-1204 799-101-5002 M 790-261-1204 Digital hydraulic tester Digital hydraulic tester Hydraulic tester Seal washer Spacer Joint Hose Hose Measuring cylinder Stopwatch Dial gauge Hydraulic tester 799-401-2320 795-471-1450 Digital hydraulic tester Gauge Adapter Digital hydraulic tester Gauge Hydraulic tester Gasket Blow-by checker Hydraulic tester 1 For 140E-5 engine 1 1 Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
Symbol
Part No. 799-201-2202
Part name Boost gauge kit Hose Digital thermometer Handy smoke checker Smoke meter Clearance gauge Compression gauge Adapter
Qty
Remarks
1 101 200 kPa {760 1,500 mmHg}
A 799-201-2220 B 1 799-101-1502 799-201-9001 Commercially available Commercially available 795-502-1590 795-471-1330
1 99.9 1,299 C 1 Bosch index: 0 9 1 1 (Intake: 0.35 mm, Exhaust: 0.57 mm) 1 0 7 MPa {0 70 kg/cm2} 1 For 140E-5 engine
1 Pressure gauge: 60 MPa {600 kg/cm2} 1 1 Pressure gauge: 1 MPa {10 kg/cm2} Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
1 Pressure gauge: 60 MPa {600 kg/cm2} 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 8 1.25 o R1/8 1 1 Inside diameter: 14 mm 1 Inside diameter of joint: 10 mm 1 5mm 2 3 m 1 15mm 2 3 m 1 1 1 With magnet 1 Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
1 Pressure gauge: 60 MPa {600 kg/cm2} 1 Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
1 Pressure gauge: 60 MPa {600 kg/cm2}
PC600-8
SEN00444-04
Test, measurement item
Symbol
Part No. 799-101-5002
Part name Hydraulic tester Digital hydraulic tester Differential pressure gauge Nipple O-ring Adapter Cap O-ring Disc gauge Hydraulic tester Digital hydraulic tester Adapter Hydraulic tester Digital hydraulic tester Adapter Multiple tachometer Hydraulic tester Digital hydraulic tester Measuring cylinder Wear gauge
Qty 1 1 1 2 2
Remarks Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2}
1 790-261-1204 Testing and adjusting piston pump control oil pressure N 2 3 07002-11023 4 Testing servo piston stroke 1 P 2 07000-B2065 566-98-41120 799-101-5002 Measuring PPC valve output pressure 1 Q 2 Measuring outlet pressure of solenoid valve and PPC shuttle valve Measuring fan speed Measuring fan circuit oil pressure 790-261-1204 799-401-3200 799-101-5002 1 R 2 S 790-261-1204 799-401-3200 799-205-1100 799-101-5002 T 799-261-1204 Measuring oil leakage Measuring wear of sprocket Measuring water temperature and oil temperature Measuring operating effort and pressing force Measuring stroke and hydraulic drift Measuring work equipment speed Measuring voltage and resistance U Commercially available 796-627-1140 1 1 1 1 1 1 1 799-401-3200 708-25-14140 799-401-2701 799-101-5220
Size: 10 1.25 mm
2 Size: 03 1 For HPV95 + 95 pump
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2}
1 Size: 03 1 Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2}
1 Size: 03 1 1 Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2}
1 Same as PC600, 600LC-7
799-101-1502 79A-264-0021
Digital thermometer Push-pull scale Push-pull scale Scale Stopwatch Multimeter
1 99.9 1,299 C 1 0 294 N {0 30 kg} 1 0 490 N {0 50 kg} 1 1 1
79A-264-0091 Commercially available Commercially available Commercially available
PC600-8
SEN00444-04
Symbol
Part No. 799-601-4101 or 799-601-4201 799-601-4211 799-601-4220 799-601-9020 799-601-4240
Part name
Qty
Remarks
Troubleshooting for engine controller / sensors / actuators
T-adapter T-adapter T-adapter T-adapter Socket Deep socket (21mm) (MITOLOY 4ML-21 or equivalent) Applicable engine serial No.: 530001-534132
1 1 Engine controller 1 Engine controller 1 Ambient pressure sensor 1 For 16 A
Commercially available
1 For coolant temperature sensor
Deep socket (19mm) (MITOLOY 4ML-19 or 795T-981-1010 equivalent) Applicable engine serial No.: 534133 and up 799-601-4101 or 799-601-4201 or 799-601-9000 or 799-601-9100 or 799-601-9200 799-601-9020 799-601-9030 799-601-9050
T-adapter assembly
Troubleshooting for chassis / sensors / wiring harnesses
Adapter for DT Adapter for DT Adapter for DT
1 1 1
For DT2P (Does not include 799-601-9100) For DT3P (Does not include 799-6014101, 799-601-4201 and 799-601-9100) For DT6P (Does not include 799-6014101, 799-601-4201 and 799-601-9100) For DT12GRP (Does not include 799-601-4101, 799-601-4201 and 799-601-9100)
799-601-9110
Adapter for DT (GR)
799-601-9120
Adapter for DT (B)
For DT12BP 1 (Does not include 799-601-4101, 799-601-4201 and 799-601-9100) For DT12GP 1 (Does not include 799-601-4101, 799-601-4201 and 799-601-9100) 1 For HD30 (Does not include 799-6014101, 799-601-4201 and 799-601-9200)
799-601-9130
Adapter for DT (G)
799-601-9240 799-601-7000 or 799-601-7100 or 799-601-7400 or 799-601-8000
T-adapter for HD30
T-adapter assembly
PC600-8
SEN00444-04
Symbol
Part No. 799-601-7010 799-601-7020 799-601-7040 799-601-7060 799-601-7210 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7140 799-601-7160 799-601-7170 799-601-7520 799-601-8000
Part name Adapter for X Adapter for X Adapter for X Adapter for SWP Adapter for 040 Adapter for M Adapter for M Adapter for M Adapter for M Adapter for M Adapter for S Adapter for S Adapter for S T-adapter assembly Adapter for 070
Qty 1
Remarks For X1P (Does not include 799-601-7000 and 799-601-7100)
Troubleshooting for chassis / sensors / wiring harnesses
1 For X2P 1 For X4P 1 For SW8P (Does not include 799-601-8000)
1 For A16P 1 For M1P (Does not include 799-601-7000 and 799-601-7100)
1 For M2P 1 For M3P 1 For M4P 1 For M6P 1 For S8P 1 For S12P (Does not include 799-6018000)
1 For S16P 1 1 For 070-12P
PC600-8
SEN00444-04
Socket
PC600-8
SEN00444-04
4. Measuring all-pump relief speed 1) Start the engine and set the fuel control dial in the high idle position (MAX). 2) Set the working mode switch in the P mode position. 3) Relieve the boom circuit by raising the boom and measure the engine speed. 5. Measuring power max. ON + all-pump relief speed 1) Start the engine and set the fuel control dial in the high idle position (MAX). 2) Set the working mode switch in the P mode position. 3) While relieving the boom circuit by raising the boom and holding the power max. switch, measure the engine speed. a The power max. function is reset automatically in about 8.5 seconds even if the switch is kept held. Accordingly, measure the engine speed in that period. 6. Measuring high idle-cut ON speed 1) Start the engine and set the fuel control dial in the high idle position (MAX). 2) Turn the auto-deceleration switch OFF. 3) Set the work equipment control, swing control, and travel levers in neutral and measure the engine speed when the high idle-cut function is turned ON. a The engine speed lowers to a certain level approx. 4 seconds after all the control levers are set in neutral. This level is the high idlecut ON speed. 7. Measuring auto-deceleration ON speed 1) Start the engine and set the fuel control dial in the high idle position (MAX). 2) Turn the auto-deceleration switch ON. 3) Set the work equipment control, swing control, and travel levers in neutral. When the auto-deceleration operates, measure the engine speed. a The engine speed lowers to a certain level about 6 seconds after all the levers are set in neutral. This level is the auto-deceleration speed.
Measuring engine speed

a Measure the engine speed under the following condition. Engine coolant temperature: Within operating range Hydraulic oil temperature: Within operating range 1. Preparation work Turn the starting switch ON and set the machine monitor to Monitoring. a For the operating method, see Special function of machine monitor. a Monitoring code: 01002 Engine speed 01006 Engine speed a Code 01002 is information of the engine controller and code 01006 is information of the pump controller. The engine speed can be measured with either of those codes. a The engine speed is displayed in rpm.
2. Measuring low idle speed 1) Start the engine and set the fuel control dial in the low idle position (MIN). 2) Set the work equipment control, swing control, and travel levers in neutral and measure the engine speed. 3. Measuring high idle speed 1) Start the engine and set the fuel control dial in the high idle position (MAX). 2) Set the working mode switch to the P mode position. 3) Turn the auto-deceleration switch OFF. 4) Turn the swing lock switch ON, release the lock lever, and measure the engine speed while operating the swing control lever finely. a Operate the swing control lever to a degree that the PPC oil pressure switch is turned ON. Do not relieve the swing.
PC600-8
SEN00444-04
Measuring intake air pressure (boost pressure)

a Tools for measuring intake air pressure (boost pressure)
Symbol A Part No. 799-201-2202 Part name Boost gauge kit
a When installing and removing the measuring tools, take care not to touch a hot part of the engine. a Measure the intake air pressure (boost pressure) under the following condition. Engine coolant temperature: Within operating range Hydraulic oil temperature: Within operating range 1. Open the engine hood. 2. Remove intake air pressure measurement plug (1) at turbocharger outlet tube.
4. Run the engine at a medium or higher speed and drain the oil from the hose. a Insert the connecting parts of the gauge and hose about a half and open the self-seal on the hose side repeatedly, and the oil will be drained. a If Pm kit A is available, the air bleed coupling (790-261-1130) inside the kit can also be used. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil. 5. Set the working mode switch to P mode and turn the power max. switch ON. 6. Run the engine at high idle and measure the intake air pressure (boost pressure) when the boom RAISE circuit is relieved.
7. After completing the measurement, remove the measuring tools and set to the original condition.
3. Install nipple [1] of boost gauge kit A and connect gauge [2].
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4. Install sensor [1] of digital thermometer B and connect them to meter [2]. a Clamp the wiring harness of the digital thermometer so that it does not touch any high temperature part during the measurement.
Measuring exhaust gas temperature

a Tools for measuring exhaust gas temperature
Symbol B Part No. 799-101-1502 Part name Digital thermometer
k Wait for the temperature of the exhaust manifold to go down before installing and removing the measuring tools. a Measure the exhaust gas temperature under the following conditions. Engine coolant temperature: Within operating range Hydraulic oil temperature: Within operating range 1. Open the engine hood. 2. Remove heat insulation cover (1). 5. Procedure for measuring maximum exhaust gas temperature for troubleshooting Operate the machine actually and measure the maximum exhaust gas temperature. a Set the digital thermometer in the PEAK mode. 6. Procedure for measuring exhaust gas temperature periodically for preventive maintenance (Pm Clinic), etc. 1) Set the working mode switch in the P mode position and turn the power max. switch ON. 2) Run the engine at high idle and measure the exhaust gas temperature when boom RAISE circuit is relieved. a Measure the exhaust gas temperature after it is stabilized. 3. Remove exhaust gas temperature measurement plug (2).
7. After completing the measurement, remove the measuring tools and set to the original condition.
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Measuring exhaust gas color

a Tools for measuring exhaust gas color
Symbol 1 C 2 Part Number 799-201-9001 Commercially available Part name Handy smoke checker Smoke meter
k Be careful not to touch hot areas when installing and removing the measuring tools. a When air source or electric power supply is not available in field, use C1 handy smoke checker, but use C2 smoke meter, when recording official data. a Measure exhaust gas color under the following conditions: Engine coolant temperature: Within the operating range. 1. Measurement with C1, Handy Smoke Checker 1) Set a filter paper in the handy smoke checker C1. 2) Insert the exhaust gas suction port in the exhaust pipe (1). 3) Start the engine. 4) Operate the handle of the smoke checker C1 , and adhere exhaust gas to the filter paper when accelerating the engine quickly or at a high idle.
2) Connect the probe hose, the receptacle of the accelerator switch and the air hose to the smoke meter C2. a The supply air pressure shall be less than 1.5 MPa {15 kg/cm2} 3) Connect the power cord to power receptacle. a Before connecting the power cord, make sure that the power switch of the smoke meter is turned off. 4) Loosen the cap nut of the suction pump and set a filter paper there. a Set the filter paper accurately so that exhaust gas does not leak out. 5) Turn on the power switch of the smoke meter C2.
5) Remove the filter paper and compare the color on the filter paper with the accessory scale. 6) After the measurement, remove the measuring tools and return the engine to the original state. 2. Measurement with Smoke Meter C2 1) Insert the probe [1] of the smoke meter C2, in the outlet of the exhaust pipe (1) and fix it to the exhaust pipe with clip.
6) Start the engine. 7) When accelerating the engine quickly or at a high idle, step down the accelerator pedal of the smoke meter C2 , and collect exhaust gas in the filter paper. 8) Place the filter paper contaminated with exhaust gas on new filter papers (more than 10 sheets) in the filter paper holder and read the indicated value. 9) After completing the measurement, remove the measuring tools and set to the original condition.
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4. Insert clearance gauge D in the clearance between rocker arm (5) and crosshead (6), and turn adjustment screw (3) to adjust the valve clearance. a With clearance gauge D inserted, turn the adjustment screw and adjust until the clearance is a sliding fit. a Valve clearance Intake valve : 0.35 mm Exhaust valve : 0.57 mm 5. Fix adjustment screw (3) and tighten locknut (4). 3 Locknut: 45.1 51.0 Nm {4.6 5.2 kgm} a After tightening the locknut, check the valve clearance again.
Adjusting valve clearance

a Tools for adjusting valve clearance
Symbol D Part No. Commercially available Part name Clearance gauge
1. Open the engine hood and remove all the heat insulation covers. 2. Remove all the cylinder head covers (1).
3. Rotate the crankshaft in the normal direction to align [1.6 TOP] line (a) on the damper with pointer (2), and set the No.1 cylinder to the compression top dead center. a Check the pointer from the alternator side. a Crank the engine with the hexagonal part at the water pump drive shaft on the alternator side. a At the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by hand an amount equal to the valve clearance. If the rocker arm does not move, it is not at the compression top dead center, so rotate the crankshaft one more turn.
6. Rotate the crankshaft 120 each time in the normal direction and repeat Steps 2 4 to adjust the valve clearance of each cylinder according to the firing order. a Firing order: 1 5 3 6 2 4 7. After completing the adjustment, set to the original condition. 3 Cylinder head cover mounting bolt: 29.4 34.3 Nm {3.0 3.5 kgm}
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Measuring compression pressure

a Tools for measuring compression pressure
Symbol 1 E 2 6261-71-615A Gasket Part No. 795-502-1590 795-471-1330 Part name Compression gauge Adapter
a Pass a wire, etc. under the fuel path projected sideways and pull up the injector (Do not pry the injector top up).
a When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. a Measure the compression pressure under the following condition. Engine oil temperature: 40 60C 1. Open the engine hood and remove all the heat insulation covers. 2. Remove head cover (1) of the cylinder to measure the compression pressure.
5. Install adapter E2 and connect it to compression gauge E1. a Install gasket to the tip of adapter E2. a Secure the adapter with the injector holder. 3 Mounting bolt: 58.8 73.5 Nm {6.0 7.5 kgm} a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily. 6. Install rocker arm assembly (2) and adjust the valve clearance. 3 Mounting bolt: 93 103 Nm {9.5 10.5 kgm} a See Adjusting valve clearance.
3. Remove rocker arm assembly (2). a Referring to Adjusting valve clearance, set the cylinder to be measured at the compression top dead center so that you can work easily. 4. Disconnect fuel high-pressure tube (3) and remove the injector wiring harness and injector (4). a Use a high-pressure pipe ring wrench (on the market) to disconnect and connect the fuel high-pressure tube. At this time, loosen the clamps on the common rail side and at the intermediate part. a Disconnect the terminal of the injector wiring harness on the injector side and the plate on the rocker housing side and remove the injector wiring harness (Loosen the terminal nuts alternately).
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5) Tighten sleeve nut (15) of the fuel high-pressure tube securely. 3 Sleeve nut: 39.2 49.0 Nm {4 5 kgm} 6) Tighten the intermediate clamp of the fuel high-pressure tube. 7) Install the injector wiring harness. a Tighten the terminal nuts at the injector top alternately. 3 Nut: 2 0.2 Nm {0.2 0.02 kgm}
7. Operate the machine monitor to set it to the noinjection cranking function. a See No-injection cranking. 8. Turn the starting switch ON and prepare for measuring the engine speed with the machine monitor. a See Measuring engine speed. 9. Crank the engine with the starting motor and measure the compression pressure. a Read the pressure gauge pointer when it is stabilized. a When measuring the compression pressure, measure the engine speed, too, and check that it is in the measurement condition range. 10. After completing the measurement, remove the measuring tools and set to the original condition. a Install the injector and fuel high-pressure tube according to the following procedure. 1) Assemble injector (11) and holder (12) together and set them to the mounting position of the cylinder head. a When setting the injector, pull the fuel high-pressure tube to outside of the cylinder head so that the threads of the injector will not interfere with the taper seal of the fuel high-pressure tube. 2) Tighten mounting bolt (13) temporarily. a Tighten the mounting bolt to a degree that you can move the injector. 3) Tighten sleeve nut (15) of the fuel high-pressure tube to injector (11) lightly. a Use a high-pressure pipe ring wrench (on the market) to disconnect and connect the fuel high-pressure tube. a Tighten the sleeve nut lightly until it is stopped by the injector. 4) Tighten mounting bolt (13) securely. 3 Mounting bolt: 58.8 73.5 Nm {6.0 7.5 kgm} a After installing the rocker arm assembly, adjust the valve clearance. For details, see Adjusting valve clearance. 3 Rocker arm assembly mounting bolt: 93 103 Nm {9.5 10.5 kgm} 3 Cylinder head cover mounting bolt: 29.4 34.3 Nm {3.0 3.5 kgm}
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Measuring blow-by pressure

a Tools for measuring blow-by pressure
Symbol F Part No. 799-201-1504 Part name Blow-by checker
Measuring engine oil pressure

a Tools for measuring engine oil pressure
Symbol 1 Part No. 799-101-5002 G 2 790-261-1204 799-401-2320 Part name Hydraulic tester Digital hydraulic tester Gauge
a Measure the blow-by pressure under the following conditions. Engine coolant temperature: Within operating range Hydraulic oil temperature: Within operating range 1. Remover the engine under cover (front side). 2. Install the nozzle [1] of blow-by checker F to blow-by hose (1). 3. Connect the hose [2] and gauge [3].
a Measure the engine oil pressure under the following conditions. Engine coolant temperature: Within operating range 1. Remove the engine room cover (control valve side) or under cover (front side). 2. Install hose [1] of hydraulic tester G1 and connect them to gauge G2.
4. Start the engine and set the working mode switch to the P mode position. 5. Run the engine at high idle and measure the blow-by pressure when arm IN circuit is relieved.
3. Start the engine and measure the oil pressure with the engine at low idle and high idle.
6. After finishing measurement, remove the measuring tools and set to the original condition.
4. After completing the measurement, remove the measuring tools and set to the original condition. 3 Oil pressure switch: 2.9 5.9 Nm {0.3 0.6 kgm}
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3. Connect hydraulic testers [2] and [3] (Component part of tool G1) to the nipple [1]. 4. Start the engine and measure the oil pressure at low idle and high idle.
Testing EGR valve and bypass valve drive oil pressure

a Testing instrument for EGR valve and bypass valve drive oil pressure
Symbol G 1 790-261-1204 Digital hydraulic tester Part No. 799-101-5002 Part name Hydraulic tester
1. Remove oil pressure pickup plug (2) from the left side of timing gear cover (1). 2. Install nipple [1] of hydraulic tester G1 to the hole from which the oil pressure pickup plug was removed.
5. After finishing measurement, remove the measuring instruments and return the removed parts. a Remove the gasket sealant remaining on the threads of the removed plug with a wire brush and apply new adhesive or gasket sealant to the plug before installing. 2 Plug: LT2 or LG-5 3 Plug: 9.8 19.6 Nm {1.0 2.0 kgm}
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Handling equipment in fuel circuit

a Precautions in inspection and maintenance of fuel system equipment The common rail type fuel injection system (CRI) is composed of more precise components than the usual fuel injection pump and nozzle and will probably get out of order when foreign matters enter the system. During inspection and maintenance of the fuel system, pay more attention to foreign matters than in case of usual fuel injection pumps and wash the system carefully with clean fuel if dusts enter the system. a Precautions in replacement of fuel filter cartridge Be sure to use genuine fuel filter cartridge of Komatsu. The common rail type fuel injection system (CRI) is composed of more precise components than the usual fuel injection pump and nozzle and is equipped with special filter with highly efficient filtration performance to prevent foreign matters from entering the system. Therefore, be sure to use genuine filters only. Otherwise, the fuel system will possibly get out of order.
Releasing remaining pressure in fuel system

a While the engine is rotating, pressures occur in the low pressure circuit and the high pressure circuit of the fuel system. Low pressure circuit : feed pump fuel filter fuel supply pump High pressure circuit : fuel supply pump common rail fuel injector a When 30 seconds elapse after the engine stopped, pressures in both the low pressure circuit and the high pressure circuit drop to the safe level automatically. a Since pressure remaining in the fuel system should be released certainly before inspection of the fuel system and mounting and removing of equipment, be sure to observe the following precautions: k Inspect the fuel system or mount or remove equipment more than 30 seconds after the engine stopped and after pressure remaining in the fuel system is released. (Pressure remains in the fuel system right after the engine stopped, so do not start any work until 30 seconds elapse.)
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3. Run the engine at high idle and measure the fuel pressure. a If the fuel pressure is in the following range, it is normal.
Engine speed High idle Fuel pressure 0.15 0.3 MPa {1.5 3 kg/cm2}
Measuring fuel pressure

a Tools for measuring fuel pressure
Symbol 1 790-261-1204 H 2 799-401-2320 795-471-1450 3 07005-00812 Digital hydraulic tester Gauge Adapter (8 1.25 o R1/8) Seal washer Part No. 799-101-5002 Part name Hydraulic tester
a Test only the fuel pressure in the low-pressure circuit from the feed pump through the engine controller cooler and fuel filter to the supply pump. k Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot be measured. 1. Remove fuel pressure measuring plug (1) on fuel filter head. 4. After finishing testing, remove the testing tools and return the removed parts.
2. Install adapter H3, hydraulic tester H1 (elbow) [1] and nipple [2], and connect gauge H2.
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Reduced cylinder mode operation

a Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows. 1. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). 2. When a cylinder is selected for the reduced cylinder mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has 1 or more defects. The possible defects are as follows. Leakage through cylinder head gasket Defective injection Defective piston, piston ring, or cylinder liner Defective valve mechanism (Moving valve system) Defect in electrical system 3. Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to find out a defective cylinder. a See Special functions of machine monitor, no-injection cranking.
No-injection cranking
a No-injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. Before the engine is started after it or the machine has been stored for a long period, the noinjection cranking is performed to lubricate the engine parts and protect them from seizure. a See Special functions of machine monitor, noinjection cranking.
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Testing leakage from pressure limiter and return rate from injector
a Testing tools for measuring leakage and return rate of fuel

Symbol 1 2 3 J 4 5 6 Part No. 6151-51-8490 6206-71-1770 Commercially available Commercially available Commercially available Commercially available Part name Spacer Joint Hose Hose Measuring cylinder Stopwatch
1. Preparation work 1) Remove tube (3) between common rail (1) and supply pump (2). 2) Insert spacer J1 on supply pump (2) side and tighten the removed joint bolt again. a Connect the return pipe to the fuel tank again, too. a Be sure to fit the gaskets to both ends of the spacer.
a Prepare an oil pan of about 20 l to receive the fuel flowing out during the test.
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3) Insert joint J2 on common rail (1) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the joint. 4) Connect test hose J3 to the end of joint J2. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. a The above is the preparation work for testing the leakage from the pressure limiter.
5) After finishing testing, stop the engine. 3. Testing return rate from injector a Keep the hose on the pressure limiter side connected and keep its end in the oil pan while testing the return rate from the injector. 1) Disconnect return hose (5) of return block (4) and connect test hose J4. a Stop the return hose with a plug, etc. and fix it to the fuel tank. Plug: 07376-70315 a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. 2) Lay test hose J4 so that it will not slacken and put its end in the oil pan.
2. Testing leakage from pressure limiter 1) Lay test hose J3 so that it will not slacken and put its end in the oil pan. 2) Operate machine monitor to set it so that it can check the engine speed. 3) Start the engine and keep its speed equivalent to the rated load. 4) After the engine speed is stabilized, test the leakage in 1 minute with measuring cylinder J5. a You may test for 20 seconds and judge by multiplying the result by 3. a If the leakage from the pressure limiter is in the following range, it is normal.
Engine speed (rpm) Operation with rated outout Leakage (cc/min) Max. 10
3) Operate machine monitor to set it so that it can check the engine speed. 4) Start the engine and keep its speed equivalent to the rated load.
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5) After the engine speed is stabilized, test the return rate in 1 minute with measuring cylinder J5. a You may test for 20 seconds and judge by multiplying the result by 3. a If the supply pump is not supplying fuel, the engine speed may not rise. In this case, record the engine speed, too, during the test. a If the return rate (spill) from the injector is in the following range, it is normal.
Rated output speed (rpm) 1,600 1,700 1,800 1,900 2,000 Limit of return rate (spill) (cc/min) 960 1,020 1,080 1,140 1,200
Bleeding air from fuel circuit

a If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. 1. Remove fuel prefilter (1) and fill it with fuel. a Fill the fuel prefilter with clean fuel and take care that dirt will not enter it. a Check that the cap is fitted to part (a) (central hole) of the fuel prefilter, and then add fuel through part (b) (holes around the central hole). a After filling the fuel prefilter with fuel, remove the cap from part (a). a If clean fuel is not available, do not remove the prefilter but fill it with the fuel by operating priming pump (4). a Do not add fuel to fuel main filter (2) from outside.
6) After finishing testing, stop the engine. 4. Work after finishing testing After finishing all testing, remove the testing tools and return the removed parts.
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2. Install fuel prefilter (1) to the filter head. a Thinly apply engine oil to the packing surface on the fuel prefilter. a After the packing surface on the fuel prefilter side touches the seal surface of the filter head, tighten the fuel prefilter by 3/4 turns. 3. Remove air bleeding plug (3) of the main fuel filter and operate priming pump (4). a Operate the priming pump until fuel flows out of the plug hole. After fuel starts flowing out, install plug (3). 3 Air bleeding plug: 7.8 9.8 Nm {0.8 1.0 kgm} 4. Loosen air bleeding plug (5) of the main fuel filter and operate priming pump (4). a Operate the priming pump until fuel flows out of the plug hole. After fuel starts flowing out, install plug (5). 3 Air bleeding plug: 7.8 9.8 Nm {0.8 1.0 kgm}
6. Start the engine with the starting motor. a The air in the high-pressure circuit is bled automatically if the engine is rotated. a If the engine does not start, there may be still air in the low-pressure circuit. In this case, repeat the above procedure from step 3.
5. Loosen air bleeder (6) of the fuel supply pump and operate priming pump (4) 90 100 times. a Operate the priming pump until fuel flows out of the bleeder. After fuel starts flowing out, tighten the bleeder and operate the priming pump several times until it becomes heavy. 3 Air bleeder: 4.9 6.9 Nm {0.5 0.7 kgm}
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9. Inspect the fuel piping and devices for fuel leakage. a Inspect mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. a If no fuel leakage is detected, inspection is completed.
Testing fuel system for leakage
k Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, test it for fuel leakage according to the following procedure. a Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage. 1. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping. 2. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized. 3. Inspect the fuel piping and devices for fuel leakage. a Inspect mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. 4. Run the engine at low idle. 5. Inspect the fuel piping and devices for fuel leakage. a Inspect mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. 6. Run the engine at high idle. 7. Inspect the fuel piping and devices for fuel leakage. a Inspect mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. 8. Run the engine at high idle and load it, and relieve the oil from the hydraulic pump.
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Testing and adjusting alternator belt tension

Testing Press the intermediate point of the belt between alternator pulley and drive pulley with a finger and measure deflection (a) of the belt. a Pressing force: Approx. 98 N {Approx. 10 kg} a Deflection (a): 13 16 mm (1 piece)
Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1. Loosen mounting bolts (2) and (3) of alternator (1), and then loosen locknut (4). 2. Move alternator (1) with adjustment nut (5) to adjust the tension of belt (6). 3. Tighten locknut (4), and then tighten mounting bolts (3) and (2). a After adjusting, test the belt tension again.
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3. Tighten nuts and bolts (4), (3), (2) and (1) in this order. a When the belt was replaced, readjust it after 1 hour operation.
Testing and adjusting air conditioner compressor belt tension

Testing 1. Open the engine hood and remove the insulation cover on the air conditioner compressor side. 2. Measure the belt deflection (a) when pushing a point midway between the air conditioner compressor pulley and drive pulley with a finger. a Deflection (a) when pressing force is approx. 58.8 N {approx. 6 kg}: 10 15 mm
Adjusting a Adjust the belt tension according to the following procedure when the belt deflection is not normal. 1. Loosen the mounting bolts (1) and (2), locknut (3). 2. Turn adjusting nut (4) to move compressor (5) and adjust the belt tension. a If nut (4) is: Tightened clockwise, the belt is loosened. Loosened counterclockwise, the belt is tensed. a Check each pulley for breakage, check the V-grooves and V-belts for wear, and check that the V-grooves and V-belts are in good contact with each other. a If the belts are so lengthened that their tension cannot be adjusted any more or they have a cut or a crack, replace them.
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Testing clearance of swing circle bearing

a Tools for testing clearance of swing circle bearing
Symbol K Part No. Commercially available Part name Dial gauge (with magnet)
3. Set the dial gauge K to the zero point. 4. Arrange the arm almost at right angles to the ground and lower the boom until the front leg of the machine body rises. a At the time, the front of the upper structure rises and its rear lowers.
a When measuring swing circle bearing clearance on a machine, follow the procedures below: a For the standard values, see Structure, function and maintenance standard, Swing circle. 1. Fix the dial gauge K to the track frame (center frame) and bring the stylus to the outer race end face. a Set the dial gauge to the front or to the rear.
5. At the time, read the value on the dial gauge K. This value on the dial gauge indicates the swing circle bearing clearance.
k During the measurement, never place hands and legs below the undercarriage.
6. Return the work equipment to the state in Paragraph 2 and make sure that the dial gauge K has returned to the zero point. If not, repeat Steps 2 to 5. 2. Set the work equipment to the maximum reach and set the bucket tip to the height of the revolving frame lower face. a At the time, the front of the upper structure lowers and its rear rises.
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Adjusting a If the track shoe tension is not proper, adjust it in the following manner. 1. When the tension is too strong Discharge grease by loosening valve (3).
Testing and adjusting track shoe tension

Testing 1. Travel the machine forward by the length of track on ground, keeping the engine at low idle, and stop the machine slowly. 2. Place steel bar [1] on the track shoe between second carrier roller (1) and third carrier roller (2). a L beam is recommended for bar [1], because of its deflection-free nature. 3. Measure max. clearance (a) between bar [1] and the track shoe. Max. standard clearance (a): 10 30 mm
k Do not loosen valve (3) more than one turn, because grease will spurt due to its internal high pressure.
2. When the tension is too weak Add grease through grease fitting (4). a If the normal track shoe tension is not restored even after greasing, move the machine slowly back and forth.
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Testing and adjusting work equipment, swing, and travel circuit oil pressures
a Tools for testing and adjusting work equipment, swing, and travel circuit oil pressures
Symbol L 790-261-1204 Digital hydraulic tester Part No. 799-101-5002 Part name Hydraulic tester
Measuring a Measure the work equipment, swing and travel circuit oil pressures under the following conditions: Hydraulic oil temperature: Within operating range a The work equipment, swing, and travel circuit oil pressures can be checked in the monitoring function of the machine monitor, too. (For the operating method, see Special function of machine monitor panel.) Monitoring code: 01100 F pump pressure 01101 R pump pressure The pump oil pressure is displayed in 0.1 MPa (1 kg/cm2, 1 PSI).
a Use quick coupler (2) to measure the rear pump (No. 1 R + No. 2 R) circuit oil pressure. a Use quick coupler (1) to measure the front pump (No.1F + No.2F) circuit oil pressure. a The relief pressure of the boom LOWER circuit can be measured only in the front pump circuit. a The relief pressure of the bucket DUMP circuit can be measured only in the rear pump circuit. a The relief pressure of the swing circuit can be measured only in the front pump circuit. a Use the oil pressure gauges of 60 MPa {600 kg/cm2}.
1. Preparation work
k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1) Open the pump compartment cover (both front and rear end). 2) Connect oil pressure gauges [1] of hydraulic tester L to quick couplers (1) and (2) installed to the outlet of each pump of the circuit to be measured.
2. Measuring work equipment circuit oil pressure 1) Measuring normal relief pressure i) Start the engine and set the working mode switch to the A mode position. ii) Run the engine at high idle, relieve each cylinder singly at the stroke end, and measure the oil pressure. a The main relief valves of the control valve (left and right) relieve on the lowpressure setting side. a If the boom cylinder is relieved at the LOWER stroke end, the safety-suction valve on the boom head side of the right side 4-spool control valve relieves on the low-pressure setting side (The set pressure of the safety-suction valve is lower than that of the main relief valve).
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3. Measuring swing circuit oil pressure 1) Start the engine and set the working mode switch in the P mode position. 2) Turn the swing lock switch ON. 3) Run the engine at high idle, relieve the swing motor, and measure the oil pressure. a The safety valves of the front and rear swing motors relieve. (The set pressure of the safety valves is lower than that of the main relief valve.)
2) Measuring relief pressure during L mode i) Start the engine and set the working mode switch in the L mode position. ii) Run the engine at high idle, relieve the boom cylinder singly at the RAISE stroke end, and measure the oil pressure. a The main relief valves of the control valve (left and right) relieve on the highpressure setting side. 3) Measuring relief pressure during machine push-up operation i) Start the engine and set the working mode switch in the P mode position. ii) Turn the machine push-up switch ON. iii) Run the engine at high idle, relieve the boom cylinder singly at the LOWER stroke end, and measure the oil pressure. a Since the set pressure of the safety-suction valve on the boom head side of the right side 4-spool valve rises higher than the set pressure of the main relief valve, the main relief valve relieves on the lowpressure setting side. 4) Measuring relief pressure during one-touch power max. operation i) Start the engine and set the working mode switch in the P mode position. ii) Run the engine at high idle, relieve each work equipment cylinder singly at the following stroke end, press the one-touch power max. switch, and measure the oil pressure. Boom: RAISE stroke end Arm: IN stroke end Bucket: CURL stroke end a The one-touch power max. function is reset automatically in about 8.5 seconds even if the switch is kept held. Accordingly, measure the engine speed in that period.
4. Measuring travel circuit oil pressure 1) Start the engine and lock the travel mechanism.
k Put pin [2] between the sprocket and track frame to lock the travel mechanism securely.
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2) Run the engine at high idle, relieve the travel motor, and measure the oil pressure. a The main relief valves of the control valve (left and right) relieve on the high-pressure setting side.
4) Turn holder (7) to adjust the pressure. a If the holder is: Turned to the right, the pressure rises. Turned to the left, the pressure lowers. a Pressure changed by 1 turn of holder: 12.5 MPa {128 kg/cm2} 5) Fix holder (7) and tighten locknut (8). 3 Locknut: 93.2 122.6 Nm {9.5 12.5 kgm} a If the high-pressure setting side is adjusted, the low-pressure setting side changes. Accordingly, adjust the lowpressure setting side, too.
Adjusting a Do not adjust any safety valve other than the swing motor safety valve. a When adjusting the main relief valves of the left side 4-spool valve and right side 5-spool valve, remove the control valve top cover. 1. Adjusting main relief valve (high-pressure setting) of right side 5-spool control valve a If the work equipment oil pressure in the front pump circuit (during L mode) and the L.H. travel oil pressure are abnormal, adjust the high-pressure setting side of main relief valve (3) of the right side 5-spool control valve according to the following procedure. 6) Fix elbow (6) and tighten locknut (5). 7) Connect hose (4). 8) After completing the adjustment, check the oil pressure again according to the above described measurement procedure. 2. Adjusting main relief valve (low-pressure setting) of right side 5-spool control valve If the work equipment oil pressure in the front pump circuit (during normal relief operation) is abnormal or the high-pressure setting side was adjusted, adjust the low-pressure setting side of main relief valve (3) of the right side 5-spool control valve according to the following procedure. If the left travel oil pressure and power maximizing oil pressure are abnormal, adjust the low-pressure setting of main relief valve (3) of the right side 5-spool control valve according to the following procedure. a The low-pressure setting is the state in which the 2-stage relief solenoid valve is turned OFF and the pilot pressure is not applied to the changeover port. 1) Disconnect hose (4). 2) Loosen locknut (5) and set elbow (6) free. 3) Fix union (9) and loosen locknut (10). 4) Turn union (9) to adjust the pressure. a If the union is: Turned to the right, the pressure rises. Turned to the left, the pressure lowers.
a The high pressure setting is the state in which the 2-stage relief solenoid valve is turned ON and the pilot pressure is applied to the changeover port. 1) Disconnect hose (4). 2) Loosen locknut (5) and set elbow (6) free. 3) Fix holder (7) and loosen locknut (8).
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4. Adjusting main relief valve (low-pressure setting) of left side 4-spool control valve 1) If the work equipment oil pressure in the rear pump circuit (during normal relief operation) is abnormal or the high-pressure setting side was adjusted, adjust the lowpressure setting side of main relief valve (11) of the left 4-spool control valve according to the following procedure. a Adjust the left side 4-spool control valve similarly to the right side 5-spool control valve. 2) If the right travel oil pressure and power maximizing oil pressure are abnormal, adjust the low-pressure setting of main relief valve (11) of the left side 4-spool control valve according to the following procedure. a Adjust the left side 4-spool control valve similarly to the right side 5-spool control valve.
a Pressure changed by 1 turn of union: 12.5 MPa {128 kg/cm2} 5) Fix union (9) and tighten locknut (10). 3 Locknut: 39.2 49.0 Nm {4.0 5.0 kgm}
6) Fix elbow (6) and tighten locknut (5). 7) Connect hose (4). 8) After completing the adjustment, check the oil pressure again according to the above described measurement procedure. 3. Adjusting main relief valve (high-pressure setting) of left side 4-spool control valve a If the work equipment oil pressure in the rear pump circuit (during L mode) oil pressure are abnormal, adjust the high-pressure setting side of main relief valve (11) of the left side 4-spool control valve according to the following procedure.
5. Adjusting swing motor safety valve a If the relief pressure of the swing motor is abnormal, adjust safety valves (12) and (13) of the swing motor according to the following procedure. (12): Safety valve of left swing motor
(13): Safety valve of right swing motor
a Adjust the left side 4-spool control valve similarly to the right side 5-spool control valve.
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1) Fix adjustment screw (14) and loosen locknut (15). 2) Turn adjustment screw (14) to adjust the pressure. a If the adjustment screw is: Turned to the right, the pressure rises. Turned to the left, the pressure lowers. a Pressure changed by 1 turn of adjustment screw: 3.87 MPa {39.5 kg/cm2} 3) Fix adjustment nut (14) and tighten locknut (15). 3 Locknut: 118 147 Nm {12 15 kgm}
4) After completing the adjustment, check the oil pressure again according to the above described measurement procedure.
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3. Run the engine at high idle, set the work equipment swing lever and travel lever in neutral, and measure the oil pressure.
Testing and adjusting control circuit oil pressure

a Tools for testing and adjusting control circuit oil pressure
Symbol M 790-261-1204 Digital hydraulic tester Part No. 799-101-5002 Part name Hydraulic tester
Measuring a Measure the control circuit oil pressure under the following condition. Hydraulic oil temperature: Within operating range k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1. Open the pump compartment cover (front side) and remove oil pressure measurement plug (1).
Adjusting a If the control circuit oil pressure is abnormal, adjust control relief valve (2) according to the following procedure.
1. Remove cap (3). 2. Fix adjustment screw (4) and loosen locknut (5). 2. Install nipple [1] of hydraulic tester M and connect it to oil pressure gauge [2]. a Use the oil pressure gauges of 6 MPa{60 kg/ cm2} 3. Turn adjustment screw (4) to adjust the pressure. a If the adjustment screw is: Turned to the right, the pressure rises. Turned to the left, the pressure lowers. 4. Fix adjustment screw (4) and tighten locknut (5). 3 Locknut: 9.8 Nm {1 kgm}
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5. After completing the adjustment, repeat the procedure in above to check the set pressure again.
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3) Install nipple N3 and connect oil pressure gauge [1] of hydraulic tester N1. a Use the oil pressure gauges of 6 MPa {60 kg/cm2}. a Fig. shows the view from the pump room under cover side.
Testing and adjusting piston pump control oil pressure

a Tools for testing and adjusting piston pump control oil pressure
Symbol 1 790-261-1204 2 N 799-101-5220 3 07002-11023 4 799-401-3200 O-ring Adapter (Size: 03) 799-401-2701 Digital hydraulic tester Differential pressure gauge Nipple (10 1.5 mm) Part No. 799-101-5002 Part name Hydraulic tester
Measuring a Measure the piston pump control oil pressure under the following conditions: Hydraulic oil temperature: Within the operating range k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1. Measuring TVC valve output pressure a Since the TVC valve output pressure varies with the discharge pressure of each pump, check that the work equipment, swing, and travel circuit oil pressure is normal before starting measurement. a Since the basic pressure of the TVC valve output pressure is the control circuit pressure, check that the control circuit oil pressure is normal before starting measurement. 1) Open the pump compartment cover (front side) 2) Remove oil pressure measurement plug (1) of the No. 1 front pump.
4) Start the engine and set the working mode switch in the P mode position. 5) Set all the control levers in neutral and measure the TVC valve output pressure under the following condition. i) Set all the control levers in neutral. ii) Run the engine at high idle and measure the output pressure. 6) Relieve the boom circuit by raising the boom (normally), and measure the TVC valve output pressure under the following condition. Run the engine at high idle, relieve the boom circuit by raising the boom, and measure the output pressure. 7) Set the working mode switch in the L mode position, relieve the boom circuit by raising the boom, and measure the TVC valve output pressure under the following condition. i) Select L mode. ii) Run the engine at high idle, relieve the boom circuit by raising the boom, and measure the output pressure.
8) After completing the measurement, remove the measuring tools and set to the original condition.
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2. Measuring CO NC valve output pressure 1) Open the undercover of the No. 2 pump. 2) Remove oil pressure measurement plugs (2) and (3) of the No. 2 pump. (2): For front pump circuit (3): For rear pump circuit
7) Drive the travel motor under no load and measure the CO NC valve output pressure under the following condition. i) Raise the track shoe to be measured by using the boom and arm. ii) Run the engine at high idle, drive the travel motor under no load (with the lever at the stroke end), and measure the output pressure. 8) Set the working mode switch in the L mode position, relieve the boom circuit by raising the boom, and measure the output pressure under the following condition. i) Select L mode. ii) Run the engine at high idle, relieve the boom circuit by raising the boom, and measure the output pressure.
3) Install nipple N3 and connect oil pressure gauge [1] of hydraulic tester N1. a Use the oil pressure gauges of 6 MPa {60 kg/cm2}.
4) Start the engine and set the working mode switch in the P mode position. 5) Set all the control levers in neutral and measure the CO NC valve output pressure under the following condition. i) Set all the control levers in neutral. ii) Run the engine at high idle and measure the output pressure. 6) Relieve the boom circuit by raising the boom (P mode) and measure the CO NC valve output pressure under the following condition. i) Run the engine at high idle, relieve the boom circuit by raising the boom, and measure the output pressure.
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3. Measuring jet sensor output differential pressure of right side 5-spool control valve and left side 4-spool control valve 1) Remove oil pressure measurement plugs (4) and (5) under the right side 5-spool control valve and oil pressure measurement plugs (6) and (7) under the left side 4-spool control valve. (4): High pressure side (Pt) of right side 5-spool control valve (F pump) (5): Low pressure side (Pd) of right side 5-spool control valve (F pump) (6): High pressure side (Pt) of left side 4-spool control valve (R pump) (7): Low pressure side (Pd) of left side 4-spool control valve (R pump) a The jet sensor output differential pressure may be measured at the inlet hose of the No. 1 pump by using adapter N4 and nipple N3.
3) Start the engine and set the working mode switch in the P mode position. 4) Set all the control levers in neutral and measure the jet sensor output differential pressure under the following condition. i) Set all the control levers in neutral. ii) Run the engine at high idle and measure the output differential pressure. a Jet sensor output differential pressure = High pressure (Pt) Low pressure (Pd) 5) Drive the travel motor under no load and measure the jet sensor output differential pressure under the following condition. i) Raise the track shoe to be measured by using the boom and arm. ii) Run the engine at high idle, drive the travel motor under no load, and measure the output differential pressure. a Jet sensor output differential pressure = High pressure (Pt) Low pressure (Pd)
2) Install nipple [2] of hydraulic tester N1 and connect it to differential pressure gauge N2 or oil pressure gauge [1] of N1. a When using differential pressure gauge: Connect the high pressure (Pt) to the high pressure side (back side) of the differential pressure gauge and connect the low pressure (Pd) to the low pressure side (lower side). Since the differential pressure gauge needs DC 12 V, connect 1 battery to it. a When using pressure gauge: Connect the pressure gauge of 6 MPa {60 kg/cm 2 } to the high pressure side (Pt) and connect the pressure gauge of 2.5 MPa {25 kg/cm2} to the low pressure side (Pd).
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3) Fix adjustment screw (9) and tighten locknut (10). 3 Locknut: 5.9 9.8 Nm {0.6 1.0 kgm}
6) After completing the measurement, remove the measuring tools and set to the original condition. Adjusting 1. Adjusting TVC valve a When adjusting the TVC valve, open the pump compartment cover. a If the TVC valve output pressure is abnormal, adjust TVC valve (8) of the No. 1 pump according to the following procedure. 4) After completing the adjustment, check the oil pressure again according to the above described measurement procedure. 2. Adjusting CO NC valve a When adjusting the CO valve side of the CO NC valve, remove the No. 1 pump undercover. When adjusting the NC valve side, open the pump compartment cover. a If the CO NC valve output pressure is abnormal, adjust CO valves (11) and (12) and NC valves (13) and (14) of the No. 1 pump according to the following procedure. (11): Front CO valve of No. 1 pump (12): Rear CO valve of No. 1 pump
1) Fix adjustment screw (9) and loosen locknut (10). 2) Turn adjustment screw (9) to adjust the pressure. a If the adjustment screw is: Turned to the right, the pressure rises. Turned to the left, the pressure lowers. a Pressure changed by 1 turn of adjustment screw: 0.34 MPa {3.5 kg/cm2}
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a If the adjustment screw is: Turned to the right, the pressure rises. Turned to the left, the pressure lowers. a Pressure changed by 1 turn of adjustment screw: 0.39 MPa {4.0 kg/cm2} (at J/S difference pressure) iii) Fix adjustment screw (17) and tighten locknut (18). 3 Locknut: 5.9 9.8 Nm {0.6 1.0 kgm}
(13): Front NC valve of No. 1 pump (14): Rear NC valve of No. 1 pump
1) Adjusting CO valve side i) Fix adjustment screw (15) and loosen locknut (16). ii) Turn adjustment screw (15) to adjust the pressure. a If the adjustment screw is: Turned to the right, the pressure rises. Turned to the left, the pressure lowers. a Pressure changed by 1 turn of adjustment screw: 4.05 MPa {41.25 kg/cm2} (at pump pressure) iii) Fix adjustment screw (15) and tighten locknut (16). 3 Locknut: 5.9 9.8 Nm {0.6 1.0 kgm}
iv) After completing the adjustment, check the oil pressure again according to the above described measurement procedure. 3. Adjusting jet sensors of right side 5-spool control valve and left side 4-spool control valve a If the jet sensor output differential pressure of the right side 5-spool control valve or left side 4-spool control valve is abnormal, adjust jet sensor relief valves (19) and (20) according to the following procedure. (19): Jet sensor relief valve of right side 5spool control valve (20): Jet sensor relief valve of left side 4spool control valve
iv) After finishing adjustment, check the oil pressure again according to the above described measurement procedure. 2) Adjusting NC valve side i) Fix adjustment screw (17) and loosen locknut (18). ii) Turn adjustment screw (17) to adjust the pressure.
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1) Fix adjustment screw (21) and loosen locknut (22). 2) Turn adjustment screw (21) to adjust the pressure. a If the adjustment screw is: Turned to the right, the pressure rises. Turned to the left, the pressure lowers. a Pressure changed by 1 turn of adjustment screw: 0.288 MPa {2.94 kg/cm2} 3) Fix adjustment screw (21) and tighten locknut (22). 3 Locknut: 59 78 Nm {6 8 kgm}
4) After completing the adjustment, check the oil pressure again according to the above described measurement procedure.
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a After checking that the rod moves smoothly, keep it at the position where it is most protruded. 5) Stop the engine and measure the size of the rod protrusion (a2). 6) Calculate the servo piston stroke (b) from the measured size. a Servo piston stroke (b) = (a2) (a1) a Standard stroke (b): 9.37 mm
Testing servo piston stroke

a Tools for testing servo piston stroke
Symbol 1 P 2 07000-B2065 566-98-41120 O-ring Disc gauge Part No. 708-25-14140 Cap Part name
a When the NC valve output pressure is normal but the pump performance is considered inappropriate, inspect the acceptability of the servo valve and piston according to the following procedures: 1. Preparation of tool Drill a through hole PT1/4 in the center of the cap P1 and screw the disc gauge P2 in the hole. a Prepare the cap for the side where the spring of the hydraulic pump servo piston is fitted.
7) After completing the testing, remove the testing tools and set to the original condition. 3. Judgment of servo valve a If the servo piston stroke is abnormal, remove the servo valve, servo piston cap, and spring, and check that you can move the servo piston smoothly before judging the condition of the servo valve. 1) When servo piston stroke is normal: Servo valve is normal. 2) When servo piston stroke is abnormal: Servo piston moves smoothly; Servo valve is abnormal. Servo piston does not move smoothly; Servo valve is normal.
2. Measurement of stroke 1) Remove the cap and the shim of the servo valve on the measuring side. a Since the cap is pressed with the spring, remove the cap carefully with the long bolt (01016-31070, etc.) and the nut so that the cap does not jump out. 2) Mount the measuring tools P, on the servo piston together with the removed shim. a Be careful so that the shim is not caught in the bolt threads. 3) Push in the rods of the measuring tools P, fully and measure the size of the protrusion (a1). 4) Start the engine, keep it at full throttle and move the track shoe under no load. a Operate the lever to the full stroke. a During the measurement, press the rod with hand and check at the same time that the rod moves smoothly as the control lever changes the stroke.
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Measuring PPC valve output pressure

a Tools for measuring PPC valve output pressure
Symbol 1 Q 2 790-261-1204 799-401-3200 Digital hydraulic tester Adapter (Size: 03) Part No. 799-101-5002 Part name Hydraulic tester
(3) : For boom LOWER circuit (4) : For arm IN circuit
a Measure the PPC valve output pressure under the following conditions: Hydraulic oil temperature: Within operating range k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1. Remove the control valve top cover or operator's cab undercover (front side). 2. Remove the PPC oil pressure switches (1) - (8) of the circuits to be measured. (1) : For boom RAISE circuit (2) : For bucket DUMP circuit
(5) : For arm OUT circuit (6) : For bucket CURL circuit
(7) : For swing circuit (left and right)
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(8) : For travel circuit (left and right, forward, and reverse)
3. Install nipple [1] of hydraulic tester Q1 and connect it to oil pressure gauge [2]. a Use an oil pressure gauge of 6 MPa {60 kg/ cm2}. a The measuring tools installed to the swing circuit are shown in the figure.
5. After completing the measurement, remove the measuring tools and set to the original condition. a The PPC valve output pressure may be measured at the PPC hose joint, using adapter Q2 (For the hose to be measured, see the connection diagram on the next page). 4. Run the engine at high idle and operate the control lever of the PPC circuit to be measured and measure the oil pressure. a Measure the oil pressure with the lever at a stroke end. a Set the actuators to be measured as shown below. When measuring the work equipment circuit, set each cylinder to the stroke end. When measuring the swing circuit, turn the swing lock switch ON. When measuring the travel circuit, put pin [3] between the sprocket and track frame to lock the travel system.
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Connection diagram of pilot piping (PPC, Solenoid, OLSS circuit)
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a The colors in ( ) in the figure are the colors of the tapes wound onto the hoses.
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Measuring outlet pressures of solenoid valve and PPC shuttle valve

a Tools for measuring outlet pressures of solenoid valve and PPC shuttle valve
Symbol 1 R 2 790-261-1204 799-401-3200 Digital hydraulic tester Adapter (Size: 03) Part No. 799-101-5002 Part name Hydraulic tester
a Measure the outlet pressures of solenoid valve and PPC shuttle valve under the following condition. Hydraulic oil temperature: Within operating range k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1. Measuring outlet pressure of solenoid valve 1) Remove operators cab under cover (rear side) or control valve upper cover. 2) Disconnect outlet hoses (1) (7) of the solenoid valves to be measured, and install adapter R2 and connect the hoses again. (1): PPC lock solenoid valve
(7): Bucket CURL Hi cancel solenoid valve
3) Install nipple [1] of hydraulic tester R1 and connect it to oil pressure gauge [2]. a Use a pressure gauge of 6 MPa {60 kg/ cm2}. a The following figure shows the measuring devices installed to the outlet hose of the safety lock solenoid valve.
(2): CO cancel solenoid valve (3): 2-stage relief solenoid valve (4): Machine push-up solenoid valve (5): Travel speed select solenoid valve (6): Swing holding brake solenoid valve
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4) Run the engine at high idle, set the condition or operate the control levers as shown in the table, and measure the output pressure. a When operating the work equipmentswing or travel control lever, operate it finely to a degree that the PPC oil pressure switch is turned ON. a If the solenoid valve outlet pressure is as shown in the table, the solenoid valve is normal.
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Measurement conditions for solenoid valve a The measurement conditions in the following table are for measuring the solenoid valve outlet pressure and they are a part of the operating condition of each solenoid valve.
No. Solenoid valve Measurement condition Set lock lever in LOCK position. 1 PPC lock Set lock lever in FREE position. Set working mode switch in L mode. 2 CO cancel Power max. switch ON (only 8.5 sec.). Turn heavy lift switch ON and raise boom singly. Swing lock switch ON Operate travel lever. Set working mode switch in L mode. Turn machine push-up switch ON. 4 Machine push-up Turn machine push-up switch OFF. Set travel speed switch in Lo position. 5 Travel speed select Set travel speed switch in Hi position. Turn swing lock switch ON. About 10 seconds after work equipment swing control lever is set in NEUTRAL position. Turn swing lock switch OFF and operate work equipment swing control lever. Swash plate angle of travel motor is set to minimum. Swing holding brake is applied. ON Min. 2.74 {Min. 28} Boom LOWER safety valve is set to low pressure. Swash plate angle of travel motor is set to maximum. ON OFF Min. 2.74 {Min. 28} 0 {0} Basic pressure circuit to PPC valve is opened. Pump CO function is turned ON. ON OFF Min. 2.74 {Min. 28} 0 {0} Operation of machine Basic pressure circuit to PPC valve is closed. Operation Oil pressure of (MPa {kg/cm2}) solenoid OFF 0 {0}
Pump CO function is turned OFF.
ON
Min. 2.74 {Min. 28}
2-stage relief
Main relief valve is set to high pressure. Boom LOWER safety valve is set to high pressure.
ON OFF
Min. 2.74 {Min. 28} 0 {0}
OFF
0 {0}
Swing holding brake
Swing holding brake is released.
ON
Min. 2.74 {Min. 28} Min. 2.35 {Min. 24} 0 {0}
Bucket CURL operated singly. Bucket Hi spool is operated Bucket CURL Hi cancel (see Note) Bucket CURL operated other Bucket Hi spool is stopped. than above.
OFF ON
Note:
The inlet pressure of the bucket CURL Hi cancel solenoid valve is the boom RAISE PPC circuit pressure. Accordingly, when measuring the outlet pressure, move the bucket control lever to the CURL stroke end (The bucket cylinder may be at the CURL stroke end).
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2. Measuring outlet pressures of boom bucket PPC shuttle valves 1) Remove the control valve top cover. 2) Disconnect control valve inlet hose (8), install adapter R2 , and connect the hose again.
5) After completing the measurement, remove the measuring tools and set to the original condition. 3. Measuring outlet pressures of arm swing PPC shuttle valves (arm side) 1) Remove the control valve top cover. 2) Disconnect control valve inlet hose (9), install adapter R2 , and connect the hose again.
3) Install nipple [1] of hydraulic tester Q1 and connect it to oil pressure gauge [2]. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
4) Run the engine at high idle, set the condition as shown in the following table, and measure the output pressure. a If the outlet pressures of the boom and bucket PPC shuttle valve are as shown in the following table, the boom bucket PPC shuttle valve are normal.
Measurement condition Neutral Operated to boom RAISE Right work Operated to equipment boom LOWER control lever Operated to bucket CURL Operated to bucket DUMP Oil pressure (MPa {kg/cm2}) 0 {0} Min. 2.35 {Min. 24} Min. 2.35 {Min. 24} Min. 2.35 {Min. 24} Min. 2.35 {Min. 24}
3) Install nipple [1] of hydraulic tester R1 and connect it to oil pressure gauge [2]. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
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4) Run the engine at high idle, set the condition as shown in the following table, and measure the output pressure. a If the outlet pressures of the arm swing PPC shuttle valve are as shown in the following table, the arm swing PPC shuttle valve (arm side) are normal.
Measurement condition Neutral Right work Operated to equipment arm IN control lever Operated to arm OUT Oil pressure (MPa {kg/cm2}) 0 {0} Min. 2.35 {Min. 24} Min. 2.35 {Min. 24}
4. Measuring outlet pressures of arm and swing PPC shuttle valves (swing side) 1) Remove the control valve top cover. 2) Remove swing PPC oil pressure switch (10).
3) Install nipple [1] of hydraulic tester R1 and connect it to oil pressure gauge [2]. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
4) Run the engine at high idle, set the condition as shown in the following table, and measure the output pressure. a If the outlet pressures of the arm swing PPC shuttle valve are as shown in the following table, the arm swing PPC shuttle valve (swing side) are normal.
Measurement condition Neutral Right work Operated to equipment swing LEFT control lever Operated to swing RIGHT Oil pressure (MPa {kg/cm2}) 0 {0} Min. 2.35 {Min. 24} Min. 2.35 {Min. 24}
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Adjusting work equipment, swing PPC valve

a If there is excessive play at the tip of the work equipment, swing lever, adjust as follows. 1. Remove work equipment, swing PPC valve assembly. 2. Take off boot (1). 3. Loosen lock nut (2) and screw in disc (3) until it contacts the heads of four pistons (4). a Do not move the piston while doing this work. 4. Keep disc (3) in place and tighten lock nut (2) to the specified tightening torque. 3 Lock nut: 98 127 Nm {10 13kgm} 5. Install boot (1). 6. Install work equipment, swing PPC valve assembly.
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Testing and adjusting travel deviation

Testing a Measure on a hard and flat place. 1. Start the engine and set the work equipment in the travel position. a To set the work equipment in the travel position, extend the bucket and arm cylinders fully and set the boom angle to 45 degrees. 2. Set the working mode switch to the P mode position and set the travel speed switch to the Lo position. 3. Run up for 10 m with the engine speed at high idle and continue travel under the same condition for 20 m and measure the deviation (a). a At this time, install an oil pressure gauge and measure the pump discharge pressure, too, (or monitor the pump discharge pressure with the machine monitor).
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Adjusting a If the travel deviation is abnormal, adjust the thickness of the shim at the servo piston according to the following procedure. 1. Determine where to add a shim from the direction of the travel deviation. a Adjustment method
When machine deviates to left Add shim on rear pump side (c). When machine deviates to right Add shim on front pump side (b).
No. 1 pump
No. 1 pump No. 2 pump
No. 2 pump 3. Add shim (2) according to the deviation and tighten bolt (1). a Limit the thickness of the added shim to 3 mm for each pump. 3 Bolt: 59 74 Nm {6.0 7.5 kgm} a Travel deviation and thickness of added shim.
2. Loosen 4 bolts (1) on the side to adjust the shim. a Since the shim is of split type, you do not need to remove the cap. a Since the cap is pressed by the spring, loosen the bolt to a degree that you can insert the shim. 4. After completing the adjustment, check the travel deviation again according to the above described procedure.
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Measuring fan speed

a Tools for measuring fan speed
Symbol S Part No. 799-203-8001 Part name Multitachometer
Measuring fan circuit oil pressure

a Tools for measuring fan circuit oil pressure
Symbol T 790-261-1204 Digital hydraulic tester Part No. 799-101-5002 Part name Hydraulic tester
1. Remove the covers until the fan blade end is seen. 2. Stick a reflection tape to the fan. 3. Set probe [1] of multitachometer S with stand [2], match it to the reflection tape, and connect it to meter [3]. a Take care that the probe will not interfere with the fan.
a Measure the fan circuit oil pressure under the following condition. Hydraulic oil temperature: Within operating range k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1. Connect gauge [2] of hydraulic tester T to oil pressure measurement nipple [1] of the fan pump. a Use the gauge of 40 MPa {400 kg/cm2}.
4. Run the engine at low idle and high idle and measure the fan speed.
2. Run the engine in the fan 100% speed mode at high idle and measure the fan circuit oil pressure.
5. After finishing measurement, remove the measuring instruments and return the removed parts.
3. After finishing measurement, remove the measuring instruments and return the removed parts.
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Inspection of locations of hydraulic drift of work equipment

a If there is any hydraulic drift in the work equipment (cylinders), check in the following manner to determine if the cause is in the cylinder packing or in the control valve. 1. Inspection of boom and bucket cylinders 1) Set the work equipment in the same posture as when measuring hydraulic drift, and stop the engine. a Fill the bucket with earth or apply the rated load to the bucket.
2. Inspection of arm cylinder 1) Operate the arm cylinder to move the arm to the position 100 mm before the digging stroke end, and stop the engine.
2) Operate the control lever to the RAISE position or the bucket control lever to the CURL position. If the lowering speed increases, the cylinder packing is defective. If there is no change, the control valve is defective. a Operate the control lever with the engine starting switch in the ON position. a If pressure in the accumulator has dropped, run the engine for approx. 10 seconds to charge the accumulator again.
2) Operate the control lever to the CURL position. If the lowering speed increases, the cylinder packing is defective. If there is no change, the control valve is defective. a Operate the control lever with the engine starting switch in the ON position. a If pressure in the accumulator has dropped, run the engine for approx. 10 seconds to charge the accumulator again. [Reference]If the cause of the hydraulic drift is in the defective packing, and the above operation is carried out, downward movement is accelerated for the following reasons. 1) If the work equipment is set to the above posture (holding pressure applied to the bottom end), the oil at the bottom end leaks to the head end. However, the volume at the head end is smaller than the volume at the bottom end by the volume of the rod end, so the internal pressure at the head end increases because of the oil flowing in from the bottom end. 2) When the internal pressure at the head end increases, the pressure at the bottom end also rises in proportion to this. The balance is maintained at a certain pressure (this differs according to the amount of leakage) by repeating this procedure. 3) When the pressure is balanced, the downward movement becomes slower. If the lever is then operated according to the procedure given above, the circuit at the head end is opened to the drain circuit (the bottom end is closed by the check valve), so the oil at the head end flows to the drain circuit and the downward movement becomes faster.
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2. Measuring leakage from arm cylinder 1) Run the engine and move in the arm to the stroke end.
Measuring oil leakage

a Tools for measuring oil leakage
Symbol U Part No. Commercially available Part name Measuring cylinder
a Measure the oil leakage under the following condition. Hydraulic oil temperature: Within operating range 1. Measuring leakage from boom cylinder 1) Run the engine and raise the boom to the stroke end. k Referring to Releasing remaining pressure in hydraulic circuit, release the remaining pressure from the piping on the boom cylinder head side (Operate the lever only in the RAISE direction, however). 2) Disconnect hoses (1) on the cylinder head side and block it with a flange. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose. 07379-01044 (Flange #10)
k Referring to Releasing remaining pressure in hydraulic circuit, release the remaining pressure from the piping on the arm cylinder head side (Operate the lever only in the CURL direction, however). 2) Disconnect hose (2) on the cylinder head side and block it with a flange. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose. 07379-01044 (Flange #10)
3) Run the engine at high idle and relieve the arm cylinder by operating the arm control lever in the CURL direction.
k Take care not to operate the arm control lever in the DUMP direction. 4) Start measuring the oil leakage 30 seconds after the arm cylinder is relieved and measure for 1 minute. 5) After completing the measurement, set to the original condition.
3) Run the engine at high idle and relieve the boom cylinder by operating the boom control lever in the RAISE direction. k Take care not to operate the boom control lever in the LOWER direction. 4) Start measuring the oil leakage 30 seconds after the boom cylinder is relieved and measure for 1 minute. 5) After completing the measurement, set to the original condition.
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3. Measuring leakage from bucket cylinder 1) Run the engine and curl the bucket to the stroke end. k Referring to Releasing remaining pressure in hydraulic circuit, release the remaining pressure from the piping on the bucket cylinder head side (Operate the lever only in the CURL direction, however). 2) Disconnect hose (3) on the cylinder head side and block it with a flange. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose. 07379-01044 (Flange #10)
4. Measuring leakage from swing motor 1) Disconnect drain hoses (4) and plug them. a Use the following parts to block the hoses. 07376-70522 (Plug #05)
2) Turn the swing lock switch ON. 3) Run the engine at high idle and relieve the swing circuit and measure the oil leakage. a Start measuring the oil leakage 30 seconds after the swing motor circuit is relieved and measure for 1 minute. a After measuring 1 time, swing the upper structure 180 and measure again. 4) After completing the measurement, set to the original condition.
3) Run the engine at high idle and relieve the bucket cylinder by operating the bucket control lever in the CURL direction.
k Take care not to operate the bucket control lever in the DUMP direction. 4) Start measuring the oil leakage 30 seconds after the bucket cylinder is relieved and measure for 1 minute. 5) After completing the measurement, set to the original condition.
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6. Measuring leakage from center swivel joint 1) Put pin [1] between the sprocket and track frame to lock the travel motor of the port to be inspected, and then stop the engine.
5. Measuring leakage from travel motor 1) Remove the travel motor cover.
4 Travel motor cover: 35 kg 2) Start the engine and lock the travel mechanism.
k Set pin [1] between the sprocket and track frame to lock the travel mechanism securely.
k Loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the tank. a Inspection ports, travel directions, and measurement ports (See figure on following parts)
Inspection port A B C D E T Travel direction R.H. reverse L.H. reverse R.H. forward L.H. forward Speed select Drain Measurement ports T and B A and C B and D C and E D and T
3) Disconnect drain hose (5) of the travel motor and plug it. a Use the following part to block the hose. 07376-70628 (Plug #06)
k Since wrong operation of the levers can cause an accident, make signs and confirmation securely. a Start measuring the oil leakage 30 seconds after the travel motor circuit is relieved and measure for 1 minute. a Measure the oil leakage several times, moving the motor little by little (changing the positions of the valve plate and cylinder and those of the cylinder and piston). 5) After completing the measurement, set to the original condition.
4) Run the engine at high idle and relieve the travel circuit and measure the oil leakage.
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2) Disconnect the hoses of the upper and lower measurement ports of the inspection port from the top of the swivel joint and block them. a For combination of the inspection port and measurement ports, see the above table. a Use the following parts to block the hoses. Ports A, B, C, D: 07379-01044 (Flange #10) Port E: 07376-70315 (Plug #03) Port T: 07376-70522 (Plug #05)
3) Run the engine at high idle and measure the oil leakage through the measurement ports. a When measuring ports A, B, C, and D, relieve the travel motor slowly in the revolving direction (See the table on the last page). a When measuring port E, set the travel speed select switch in the Hi position. 4) Start measuring the oil leakage 1 minute after the center swivel joint is relieved and measure for 1 minute.
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3. Release of remaining pressure from swing motor circuit a Release the remaining pressure from the swing motor circuit by performing the procedure for 2. Release of remaining pressure from hydraulic cylinder circuit. 4. Release of remaining pressure from travel motor circuit a Since the control valve spool of the travel motor is open, release the remaining pressure from the travel motor circuit by performing the procedure for 1. Release of remaining pressure from hydraulic tank.
Releasing remaining pressure in hydraulic circuit

1. Release of remaining pressure from hydraulic tank The hydraulic tank is enclosed and pressurized. When removing a hose or a plug connected to the hydraulic tank, release the remaining pressure from the hydraulic tank according to the following procedure. 1) Lower the work equipment to the ground in a stable posture and stop the engine. 2) Slowly loosen oil filler cap (1) of the hydraulic tank to release the air from the tank.
2. Release of remaining pressure from hydraulic cylinder circuit
k When disconnecting the piping between a hydraulic cylinder and the control valve, release the remaining pressure from the piping according to the following procedure. 1) Referring to 1. Release of remaining pressure from hydraulic tank, release the remaining pressure from the hydraulic tank. a Leave the oil filler cap of the hydraulic tank removed. 2) Turn the starting switch to the ON position and set the lock lever in the FREE position, and then operate the work equipment control levers on both sides forward, backward, to the right, and to the left. a The control valve is driven with the pressure in the accumulator. If it is operated 2 3 times, the pressure lowers. 3) Start the engine and run it at low idle for 5 seconds to heighten the pressure in the accumulator. 4) Repeat above steps 2) and 3) 2 3 times, and all residual pressure is released from the piping.
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Bleeding air from each part

Air bleeding procedure 3 4 5 6 Bleeding Bleeding Checking Bleeding air from air from oil level air from swing travel and startcylinder motor motor ing work q q q q (see Note) (see Note) q q q
1 Air bleeding item Bleeding air from Contents of work hydraulic pump Replacement of hydraulic oil q Cleaning of strainer Replacement of return filter element Replacement or repair of hydraulic pump q Removal of suction piping Replacement or repair of control valve Removal of control valve piping Replacement or repair of cylinder Removal of cylinder piping Replacement or repair of swing motor Removal of swing motor piping Replacement or repair of travel motor Removal of travel motor piping Replacement or repair of swivel joint Removal of swivel joint piping Note:
2 Starting engine q q q
Bleed air from the swing motor and travel motor only when the oil was drained from the motor cases. 3) After clear oil flows out of bleeders (1) and (2), tighten the bleeders. 3 Bleeder: 7.8 9.8 Nm {0.8 1.0 kgm}
1. Bleeding air from hydraulic pump 1) Loosen air bleeders (1) and (2) by 4 turns and remove the oil filler cap of the hydraulic tank. a Leave the machine under the above condition for 10 minutes or more. 2) After oil flows out of bleeders (1) and (2), run the engine at low idle. a If the engine coolant temperature is low and the automatic warm-up operation is started, stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial (Set the starting switch in the ON position and hold the fuel control dial in the MAX position for 3 seconds, and the automatic warm-up operation is reset). a Set the lock lever in the LOCK position so that you will not operate a lever by mistake.
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5. Bleeding air from travel motor 1) Remove the travel motor cover.
2. Starting engine When running the engine after performing step 1, keep its speed at low idle for 10 minutes. 3. Bleeding air from cylinder a If a cylinder was replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder does not move to the lowering stroke end, if it is installed to the work equipment. 1) Run the engine at low idle for about 5 minutes. 2) Running the engine at low idle, raise and lower the boom 4 5 times. a Stop the piston rod about 100 mm before each stroke end. Do not relieve the oil. 3) Running the engine at high idle, perform step 2). 4) Running the engine at low idle, move the piston rod to the stroke end and relieve the oil. 5) Bleed air from the arm cylinder and bucket cylinder according to steps 2) 4). 4. Bleeding air from swing motor 1) Motor unit a Bleed air from the motor unit according to the following procedure. i) Run the engine at low idle. ii) Swing to the right and left slowly to bleed air. 2) Parking brake circuit a Normally, air in the parking brake circuit is bled by swinging the machine in step 1). If you feel dragging of the brake during swinging operation, however, bleed air from the parking brake circuit according to the following procedure. i) Loosen the adapter of brake hose (3) and start the engine. ii) Run the engine at low idle and set the swing holding brake release switch to the RELEASE and NORMAL positions repeatedly. After clear oil oozes out, tighten the adapters.
4 Travel motor cover: 35 kg 2) Loosen bleeder (4) by 1 turn and start the engine. a Do not loosen the bleeder more than 1 turn. 3) Run the engine at low idle and repeat the forward and reverse travel operations 4 - 5 times. After clear oil flows out, tighten the bleeder. a Limit the operation of the lever to a degree that the machine starts traveling. 3 Bleeder: 27.4 35.3 Nm {2.8 3.6 kgm}
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6. Checking oil level and refill 1) Run the engine, retract the arm cylinder and bucket cylinder to the stroke ends, lower the work equipment to the ground, and stop the engine.
2) Check the oil level by the sight gauge at the back of the hydraulic tank. a If the oil level is between lines H and L, it is normal. a If the oil level is below line L, add new oil.
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3) Determine if a specific diode is good or no good with the indicated value. No change in the indicated value: No continuity (defective). Change in the indicated value: Continuity established (normal) (Note) Note: A silicon diode shows a value between 400 and 600.
Inspection procedures for diode

a Check an assembled-type diode (8 pins) and single diode (2 pins) in the following manner. a The continuity direction of an assembled-type diode is as shown in the diagram below.
a The continuity direction of a single diode is shown on the diode surface.
1. When using digital type circuit tester 1) Switch the testing mode to diode range and confirm the indicated value. a Voltage of the battery inside is displayed with conventional circuit testers. 2) Put the red probe (+) of the test lead to the anode (P) and the black probe () to the cathode (N) of diode, and confirm the displayed value.
2. When using analog type circuit tester 1) Switch the testing mode to resistance range. 2) Check the needle swing in case of the following connections. i) Put the red probe (+) of the test lead to the anode (P) and the black probe () to the cathode (N) of diode. ii) Put the red probe (+) of the test lead to the cathode (N) and the black probe () to the anode (P) of diode. 3) Determine if a specific diode is good or no good by the way the needle swings. If the needle does not swing in Case i), but swings in Case ii): Normal (but the breadth of swing (i.e. resistance value) will differ depending on a circuit tester type or a selected measurement range) If the needle swings in either case of i) and ii): Defective (short-circuited internally) If the needle does not swing in any case of i) and ii): Defective (short-circuited internally)
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HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8

Testing and adjusting, Part 2
Special function of machine monitor .................................................................................................................... 2 Handling controller voltage circuit ...................................................................................................................... 36 Procedure for turning on KOMTRAX terminal.................................................................................................... 37 KOMTRAX terminal lamp indications................................................................................................................. 40 Preparation work for troubleshooting electrical system...................................................................................... 43 Adjusting mirrors ................................................................................................................................................ 45 Pm-clinic service ................................................................................................................................................ 46 Undercarriage inspection ................................................................................................................................... 52
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Special function of machine monitor
[1] Figure input switch 1 [2] Figure input switch 2 [3] Figure input switch 3 [4] Figure input switch 4 [5] Figure input switch 5
[6] Figure input switch 6 [7] Figure input switch 7 [8] Figure input switch 8 [9] Figure input switch 9 [0] Figure input switch 0
[ [ [ [
] Return switch ] Upward move switch ] Downward move switch ] Input confirmation switch
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Ordinary functions and special functions of machine monitor The machine monitor has the ordinary function and special functions and displays information of various types on the multi-display. Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches. 1. Ordinary functions: Operator menu The items in this menu are displayed ordinarily. The operator can display and set them by operating the switches. 2. Special functions: Service menu The items in this menu are not displayed ordinarily. Each serviceman can display them by operating the switches specially. This menu is used for special setting, testing, adjusting, or troubleshooting.
Operator menu 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Function of inputting and setting password Function for showing KOMATSU logo Function for check before starting Function for machine maintenance Function for showing caution items Function for confirming working mode and travel speed Function for display of ordinary items Function for adjusting display luminance and contrast Function for confirming maintenance information Function for showing service meter reading Function for checking display LCD Function for showing occurrence of caution item Function for showing action code No. Function for showing failure code No. Function of reversing fan rotation and adjusting economy mode value 22 23 24 21 16 17 18 19 20
Service Menu Function of Monitoring [01] Function for Abnormality Record [02] Electrical system Mechanical system
Function for Maintenance Record [03] Function for Maintenance Mode Change [04] Function for Phone Number Entry [05] Key-ON mode Function for AAAA/ Default [06] Language Unit Setting of wiper Function for Adjustment [07] Function of Cylinder Cut Out [08] Function of no injection [09]
PC600-8
SEN00445-03 Operation of operator's menu and display (outline)

a This section introduces only the outline of the operator's menu. For details on the contents and operation steps of each menu, refer to the OPERATION AND MAINTENANCE MANUAL or the chapter of Structure, function and maintenance standard in this shop manual. 1. Function of inputting and setting password When the starting switch is turned ON, the screen to input a password is displayed. a This screen is displayed only if the password function has been set.
4. Function for machine maintenance Following the display of machine check before starting, the maintenance mark appears for 30 seconds, if there are oils and filters whose maintenance time is approaching or has just passed. a This display appears only when the maintenance function is set.
2. Function for showing KOMATSU logo When the engine starting switch is turned ON, KOMATSU logo is shown for two seconds.
5. Function for showing caution items If there is any item of machine check before starting day's work that indicates some abnormality, a corresponding symbol mark is shown after the display of machine check before starting day's work.
3. Function for check before starting Following the KOMATSU logo, the display of machine check before starting day's work is shown for 2 seconds.
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8. Function for adjusting display luminance and contrast Luminance as well as contrast of the display can be adjusted by operating the display adjusting switch.
6. Function for confirming working mode and travel speed After the display of machine check before starting day's work, amplified symbol marks for working mode and travel speed are shown for 2 seconds to urge an operator to confirm the setting.
7. Function for display of ordinary items The display of confirming working mode and travel speed is switched to this display of ordinary items. a If the working mode setting or travel speed setting is changed, or auto-deceleration or windshield wiper setting is activated while this is in display, an amplified corresponding symbol mark is shown for 2 seconds. a In this display, a symbol mark for preheat monitor is shown only when preheating is carried out.
9. Function for confirming maintenance information Detailed information on maintenance items (set time and elapse of time) can be confirmed and resetting after the confirmation is feasible by operating the maintenance switch. a Use service menu for setting or releasing maintenance items and setting maintenance time.
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10. Function for showing service meter reading Only the service meter reading can be shown by the following switching operation, when the engine starting switch is turned OFF. Switching operation: [ ] + [ ] (synchronized switching operation)
12. Function for showing occurrence of caution item If any of the caution items occurs, the magnified corresponding symbol mark is shown for 2 seconds and thereafter stays on the display as a small symbol mark until it is dissolved.
11. Function for checking display LCD Display of the Display LCD can be confirmed by the following switching operation in the display of ordinary items Switching operation: [ ] + [A] (synchronized switching operation) a All the LCD light up, turning the entire screen white. If there is no showing in black, the display is normal. a This display returns to the immediately preceding one, if making any other switching operation.
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13. Function for showing action code No. When a trouble occurs on the machine, the action code is automatically displayed depending on the magnitude of the trouble to call attention of the operator for a proper action. a This display turns to the display of failure code, if operating the switch (Refer to Item No. 14).
a Action codes and instructions given to operator

Action code E02 E03 Failure mode Instructions given to operator If the emergency pump drive switch is set to the upper (emergency) position, the machine can operate normally. Have the machine inspected immediately, however. Have the machine inspected immediately.
Error in pump control system Error in swing brake system Error in engine controller power supply system Abnormality in engine controller drive system circuit (engine stop) Error in engine controller system (Engine protection output down) Error in throttle system Error in engine sensor (water temperature, fuel temperature and oil pressure) Error in network
E10
Have the machine inspected immediately.
E11 E14
Set the machine in a safe position and have the machine inspected immediately. Set the machine in a safe position and have the machine inspected immediately. Ordinary operation is possible. Have the machine inspected immediately, however. Set the machine in a safe position and have the machine inspected immediately.
E15
E0E
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14. Function for showing failure code No. If the following switching operation is made while the action code No. is shown, a phone symbol (if registered), phone numbers (if registered), failure code No. is shown in turn. Switching operation: [ ] a The following display is repeated in order according to the operation of the switch. [1] Telephone symbol mark [2] Telephone No. [3] Failure code No. a The telephone symbol mark and telephone No. are shown only when they are registered in the machine monitor. For registration, correction and deletion of telephone No., use Service Menu. a For details on the displayed failure code No., refer to the Table for failure code No.
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SEN00445-03 Failure code table
Action code E10 E10 E11 E11 E14 E14 E15 E15 E15 E15 E15 E15 E15 E15 E15 E15 E03 E15 E15 E11
Failure code A000N1
Trouble (Displayed on screen) Eng. Hi Out of Std
Alarm buzzer
Component Category of in charge record MON MON MON MON MON MON MON MON ENG Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
AA10NX Aircleaner Clogging AB00KE Charge Voltage Low B@BAZG Eng. Oil Press. Low B@BAZK Eng. Oil Level Low B@BCNS Eng. Water Overheat B@BCZK Eng. Water Lvl Low B@HANS Hydr. Oil Overheat CA111 CA115 CA122 CA123 CA131 CA132 CA135 CA141 CA144 CA145 CA153 CA154 CA187 CA221 CA222 CA227 CA234 CA238 CA263 CA265 CA271 ECM Critical Internal Failure Eng Ne and Bkup Speed Sens Error Chg Air Press Sensor High Error Chg Air Press Sensor Low Error Throttle Sensor High Error Throttle Sensor Low Error Eng Oil Press Sensor High Error Eng Oil Press Sensor Low Error Coolant Temp Sens High Error Coolant Temp Sens Low Error Chg Air Temp Sensor High Error Chg Air Temp Sensor Low Error Sens Supply 2 Volt Low Error Ambient Press Sens High Error Ambient Press Sens Low Error Sens Supply 2 Volt High Error Eng Overspeed Ne Speed Sens Supply Volt Error Fuel Temp Sensor High Error Fuel Temp Sensor Low Error IMV/PCV1 Short Error q q q q q q q q q q q q q q q q q q q
ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG
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Action code E11 E11 E11 E11 E11 E11 E11 E11 E11 E10 E10 E15 E15 E10 E10 E11 E11 E11 E15 E15 E11 E11 E10 E11 E15 E11 E11 E11 E15
Failure code CA272 CA273 CA274 CA322 CA323 CA324 CA325 CA331 CA332 CA342 CA351 CA352 CA386 CA441 CA442 CA449 CA451 CA452 CA553 CA554 CA559 CA689 CA731 CA757 CA778 CA1228 CA1625 CA1626 CA1627 CA1628
Trouble (Displayed on screen) IMV/PCV1 Open Error PCV2 Short Error PCV2 Open Error Inj #1(L#1) Open/Short Error Inj #5(L#5) Open/Short Error Inj #3(L#3) Open/Short Error Inj #6(L#6) Open/Short Error Inj #2(L#2) Open/Short Error Inj #4(L#4) Open/Short Error Calibration Code Incompatibility Injectors Drive Circuit Error Sens Supply 1 Volt Low Error Sens Supply 1 Volt High Error Battery Voltage low error Battery Voltage high error Rail Press Very High Error Rail Press Sensor High Error Rail Press Sensor Low Error Rail Press High Error Rail Press Sensor In Range Error Rail Press Low Error Eng Ne Speed Sensor Error Eng Bkup Speed Sens Phase Error All Persistent Data Lost Error Eng Bkup Speed Sensor Error EGR Valve Servo Error 1 EGR Valve Servo Error 2 BP Valve Sol Current High Error BP Valve Sol Current Low Error Bypass Valve Servo Error 1
Alarm buzzer q q q q q q q q q
Component Category of in charge record ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
q q q q q q q q q
ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG
q q q q q q q q q q
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Action code E11 E11 E11 E0E E11 E11 E14 E14 E11 E11 E11 E11 E11 E15 E15 E0E E0E
Failure code CA1629 CA1631 CA1632 CA1633 CA1642 CA1653 CA2185 CA2186 CA2249 CA2271 CA2272 CA2351 CA2352 CA2555 CA2556 D110KB D163KB D195KB
Trouble (Displayed on screen) Bypass Valve Servo Error 2 BP Valve Pos Sens High Error BP Valve Pos Sens Low Error KOMNET Datalink Timeout Error EGR Inlet Press Sens Low Error EGR Inlet Press Sens High Error Throt Sens Sup Volt High Error Throt Sens Sup Volt Low Error Rail Press Very Low Error EGR Valve Pos Sens High Error EGR Valve Pos Sens Low Error EGR Valve Sol Current High Error EGR Valve Sol Current Low Error Grid Htr relay Volt Low Error Grid Htr relay Volt High Error Battery Relay Drive S/C Flash Light Relay S/C Step Light Relay S/C
Alarm buzzer q q q q q q q q q q q q q q q
Component Category of in charge record ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG PUMP PUMP PUMP PUMP PUMP PUMP Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
DA25KP Press. Sensor Power Abnormality DA2SKQ Model selection Abnormality DA80MA Auto. Lub. Abnormal DA2RMC Pump Comm. Abnormality DAFRMC Monitor Comm. Abnormality DGE5KY Ambi. Temp. Sensor S/C DGH2KB Hydr. Oil Temp. Sensor S/C DHPAMA F Pump P.Sensor Abnormality DHPBMA R Pump P.Sensor Abnormality DV20KB Travel Alarm S/C DW43KA Travel Speed Sol. Disc. DW43KB Travel Speed Sol. S/C q q
PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP
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Action code E03 E03 E11 E11 E02 E02
Failure code
Trouble (Displayed on screen)
Alarm buzzer q q
Component Category of in charge record PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
DW45KA Swing Brake Sol. Disc. DW45KB Swing Brake Sol. S/C DW48KA CO Cancel Sol. Disc. DW48KB CO Cancel Sol. S/C DW7BKA Fan Reverse Sol. Disc. DW7BKB Fan Reverse Sol. S/C DW4XKA Bucket Curl Hi Cancel Sol. Disc. DW4XKB Bucket Curl Hi Cancel Sol. S/C DWK0KA 2-stage Relief Sol. Disc. DWK0KB 2-stage Relief Sol. S/C DX16KA Fan Pump EPC Sol. Disc. DX16KB Fan Pump EPC Sol. S/C DXA0KA TVC Sol. Disc. DXA0KB TVC Sol. S/C DY20KA Wiper Working Abnormality DY20MA Wiper Parking Abnormality DY2CKB Washer Drive S/C DY2DKB Wiper Drive (For) S/C DY2EKB Wiper Drive (Rev) S/C
q q q q
a The items in this table are arranged in the order of the failure codes. a The action codes having no numbers in the action code column are not displayed on the normal screen, even if abnormality related to them occurs. They are simply recorded in the abnormality record of the service menu (Electrical system or mechanical system). a The history division column shows in which division each failure is classified, the electrical system or mechanical system, when it is recorded in the abnormality record. a Letter "E" at the head of each action code indicates the following condition. With E : The failure has not been repaired yet. Without E : The failure has been repaired.
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4] If the [ ] switch is pressed, the screen to wait for change of the fan rotation direction appears and the engine speed is lowered to low idle automatically. After about 15 seconds, the fan rotation is reversed. After 4 seconds, the engine speed returns to the level before the [ ] switch was pressed.
15. Function of reversing fan rotation and adjusting economy mode value 1) Reversing fan rotation 1] Press switch [5] of the monitor, and the following screen appears. "01": Fan rotation reversing menu "02": Economy mode value adjusting menu
a The fan speed is in proportion to the engine speed. If the engine speed is low idle, the fan speed is MIN. To increase the fan speed, increase the engine speed with the fuel control dial. a When reversing the fan rotation while the engine is stopped, turn the starting switch to the START position after the above screen appears. (This screen does not change until the engine is started. When stopping reversing the fan rotation, turn the starting switch to the OFF position.) 2] Select "1" Fan rotation reversing and press the [ ] switch, and the following screen appears. a The fan mark is green. 3] When reversing the fan rotation, press the [ ] switch. a When not reversing the fan rotation, press the return switch [ ], and the previous screen appears. 5] If the fan rotation is reversed, the following screen appears automatically and is maintained as long as the fan rotation is in reverse. a The fan mark is yellow.
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6] If any trouble occurs while the fan is rotating in reverse, the following warning monitor is displayed. In this case, see the page of explanation of the monitoring items and take necessary remedy.
3] If the [ ] switch is pressed, the screen to wait for change of the fan rotation direction appears and the engine speed is lowered to low idle automatically. After about 15 seconds, the fan rotation is returned to the normal direction. After 4 seconds, the engine speed returns to the level before the [ ] switch was pressed.
2) Returning fan rotation to normal direction 1] Press switch [5] of the panel. 4] If the fan rotation is returned to the normal direction, the initial screen appears automatically.
2] The following screen appears. When returning the fan rotation to the normal direction, press the [ ] switch. a If the [ ] switch is pressed, the previous screen appears.
Remarks 1) The screen in 2)-1] may not change to the screen in 2)-2] but the following screen may appear and the fan rotation may not be reversed. a The fan mark is blue.
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3) Adjusting economy mode value 1] In the screen of 2)-1], select "2" E mode and press the [ ] switch, and the following screen appears.
2) This state shows that reversing of the fan rotation is prohibited to protect the components under some conditions of coolant temperature and hydraulic oil temperature. a To reverse the fan rotation in this state, press the [ ] switch to return the screen to the normal screen and lower the engine speed to low idle or stop the engine to warm up (cool down) the engine. If the coolant temperature and hydraulic oil temperature gauges are in the range shown below, the fan rotation can be reversed. Perform the procedure from 2)-1]. a: Coolant temperature b: Hydraulic oil temperature
a The economy mode can be set to 4 levels of E0, E1, E2, and E3 as shown above. (It is set to E0 when delivered.) 2] While watching the economy mode adjusting menu, press the [ ] or [ ] switch of the panel to select E0 E3 and press the [ ] switch.
3] The relationship between the value and production is as follows.

Fuel consumption Production
E0 Initial value E1 Economy adjustment 1 E2 Economy adjustment 2 E3 Economy adjustment 3

Good Little
a As the value is increased to [E3 side], the fuel consumption is reduced and the production is also reduced.
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SEN00445-03 Operation and display of service menu

Way of switching to Service Menu a When using Service Menu, change the display to Service Menu display through the following special operation. 1) Confirmation of display Confirm that the display of ordinary items is shown. a Changing to Service Menu cannot be made from displays other than this.
3) Showing Service Menu display The display is changed to the initial display of service menu program. Select an appropriate item from among the menu.
No. 00 01 02 03
Service Menu Return (Termination of Service Menu) Monitoring Abnormality Record Maintenance Record Maintenance Mode Change Phone Number Entry AAAA / Default Adjustment Cylinder cut out No-injection
2) Switch operation Operate the switch as instructed below. Switch operation: [ ] + [1] o [2] o [3] (Enter a figure, depressing [
04 05
])
06 07 08 09
4) Termination of Service Menu function When terminating the initial display or any subsequent display of Service Menu, do that through any one of the following methods. [1] Depress [ ] switch. (This method may be used for terminating any display) [2] If "Return" switch is shown, depress it. [3] If "Return" menu is shown, call that menu and depress [ ] switch.
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any of the following switch operations, after the registration work has been completed. Keep [ ] switch depressed. (For about 3 seconds) Select Menu 99999 and depress [ ] switch. a The display automatically moves to the display of monitored information, when all of the registrable items have been duly registered. a Monitored information are transmitted via communication circuits. Thus the number of selected items can impact the communication speed. If truly real time monitoring is required, reduce the selected items to the minimum. a For details on the monitoring items, display unit, etc., refer to the Table for monitoring items. 3) Monitoring operation Call the monitoring information display and confirm the monitored information, while operating the machine.
16. Function of Monitoring [01] The machine monitor monitors signals from an assortment of switches, sensors and actuators installed in various parts of the machine. Monitored information can be put in display or confirmed on a real time basis through the following operations. 1) Selection of menu Select "01 Monitoring" in the initial display of Service Menu and depress [ ] switch.
2) Setting of monitoring item i) Select or register an item to be monitored through the following switch operation. [ ] switch: Selection [ ] switch: Selection [ ] switch: Registration ii) Selection with numeral keys: Input a 5-digit code to select the item of that code directly and depress [ ] switch.
a A monitoring item can be set in any number between the min. one to the max. four. (Depending upon the selected item, the max. number is less than four) a In case of monitoring 1 to 3 items, move to the monitored information display through
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4) Monitored information holding function If [ ] switch is depressed while monitoring, all the monitored information are put on hold. If [ ] switch is depressed in this condition, information holding is released.
5) Machine setting mode switching function If it becomes necessary to change settings of working mode, travel speed and autodeceleration while monitoring, depress the corresponding switch, then the mode confirmation display is shown. a When a specific setting is confirmed, depress [ ] switch, then the display returns to that of monitoring. a In case a specific setting has been changed while monitoring, the new setting is still maintained when returning from Service Menu to Operator's Menu after the monitoring is finished.
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SEN00445-03 Monitoring items list
Code No. 00000 Return
Monitoring item
Unit (Default: ISO) ISO meter (Not displayed) (Not displayed) Numeral Numeral r/min r/min MPa MPa C C C C mA mA V V V r/min MPa MPa kPa C C kPa kPa mm mm % Nm V V V V V V V V V rpm rpm kg/cm2 kg/cm2 C C C C mA mA V V V rpm kg/cm2 kg/cm2 kg/cm C C kg/cm2 kg/cm mm mm % Nm V V V V V V V V V
2 2
inch
Remarks Ending menu Display execution menu
99999 To Display Screen 00200 Controller Model Select 00201 Machine ID 01002 Engine Speed 01601 2nd Eng Speed Command 01100 F Pump Pressure 01101 R Pump Pressure 04107 Coolant Temperature 14200 Fuel Temperature 04401 Hydr. Oil Temperature 37502 Ambient Temperature 01300 TVC Sol. Curr 31623 Fan Pump EPC Sol. Curr 03200 Battery Voltage 03203 Battery Power Supply 04300 Battery Charge Vol. 01006 Engine Speed 37200 Engine Oil Pressure 36400 Rail Pressure 37400 Ambient Pressure 18400 Intake Temperature 18500 Charge Temperature 36500 Boost Pressure 18000 EGR Inlet Pressure 18100 EGR Valve Position 18200 BPS Valve Position 36700 Engine Torque Ratio 18700 Engine Output Torque 01112 F Pump Pres. Sensor Vol. 01113 R Pump Pres. Sensor Vol. 03000 Fuel Dial Pos Sens Volt 04200 Fuel Level Sensor Vol. 04105 Coolant Temp Sens Volt 14201 Fuel Temp. Sensor Vol. 04402 Hydr. Temp. Sensor Vol. 37503 Ambi. Temp. Sensor Vol. 37201 Eng Oil Press Sens Volt
rpm rpm Psi Psi F F F F mA mA V V V rpm Psi Psi Psi F F Psi Psi in in % kgfm V V V V V V V V V
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Unit (Default: ISO) ISO V V V V V V V V CA % % mg/st MPa CA L/h % Nm Nm Nm Swing Travel 01900 Pressure Switch 1 Boom Lower Boom Raise Arm Curl Arm Dump Bucket Curl 01901 Pressure Switch 2 Bucket Dump Service Travel Steering Bucket Hi Cancel Swing Brake 02300 Solenoid 1 2-Stage Relief Travel Speed Fan Reverse CO Cancel Lever SW 02200 Switch Input 1 Swing Release SW Swing Brake S meter V V V V V V V V CA % % mg/st kg/cm CA L/h % kgm kgm kgm
2
Code No.
Monitoring item
inch V V V V V V V V CA % % mg/st PSi CA L/h % Ibft Ibft Ibft
Remarks
37401 Ambient Press Sens Volt 18401 Intake Temp Sens Volt 18501 Charge Temp Sens Volt 36501 Charge Press Sens Volt 36401 Rail Pressure Sens Volt 18001 EGR In Press Sens Volt 18101 EGR Valve Pos Sens Volt 18201 BPS Valve Pos Sens Volt 17201 PCV Close Timing 17500 Engine Power Mode 31701 Throttle Position 31706 Final Throttle Position 18600 Inject Fueling Command 36200 Rail Press Command 36300 Injection Timing Command 37300 Fuel Rate (Note 1) 01602 2nd Eng. Speed Command 13113 Main Pump Absorb Torque 13114 Fan Pump Absorb Torque 13112 Total Pump Absorb Torque
Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF
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Unit (Default: ISO) ISO meter inch
Code No.
Monitoring item Model Select 1 Model Select 2
Remarks
Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF Display of ON/OFF C C F
02201 Switch Input 2
Model Select 3 Model Select 4 Model Select 5
02202 Switch Input 3 02203 Switch Input 4
Key Switch (AAC) Step Light SW Horn SW Over Load Sensor Auto Greasing Batt. Relay Dr. Step L. Relay
05500 Sensor Input 1 03700 Controller Output 1
03701 Controller Output 2
Flush L. Relay Travel Alarm Key Switch Start
04500 Monitor Input 1
Preheat Light Rad. Level Aircleaner
Eng. Oil Level Battery Charge Swing Brake SW. Bzzr Cancel SW.
Window Limit SW. W Limit SW. Upper P Limit SW. Lower P Limit SW.
20216 ECM Build Version 20217 ECM CAL Data Ver. 18900 ECM Internal Temp 20400 ECM Serial No. 20200 Monitor Prog. Version 20212 Pump Con. Prog. Version
a As the unit of display, one of "SI unit system", "Metric unit system", and "Inch unit system" can be selected. a The unit of display can be changed with "Unit" in the "AAAA/ Default" function of the Service Menu. a "CA" of the unit of display denotes the crankshaft angle. Note 1: The momentary fuel consumption (Code No.: 37300) is the theoretical fuel consumption ratio (Since it is a theoretical value, it is a little different from the actual fuel consumption ratio).
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17. Function for Abnormality Record [02] The machine monitor records failures that occurred on the machines in the past after classifying them into failures in the electric system and those in the mechanical system. Information on them can be displayed through the following operation. 1) Selection of menu Select 02 Abnormality Record in the initial display of Service Menu and depress [ ] switch.
3) Information shown in display of Abnormality Record in the electrical system [1]: The numerator expresses sequence of failure occurrence, counting from the latest one. The denominator expresses the total number of a specific failure recorded. [2]: "E" is displayed as long as the failure is not repaired. Failure Code (section in 4 digits and phenomenon in 2 digits) [3]: Time elapsed since the occurrence of the first failure [4]: Contents of failure a Refer to "Table for failure code No." in Operator's Menu.
2) Selection of Submenu Select an appropriate item from Submenu in the Abnormality Record display and depress [ ] switch.
No. 00 01 02 Abnormality Record Submenu Return (termination of Abnormality Record) Electrical Systems Mechanical Systems
4) Information shown in display of Abnormality Record in the mechanical systems [1]: Record No. [2]: Contents of Abnormality [3]: Failure Code (section in 4 digits and phenomenon in 2 digits) [4]: Total number of occurrence [5]: Service meter reading at the initial occurrence a Refer to "Table for failure code No." in Operator's Menu.
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5) Resetting Electrical Systems a Resetting the Abnormality Record (deletion) is possible only with the electrical system. The Abnormality Record in the mechanical system cannot be reset. a For resetting any specific or all information in the Electrical Systems, follow the operation explained below.
i)
ii)
Through the following switch operation, call the resetting display in the display of Electrical Systems. Switch operation: [ ] +[1] o [2] o [3] a This is the same switch operation in changing the display to Service Menu. Operate the switch, following the instructions shown in the resetting display.
a When resetting specific information only, call the display of that specific information and reset it with either [ ] switch or [ ] switch. a When resetting all the information, a display of any information will do.
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18. Function for Maintenance Record [03] The machine monitor panel records information on the maintenance of filters and oils. The stored information can be displayed through the following switch operation. 1) Selection of menu Select 03 Maintenance Record in Service Menu and depress [ ] switch.
19. Function for Maintenance Mode Change [04] Conditions set for controlling maintenance display function can be changed in the following manner. Turn the function effectual or ineffectual. Change the set interval for replacement. 1) Selection of menu Select 04 Maintenance Mode Change in the initial display of Service Menu, and depress [ ] switch.
2) Information to be displayed [1]: Name of oils and filters [2]: Times of replacement to date [3]: Service meter reading at the latest replacement
2) Selection of item to be changed Select an item to be changed in the display of Maintenance Mode Change menu.
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4) Set contents of individual items [1]: Default: The maintenance time set in the monitor (recommended by the manufacturer and cannot be changed). [2]: Set: Maintenance time that can be freely set. The maintenance mode program functions based on this maintenance time. (The maintenance time can be increased or decreased by 50 hours with [ ] or [ ] switch) [3]: On: Maintenance display function with this instruction becomes effectual. [4]: Off: Maintenance display with this instruction becomes ineffectual. a The lowest maintenance time is 50 h.
No. 00 01 02 03 04 41 05 06 07 08 09 10 11 12
Maintenance mode change item Return (Termination of maintenance mode change) Maintenance Mode On/Off Engine Oil Exch. Int. Engine Oil Filter Exch. Int. Main Fuel Filter Exch. Int. Pre Fuel Filter Exch. Int. Hydr. Oil Filter Exch. Int. H/Tank Breather Exch. Int. Corro. Resis. Exch. Int. PTO Oil Service Int. Final Drive Oil Exch. Int. S/Machinery Oil Exch. Int. Hydraulic Oil Exch. Int. Use Default Values
a 01 and 12 menus are provided for setting the whole maintenance mode, while those from 02 through 11 are for setting individual items. 3) Contents of Maintenance Mode On/Off On: The maintenance display function of all oil and filter related items are turned effectual. (Irrespective of whether "On" or "Off" set for individual items, this setting prevails) Off: The maintenance display function of all oil and filter related items are turned ineffectual. (Irrespective of whether "On" or "Off" set for individual items, this setting prevails)
5) Set contents of "Use Default Values" When selecting this menu and depressing the switch [ ], all individual time settings are reduced to the initial settings.
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20. Function for Phone Number Entry [05] In the display of Action Code, a telephone number and Failure Code are shown alternately. Phone number can be inputted or modified in the following manner. a If there is no Phone number registered, the display for Phone numbers does not appear. 1) Selection of menu Select 05 Phone Number Entry menu in the display of Service Menu, and depress [ ] switch.
3) Entry and setting phone number Following the method explained below, entry a phone number in the Phone Number Entry display (Entry automatically begins with a cursor at the left end). i) Enter a number into a cursor at the left end with a ten-key. ii) Depress [ ] switch when all the numbers have been entered. a Numbers can be entered up to the max. 12 digits, but omit unnecessary digits. a When entering a wrong number, depress [left bottom (blank)] switch, then the cursor goes back by one digit. a When input is finished, the display changes to Entry display shown above. If the inputted Phone number is shown in this display, the input is normal.
2) Changing the display Select Entry next to change the display to the Phone Number Entry display. a Even if a Phone number is already inputted, it is deleted, upon switching to the Phone Number Entry display.
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3) Function for Key-on Mode When the engine starting switch is turned ON, a working mode can be set that is shown in the machine monitor. P Mode, E Mode, L Mode, B Mode: If any of them is set, the machine always ramps up with that working mode, when turning the engine starting switch ON. Mode at Previous Key-off: If this mode is set, the machine ramps up with the working mode that was last used in the previous machine operation. Default Value: If this mode is set, the machine ramps up with the default mode (P mode only) that was originally set at the time of delivery from the factory.
21. Function for AAAA/Default [06] It is possible to change the following settings for the machine monitor as well as the machine. Make a change as is required. Working mode when the engine starting switch is in the ON position. Display language in Service Menu Display unit in the monitoring function Setting of double wiper or single wiper 1) Selection of menu Select 06 "AAAA/Default menu" in the initial display of Service Menu, and depress [ ] switch.
2) Selection of submenu Select an item to change from the submenu, and depress [ ] switch.
No. 00 01 02 03 04 05 Return Key-on Mode Language Unit Wiper Select All Default Value
AAAA/Default submenu
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4) Function for AA/Language In Service Menu, the language in use can be changed between Japanese and English. a English is used as the language for default setting in the machine monitor. a If the machine monitor for spare parts is to be used in a Japanese-speaking region or organization, change the language from English to Japanese, using this function.
6) Function for wiper select The wiper specification can be set. 1 wiper: Machine with standard cab or fixed-front window cab (Only upper wiper) 2 wipers: Machine with fixed-front window cab (if equipped) (Upper wiper and lower wiper) a If this setting is not matched to the specification of the actually installed wiper, the wiper may not operate normally or an error is detected.
5) Function for Unit As the unit to be used in the monitoring function display of Service Menu, three kinds of unit are provided. a Unit used for default setting in the machine monitor is SI, i.e. International system of units.
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3) Function of pump absorption torque The pump absorption torque can be adjusted in the following ranges. a Basically, this setting does not need to be changed.
22. Function for Adjustment [07] The machine can be adjusted with the machine monitor. 1) Selection of menu Select "07 Adjustment" on the service menu and press the [ ] switch.
Adjustment value
Pump absorption torque +98.1 Nm {+10.0 kgm} +73.5 Nm {+7.5 kgm} +49.0 Nm {+5.0 kgm} +24.5 Nm {+2.5 kgm} 0.0 Nm {0.0 kgm} 24.5 Nm {2.5 kgm} 49.0 Nm {5.0 kgm} 73.5 Nm {7.5 kgm} 98.1 Nm {10.0 kgm}
2) Selection of sub menu Select the sub menu to check the setting and press the [ ] switch.
220 221 222 223 224 225 226 227 228
No. 00 01 02 03 04
Sub menu of adjustment Return (Finish adjustment) Pump Absorption Torque Fan Speed Mode Select Fan 100% Speed Adjust Fan 70% Speed Adjust
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4) Fan speed mode selection function To adjust the fan speed, it must be fixed temporarily. Select one of the following modes as necessary.
a The set value is kept even after the starting switch is turned OFF.
Adjustment value 560 561 562 563 564 565 566 567 568 Fan 100% Speed + 140 rpm + 120 rpm + 100 rpm + 80 rpm + 60 rpm + 40 rpm + 20 rpm 0 20 rpm 40 rpm 60 rpm 80 rpm 100 rpm 120 rpm 140 rpm
Adjustment value 550 551 552
Fan speed mode selection Normal mode: For normal operation 70% speed mode: For check of meeting of regulations 100% speed mode: For fan speed adjustment
569 56A 56B 56C 56D 56E
a If the starting switch is turned OFF, the fan speed mode returns to "550: Normal mode". Keep the starting switch ON while adjusting the fan speed. 5) Fan 100% speed adjustment function After "100% speed" is set in 4) above, the fan speed can be adjusted within the following range. a Adjust the fan speed within the standard range (1,050 50 rpm).
6) Fan 70% speed adjustment function After "70% speed" is set in 4) above, the fan speed can be adjusted within the following range.
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a The set value is kept even after the starting switch is turned OFF (only when the fan is set in the 70% speed mode).
Adjustment value 570 571 572 573 574 575 576 577 578 579 57A 57B 57C 57D 57E Fan 70% Speed + 140 rpm + 120 rpm + 100 rpm + 80 rpm + 60 rpm + 40 rpm + 20 rpm 0 20 rpm 40 rpm 60 rpm 80 rpm 100 rpm 120 rpm 140 rpm
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23. Function of Cylinder Cut Out [08] The Cylinder Cut Out operation of engine can be controlled with the machine monitor. Cylinder Cut Out operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). 1) Selection of menu Select "08 Cylinder Cut Out" on the initial screen of the Service Menu and press the [ ] switch.
3) Cancellation of disabled cylinders Press switches [1] [6] on the machine monitor corresponding to the disabled cylinder Nos. to cancel disabling of those cylinders. a After a switch is pressed, if the cylinder No. corresponding to it on the monitor panel is displayed black in a black frame, disabling of the cylinder is cancelled.
2) Setting of cylinders to be disabled Press switches [1] [6] on the machine monitor corresponding to the cylinder Nos. to be disabled. a After a switch is pressed, if the cylinder No. corresponding to it on the monitor panel is displayed white in a white frame, the cylinder is disabled (If setting is wrong, press the same switch again). a Only one or more cylinders can be disabled for the reduced cylinder mode operation.
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[Reference]: How to use holding function effectively The engine speed displayed by the holding function is held on the screen until the holding function is cancelled, regardless of setting and cancellation of the Cylinder Cut Out operation. Accordingly, a defective cylinder can be found out effectively according to the following procedure. (1) Run the engine normally (without disabling any cylinder) and hold the engine speed. (2) Disable a cylinder to be checked. (3) Run the engine under the same condition as the normal operation in step (1) and compare the engine speed at this time with the held engine speed. (4) Check the cylinder once, regardless of change of the engine speed. (5) Repeat steps (2) - (4) to check the other cylinders. a If the engine speed does not lower at all or lower less when a cylinder is selected for the Cylinder Cut Out operation, combustion in that cylinder must be abnormal.
4) Function of holding engine speed If the [ ] switch is pressed while the Cylinder Cut Out operation screen is used, the engine speed is held and displayed on the lower line. If the [ ] switch is pressed while the engine speed is held, holding of the engine speed is cancelled and the engine speed displayed on the lower line goes off. a If the holding function is used, the held engine speed is displayed in ( ) on the lower line and the current engine speed is displayed on the upper line. a The holding function can be used both in and out of the Cylinder Cut Out operation.
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24. Function of no injection [09] The operator can perform no-injection with the machine monitor. No-injection cranking is the function of preventing fuel injection through the injector when the engine is rotated with the starting motor for measuring compression pressure, etc. a Be sure to set the no-injection while the engine is stopped. 1) Selecting menu In the initial screen of the service menu, select "09 No Injection" and press the [ ] switch.
4) Select "No Injection" and press the [ ] switch, and the letters of "Under Preparation" appear. a The letters of "Under Preparation" are red.
2) The initial screen of no-injection appears. a The letters of "Check Communication" are red.
5) When the engine is ready for no injection cranking, the letters of "Under Preparation" change to "After No Injection". a The letters of "After No Injection" are green. 6) Under this condition, crank the engine with the starting motor. a Limit the no injection cranking to 20 seconds to protect the starting motor.
3) After communication is checked, the letters disappear and the following screen appears.
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7) After finishing no injection, press the [ ] switch on the previous screen, and the letters of "End" are displayed for 3 seconds. a The letters of "End" are green. 8) To finish no injection cranking, select "Return".
a If you select the function of no injection cranking and then select No Injection in 4) by mistake while the engine is running, the letters of "Engine Running" are displayed. Even if the engine is stopped, the letters of "Engine Running" are kept displayed until the screen returns to the service menu screen.
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Handling controller voltage circuit

1. When disconnecting or connecting a connector between the engine controller and engine, be sure to turn the starting switch OFF. 2. If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
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Procedure for turning on KOMTRAX terminal

When the machine is delivered, KOMTRAX terminal is installed: a When the machine is delivered, KOMTRAX terminal is installed (machine with the standard equipment), implement the following procedure. 1. Reporting of machine model, model number and serial number Report the machine model, model number and serial number to the person responsible to operation of KOMTRAX. 2. Registration of KOMTRAX terminal The person responsible to operation of KOMTRAX shall register the subject terminal using the KOMTRAX client PC. a See KOMTRAX administrator manual for the procedure. a Above completes the necessary operations. When installing KOMTRAX terminal after the machine is delivered: a When installing KOMTRAX terminal after the machine is delivered (machine with the retrospective equipment), implement the following procedure. 1. Station opening inspection a Finish the operations of steps 4) to 7) within 30 seconds. 1) Turn OFF the starting switch and then, after making sure 5 seconds have elapsed, proceed to the next step. 2) Make sure visually that the inspecting connectors 1 and 2 are connected. a The test connector is clamped to the back side of the KOMTRAX terminal cover (See Preparation work for troubleshooting for electrical system). Inspecting connector 1: G02 (female) and G03 (male) Inspecting connector 2: G04 (female) and G05 (male)
3) Disconnect the inspecting connector 1 and maintain that state for 5 seconds. 4) Turn ON the starting switch and maintain that state for 5 seconds. 5) Disconnect the inspecting connector 2 and maintain that state for 5 seconds. 6) Connect the inspecting connector 1 again and maintain that state for 5 seconds. 7) Connect the inspecting connector 2 again and maintain that state for 5 seconds. 8) Make sure that the KOMTRAX terminal 7segment indicator lamps are normally turned on. a After step 7), if display is normal, the 7segment indicator lamp displays for 30 seconds (d, 0, and are displayed repeatedly).
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a As [Normal] is indicated, proceed to the next step. a If [Abnormal] is indicated, repeat the procedure from step 1).
9) Set the starting switch to START position and maintain it in that state for 5 seconds. Make sure the engine is not started. a If the engine is started, repeat the procedure from step 1). 10) Return the starting switch to ON position and maintain that state for 5 seconds. a Don't return it to OFF position. 11) Set the starting switch to START position again and make sure the engine is started. 12) Make sure that the KOMTRAX terminal 7segment indicator lamps are normally turned on. a As [Normal] is confirmed, proceed to the next step (it will take 90 seconds to 15 minutes until normal display is restored). a If [GPS position data sensing error] were displayed, check the GPS antenna and cable for external troubles. If any, repair the trouble and repeat the procedure from step 1). a If [Receiving error] were displayed, check the communication antenna and cable for external troubles. If any, repair the trouble and repeat the procedure from step 1). a If [GPS position data sensing error and receiving error] were displayed, check the GPS antenna and cable as well as the communication antenna and cable for external troubles. If any, repair the trouble and repeat the procedure from step 1). a If [Network error] were displayed, check the indication of [LED-C4] referencing KOMTRAX terminal lamp indications. (When CAN is not recognized, check KOMTRAX terminal CAN harness for troubles. If any, repair the trouble and repeat the procedure from step 1)).
13) Turn the starting switch OFF. 14) Make sure that the 7-segment indicator lamp (a) comes on normally in 5 seconds. a As [Normal] is displayed, the station opening inspection is complete. a If [Abnormal] is displayed, the inspection is incomplete and must be repeated from step 1).
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2. Application for start of use a The application for start of use is allowed only after the terminal station opening inspection has been successfully ended. 1) Concerning the machine body for which the station opening inspection has been completed, report the following information to the person responsible to operation of KOMTRAX. (1) Information of the machine body for which the station opening inspection has been completed (machine model, model number and serial number) (2) Part number and serial number of KOMTRAX terminal (3) The service meter reading when KOMTRAX terminal was installed (in 0.1 h unit)
2) The person responsible to operation of KOMTRAX shall register the machine body using the KOMTRAX client PC. a See KOMTRAX administrator manual for the procedure. a Above completes the necessary operations.
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KOMTRAX terminal lamp indications
LED for CPU 1. LED-C1 (R signal and ACC signal) 2. LED-C2 (Initial output state) 3. LED-C3 (S-NET and C signal state) 4. LED-C4 (CAN state) 5. LED-C5 (Download writing state) 6. LED-C6 (Download writing state)
7-segment and dot for CPU 7. 7-segment (Number of mails which are not transmitted yet and condition of satellite link) 8. Dot (GPS positioning state)
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KOMTRAX system displays various information in the system as well as contents of information processing on the LED display unit located at the top of KOMTRAX terminal. Thus, when a failure on the system is suspected, implement the following checkups. Checking antennas Checking terminal LED display Before using KOMTRAX, the application for start of use and the machine side station opening inspection must be completed. Checking antennas a Before inspecting display of LED, check the communication antenna and its vicinity as well as GPS antenna and its vicinity for any trouble. The communication antenna shall not be disconnected or damaged. The communication antenna cable shall not be broken and shall be appropriately connected to KOMTRAX terminal. GPS antenna shall not be disconnected or damaged. GPS antenna cable shall not broken and shall be appropriately connected to KOMTRAX terminal. Checking terminal LED indication 1. Display contents of LED for CPU a Turn ON, START the starting switch or the engine prior to inspection of LED display.
No. LED Name and function Display (*1) ON State of starting switch ACC signal, alternator R signal Quick flashing Slow flashing OFF 2 LED-C2 State of engine control signal ON OFF ON State of S-NET connection and starting switch C signal Quick flashing Slow flashing OFF ON Quick flashing Slow flashing OFF 5 6 LED-C5 Download writing state LED-C6 Contents of display Starting switch ACC signal: ON, Alternator R signal: ON Starting switch ACC signal: OFF, Alternator R signal: ON Starting switch ACC signal: ON, Alternator R signal: OFF Starting switch ACC signal: OFF, Alternator R signal: OFF Engine control signal: ON Engine control signal: OFF S-NET: Connected, starting switch C signal: OFF Starting switch C signal: ON (Not used) S-NET: Disconnected, Starting switch C signal: OFF CAN: Present (Fuel sensor: Absent) CAN: Present (Fuel sensor: Present) CAN: Absent (Fuel sensor: Present) CAN: Absent (Fuel sensor: Absent)
LED-C1
LED-C3
LED-C4
State of CAN connection
Single side Download writing mode (Special function for system adminisON trator) Both sides OFF Normal working mode
*1: Types of flashing and flashing duration Quick flashing: Flashing of approximately 1 second cycle Slow flashing: Flashing of approximately 4 seconds cycle
PC600-8
41
SEN00445-03
2. Display contents of 7-segment and dots for CPU a Turn ON the starting switch prior to inspection of LED display.
No. Display unit Name and function Number of mails which are not sent yet and satellite capturing condition) Display (*2) Lighting of 09 Quick blinking of 09 ON OFF
Contents of display Figure indicates number of mails which are not sent yet (When 10 or more mails are not sent yet, 9 is indicated). Lighting indicates that satellite is captured. Figure indicates number of mails which are not sent yet (When 10 or more mails are not sent yet, 9 is indicated). Quick blinking indicates that satellite is not captured. Positioning with GPS complete (Position is recognized, *3) Positioning with GPS incomplete (Position is not recognized, *3)
7-segment
Dot
State of positioning with GPS
*2: Types of flashing and flashing duration Quick flashing: Flashing of approximately 1.0 second cycle. Slow flashing: Flashing of approximately 4.0 seconds cycle *3: Remarks on measuring condition of GPS In a outdoor location within radio waves penetration range, it sometimes takes more than a minute from turning on of the starting switch to completion of the positioning. Positioning is not available in a location where radio waves are extremely weak or unreachable.
42
PC600-8
SEN00445-03
2. Engine controller 1) Remove controller cover (1).
Preparation work for troubleshooting electrical system

a When troubleshooting an electric circuit related to the machine monitor, engine controller, or pump controller, expose the related connectors according to the following procedure. 1. Machine monitor 1) Remove cover (1). a The cover is secured with 2 clips at the top and bottom. Those clips can be removed by pulling them up. a If a sunlight sensor for the air conditioner is installed, disconnect connector P15 on the backside of the cover.
2) Insert or connect T-adapters for troubleshooting to connectors ENG, CE02 , and CE03 of the engine controller. a Since the connectors are secured with screws, loosen those screws before disconnecting them. a After returning the connectors, tighten the screws to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm}
2) Remove the 3 mounting screws and disconnect machine monitor (2) from the mount. a Take care not to drop the mounting screws in the console. 3) Insert or connect T-adapters for troubleshooting to connectors CM01, CM02, and CM03 of the machine monitor.
PC600-8
43
SEN00445-03
3. Pump controller a The pump controller is installed in the cover at the rear of the operator's seat. 1) Remove cover (5).
2) Insert or connect T-adapters for troubleshooting to connectors CP01 , CP02 , and CP03 of the pump controller (6). a Since the connectors are secured with screws, loosen those screws before disconnecting them. a After returning the connectors, tighten the screws to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm}
44
PC600-8
SEN00445-03
3. Adjusting mirror (b) Adjust mirror (b) so that the operator can see hatched area (b') at the right rear end of the machine. a Installed position, dimension and visibility Dimension X1 of installed position: 195 mm Visibility Y (right): 3,100 mm Hatched area (b') must be seen. a Loosen mirror mounting screw (2) and bolt (3) and adjust the mirror so that the operator can see (b') most from the operator's seat.
Adjusting mirrors
1. Mirrors installed positions
2. Adjusting mirror (a) Adjust mirror (a) so that the operator can see hatched area (a') at the left rear end of the machine. a Installed position, dimension and visibility Dimension X2 of installed position: 75 mm Visibility Z (left): 2,500 mm Visibility H (height): 1,600 mm Hatched area (a') must be seen. a Loosen mirror mounting nut (1) and adjust the mirror so that the operator can see (a') most from the operator's seat.
PC600-8
45
Pm-clinic service
46
PC600-8
Measuring procedures
Positions to install measuring devices (Related to engine and PTO)
PC600-8
47
Measuring procedures
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)
48
PC600-8
PC600-8
49
3.14 - 3.53 {32 - 36}
3.14 - 3.53 {32 - 36}
50
PC600-8
Pm-CLINIC SERVICE PC600, 600LC-8

Visual check of welded structures
a If any crack is found, draw its shape below.
Arm 1. Arm cylinder bracket T Left T Right 2. Arm foot T Left T Right T End plate 3. Arm top boss T Left T Right
Boom 4. Boom top bracket T Left T Right 5. Boom cylinder bracket T Left T Right 6. Arm cylinder bracket T Left T Right 7. Boom lower plate T Left T Right 8. Boom foot T Left T Right
Revolving frame 9. Boom bracket T Left T Right Track frame 10. Circle bracket T Front T Rear T Left T Right 11. Track frame mounting section T Front T Rear T Left T Right
PC600-8
51
Undercarriage inspection
(Program form No.: SELA195001)
52
PC600-8
SEN00445-03
PC600-8
53
SEN00445-03
54
SEN03960-03
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8 PC600LC-8
Machine model
PC600-8 PC600LC-8
Serial number
30001 and up 30001 and up
40 Troubleshooting
Failure code table and fuse locations
Failure codes table............................................................................................................................................... 2 Fuse locations ...................................................................................................................................................... 6
PC600-8
SEN03960-03
40 Troubleshooting
Failure codes table

Action code E10 E10 E11 E11 E14 E14 E15 E15 E15 E15 E15 E15 E15 E15 E15 E15 E03 E15 E15 E11 Failure code A000N1 Trouble (Displayed on screen) Eng. Hi Out of Std Alarm buzzer Component Category of in charge record MON MON MON MON MON MON MON MON ENG q q q q q q q q q q q q q q q ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG q q q q ENG ENG ENG ENG Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Troubleshooting by failure code, Part 1 SEN00448-02 Reference document No.
AA10NX Aircleaner Clogging AB00KE Charge Voltage Low B@BAZG Eng. Oil Press. Low B@BAZK Eng. Oil Level Low B@BCNS Eng. Water Overheat B@BCZK Eng. Water Lvl Low B@HANS Hydr. Oil Overheat CA111 CA115 CA122 CA123 CA131 CA132 CA135 CA141 CA144 CA145 CA153 CA154 CA187 CA221 CA222 CA227 CA234 CA238 CA263 CA265 CA271 ECM Critical Internal Failure Eng Ne and Bkup Speed Sens Error Chg Air Press Sensor High Error Chg Air Press Sensor Low Error Throttle Sensor High Error Throttle Sensor Low Error Eng Oil Press Sensor High Error Eng Oil Press Sensor Low Error Coolant Temp Sens High Error Coolant Temp Sens Low Error Chg Air Temp Sensor High Error Chg Air Temp Sensor Low Error Sens Supply 2 Volt Low Error Ambient Press Sens High Error Ambient Press Sens Low Error Sens Supply 2 Volt High Error Eng Overspeed Ne Speed Sens Supply Volt Error Fuel Temp Sensor High Error Fuel Temp Sensor Low Error IMV/PCV1 Short Error
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40 Troubleshooting
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Action code E11 E11 E11 E11 E11 E11 E11 E11 E11 E10 E10 E15 E15 E10 E10 E11 E11 E11 E15 E15 E11 E11 E10 E11 E15 E11 E11 E11 E15
Failure code CA272 CA273 CA274 CA322 CA323 CA324 CA325 CA331 CA332 CA342 CA351 CA352 CA386 CA441 CA442 CA449 CA451 CA452 CA553 CA554 CA559 CA689 CA731 CA757 CA778 CA1228 CA1625 CA1626 CA1627 CA1628
Trouble (Displayed on screen) IMV/PCV1 Open Error PCV2 Short Error PCV2 Open Error Inj #1(L#1) Open/Short Error Inj #5(L#5) Open/Short Error Inj #3(L#3) Open/Short Error Inj #6(L#6) Open/Short Error Inj #2(L#2) Open/Short Error Inj #4(L#4) Open/Short Error Calibration Code Incompatibility Injectors Drive Circuit Error Sens Supply 1 Volt Low Error Sens Supply 1 Volt High Error Battery Voltage low error Battery Voltage high error Rail Press Very High Error Rail Press Sensor High Error Rail Press Sensor Low Error Rail Press High Error Rail Press Sensor In Range Error Rail Press Low Error Eng Ne Speed Sensor Error Eng Bkup Speed Sens Phase Error All Persistent Data Lost Error Eng Bkup Speed Sensor Error EGR Valve Servo Error 1 EGR Valve Servo Error 2 BP Valve Sol Current High Error BP Valve Sol Current Low Error Bypass Valve Servo Error 1
Alarm buzzer q q q q q q q q q
Component Category of in charge record ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Reference document No.
Troubleshooting by failure code, Part 1 SEN00448-02
q q q q q q q q q
q q q q q q q q q q
PC600-8
SEN03960-03
40 Troubleshooting
Action code E11 E11 E11 E0E E11 E11 E14 E14 E11 E11 E11 E11 E11 E15 E15 E0E E0E
Failure code CA1629 CA1631 CA1632 CA1633 CA1642 CA1653 CA2185 CA2186 CA2249 CA2271 CA2272 CA2351 CA2352 CA2555 CA2556 D110KB D163KB D195KB
Trouble (Displayed on screen) Bypass Valve Servo Error 2 BP Valve Pos Sens High Error BP Valve Pos Sens Low Error KOMNET Datalink Timeout Error EGR Inlet Press Sens Low Error EGR Inlet Press Sens High Error Throt Sens Sup Volt High Error Throt Sens Sup Volt Low Error Rail Press Very Low Error EGR Valve Pos Sens High Error EGR Valve Pos Sens Low Error EGR Valve Sol Current High Error EGR Valve Sol Current Low Error Grid Htr relay Volt Low Error Grid Htr relay Volt High Error Battery Relay Drive S/C Flash Light Relay S/C Step Light Relay S/C
Alarm buzzer q q q q q q q q q q q q q q q
Component Category of in charge record ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG PUMP PUMP PUMP PUMP PUMP PUMP Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
DA25KP Press. Sensor Power Abnormality DA2SKQ Model selection Abnormality DA80MA Auto. Lub. Abnormal DA2RMC Pump Comm. Abnormality DAFRMC Monitor Comm. Abnormality DGE5KY Ambi. Temp. Sensor S/C DGH2KB Hydr. Oil Temp. Sensor S/C DHPAMA F Pump P.Sensor Abnormality DHPBMA R Pump P.Sensor Abnormality DV20KB Travel Alarm S/C DW43KA Travel Speed Sol. Disc. DW43KB Travel Speed Sol. S/C q q
PC600-8
40 Troubleshooting
SEN03960-03
Action code E03 E03 E11 E11 E02 E02
Failure code
Trouble (Displayed on screen)
Alarm buzzer q q
Component Category of in charge record PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
DW45KA Swing Brake Sol. Disc. DW45KB Swing Brake Sol. S/C DW48KA CO Cancel Sol. Disc. DW48KB CO Cancel Sol. S/C DW7BKA Fan Reverse Sol. Disc. DW7BKB Fan Reverse Sol. S/C DW4XKA Bucket Curl Hi Cancel Sol. Disc. DW4XKB Bucket Curl Hi Cancel Sol. S/C DWK0KA 2-stage Relief Sol. Disc. DWK0KB 2-stage Relief Sol. S/C DX16KA Fan Pump EPC Sol. Disc. DX16KB Fan Pump EPC Sol. S/C DXA0KA TVC Sol. Disc. DXA0KB TVC Sol. S/C DY20KA Wiper Working Abnormality DY20MA Wiper Parking Abnormality DY2CKB Washer Drive S/C DY2DKB Wiper Drive (For) S/C DY2EKB Wiper Drive (Rev) S/C
q q q q
PC600-8
SEN03960-03
40 Troubleshooting
Fuse locations
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 supply Switch power supply (Battery relay terminal M) Constant power supply (Battery relay terminal B) Circuit breaker No. 1 2 3 4 5 6 7 8 9 Circuit breaker capacity 40A 20A 20A 20A 20A 20A 30A 20A 20A Destination of power Fuse box (Fuses No. 1 15) Boom working lamp, right headlamp Grease pump Pump controller power source Head lamp on cab Starting switch, Pump controller (Power supply for solenoid) Engine controller (Power supply drive) Machine monitor, Buzzer Fuse box (Fuses No. 16 20)
Circuit breaker box inside the grease pump box locatd at the front right of machine.
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40 Troubleshooting
SEN03960-03
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 power is supplied normally.
Type of power supply Fuse No. 1 2 Switch power supply (Circuit breaker 1) 3 4 Fuse capacity 10A 10A 10A 20A Destination of power TVC solenoid (for emergency pump drive) Swing holding brake solenoid (for swing brake release) Boom stabilizer solenoid Machine push up solenoid PPC lock solenoid Starting motor cut-out relay Cigarette lighter Windshield washer motor Horn Flash light Bottom dump open solenoid (for loading shovel) Intake air heater Rotary lamp (Spare) Radio Bottom dump close solenoid (for loading shovel) Machine monitor, Buzzer Air conditioner unit (Spare) (Spare) OPT power supply (1) OPT power supply (2) 12 V power supply Radio backup Room lamp Step light (Spare) (Spare) ACC (Engine controller)
5 6 7 8 9 10 11 12 13 14 15 16 Constant power supply (Circuit breaker 9) 17 18 19 20
10A 10A 10A 10A 10A 20A 25A 20A 20A 10A 10A 10A 10A 10A 10A 5A
Switch power supply (Circuit breaker 1)
Switch power supply (Circuit breaker 1)
PC600-8
SEN03960-03
SEN00447-04
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
40 Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting........................................................................................................... 2 Sequence of events in troubleshooting ................................................................................................................ 3 Checks before troubleshooting ............................................................................................................................ 4 Classification and procedures of troubleshooting ................................................................................................ 5 Information contained in troubleshooting table .................................................................................................... 6 Failure-looking phenomenon and troubleshooting No. ........................................................................................ 8 Connection table for connector pin numbers ..................................................................................................... 12 T- branch box and T- branch adapter table ........................................................................................................ 48
PC600-8
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40 Troubleshooting
Points to remember when troubleshooting

k k k k k k
Stop the machine in a level ground, and check that the lock pin, blocks, and parking brake are securely fitted. 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. 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. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative () terminal of the battery first. 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, an important point is of course to understand the structure and function. However, a shortcut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: Parts that have no connection with the failure or other unnecessary parts will be disassembled. It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? 6) When were these repairs carried out? 7) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check the oil level 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. 5) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
PC600-8
40 Troubleshooting
SEN00447-04
Sequence of events in troubleshooting
PC600-8
SEN00447-04
40 Troubleshooting
Checks before troubleshooting

Item 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Check fuel level, type of fuel Check for impurities in fuel Check hydraulic oil level Check hydraulic oil strainer Check swing machinery oil level Check engine oil level (oil pan oil level) Check coolant level Check dust indicator for clogging Check hydraulic filter Check final drive oil level Judgement value 20 30V Action Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add coolant Clean or replace Replace Add oil Tighten or replace Tighten or replace Tighten or replace Repair Repair Bleed air Replace Add or replace Replace Repair Disconnect connector and dry Replace Replace
Hydraulic, Electrical mechanical equipment equipment
Lubricating oil, coolant Electrics, electrical equipment
1. Check for looseness, corrosion of battery terminal, wiring 2. Check for looseness, corrosion of alternator terminal, wiring 3. Check for looseness, corrosion of starting motor terminal, wiring 1. Check for abnormal noise, smell 2. Check for oil leakage 3. Carry out air bleeding 1. 2. 3. 4. 5. Check battery voltage (engine stopped) Check battery electrolyte level Check for discolored, burnt, exposed wiring Check for missing wiring clamps, hanging wiring Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals) 6. Check for blown, corroded fuses 7. Check alternator voltage (engine running at 1/2 throttle or above)
8. Check operating sound of battery relay (when switch is turned ON/OFF)
After running for several minutes : 27.5 29.5V Replace
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40 Troubleshooting
SEN00447-04
Classification and procedures of troubleshooting

Classification of troubleshooting
Mode Display of code E-mode H-mode S-mode Troubleshooting for electrical system Troubleshooting for hydraulic and mechanical system Troubleshooting for engine unit Contents Troubleshooting when failure code (electrical system)/(mechanical system) is displayed
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".
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40 Troubleshooting
Information contained in troubleshooting table

a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their contents fully before proceeding to actual troubleshooting work.
Action Code Display in monitor panel Failure content Failure Code Display in monitor panel Failure phenomenon
Title of failure phenomenon shown in abnormality record
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 monidetect some failure. tor or controller Phenomenon occurring on machine Relative information Phenomenon that occurs on the machine, resulting from the above action taken by the machine monitor or controller Information on the failure occurred as well as the troubleshooting 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 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. Grounding fault A wiring harness that is not connected with a grounding circuit has a contact with the grounding circuit. Hot short Wiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. <Precaution for Troubleshooting> 1) Connector No. display method and handling of T-adapter Insert or connect T-adapters in the following manner before starting troubleshooting unless otherwise instructed. If there is no indication of "male" or "female" in a specific connector No., disconnect 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., disconnect 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. 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.
2 Presumed cause and standard value in normalcy
Cause for presumed failure 3 (The attached No. for filing and reference purpose only. It does not stand for any priority)
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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.
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40 Troubleshooting
Failure-looking phenomenon and troubleshooting No.

Troubleshooting No. Failure-looking phenomenon Code display E mode H mode S mode
Action to be taken concerning User Code, Error Code and Failure Code 1 2 Display User Code in monitor panel Display Failure Code in mechanical system after checking Abnormality Record Engine related failure 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Engine does not start Starting performance is poor (starting always takes time) Engine does not turn Engine turns but no exhaust smoke comes out Exhaust smoke comes out but engine does not start (Fuel is being injected) Engine does not pick up smoothly (follow-up is poor) Engine stops during operations Engine does not rotate smoothly (hunting) Engine lacks output (or lacks power) Exhaust smoke is black (incomplete combustion) Oil consumption is excessive (or exhaust smoke is blue) Oil becomes contaminated quickly Fuel consumption is excessive Oil is in cooling water (or water spurts back, or water level goes down) Oil pressure caution lamp lights up (drop in oil pressure) Oil level rises (water, fuel in oil) Water temperature becomes too high (overheating) Abnormal noise is made Vibration is excessive Preheater does not operate Auto engine warm-up device does not work Auto-decelerator does not operate Failure related to work equipment, swing and travel 24 25 26 27 Speed or power of all work equipment, travel, and swing is low Engine speed lowers remarkably or engine stalls All work equipment, travel, and swing systems do not work Abnormal sound is heard from around pump Work equipment-related failure 28 29 30 31 Boom speed or power is low Arm speed or power is low Bucket speed or power is low Boom does not move H-6 H-7 H-8 H-9 E-5 H-1 H-2 H-3 H-4 E-2 E-3 E-4 H-5 E-1 S-1 S-2 a) S-2 b) S-2 c) S-3 S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-12 S-13 S-14 S-15 S-16 According to displayed code
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40 Troubleshooting
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Troubleshooting No. Failure-looking phenomenon Code display E mode H mode H-10 H-11 E-31 H-12 H-13 H-14 E-6 E-7 H-15 H-16 H-17 H-18 H-19 S mode
32 33 34 35 36 37 38 39 40 41
Arm does not move Bucket does not move Bottom dump does not move Hydraulic drift of work equipment is large Time lag of work equipment is large Power max. function does not operate Machine push-up function does not operate or stop When arm and boom bucket are operated simultaneously, boom bucket speeds are low When bucket and boom arm swing travel are operated simultaneously, boom arm swing travel speeds are low When arm and swing are operated simultaneously, swing speed is low Travel related failure
42 43 44 45 46 47 48
Machine deviates in one direction Machine deviates largely at start Machine deviates largely during compound operation Travel speed or power is low Machine does not travel (only one track) Travel speed does not change Travel alarm does not sound or does not stop sounding Swing related falure E-29
H-20 H-21 H-22 H-23 H-24 H-25
49 50 51 52 53 54
Upper structure does not swing Swing speed or acceleration is low Upper structure overruns excessively when it stops swinging Large shock is made when upper structure stops swinging Large abnormal sound is made when upper structure stops swinging Hydraulic drift of swing is large Machine monitor related failure (Operators Menu: Ordinary Display)
H-26 H-27 H-28 H-29 H-30 H-31
55 56 57 58 59 60 61 62 63 64
Any item is not displayed on machine monitor Part of display on machine monitor is missing Machine monitor displays contents irrelevant to the model Fuel level monitor red lamp lights up while engine is running Engine water thermometer does not display normally Hydraulic oil temperature gauge does not display correctly Fuel gauge does not display correctly Swing lock monitor does not display correctly When monitor switch is operated, nothing is displayed Windshield wiper and window washer do not work
E-8 E-9 E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17
PC600-8
SEN00447-04
40 Troubleshooting
Troubleshooting No. Failure-looking phenomenon Code display E mode H mode S mode
Machine monitor related failure (Service Menu: Special Function Display) 65 66 67 68 69 70 71 72 "Boom RAISE" is not correctly displayed in monitoring function "Boom LOWER" is not correctly displayed in monitoring function "Arm IN" is not correctly displayed in monitoring function "Arm OUT" is not correctly displayed in monitoring function "Bucket CURL" is not correctly displayed in monitoring function "Bucket DUMP" is not correctly displayed in monitoring function "Swing" is not correctly displayed in monitoring function "Travel" is not correctly displayed in monitoring function Other failure 73 74 75 76 Air conditioner does not work Step light does not light up or go off Electric grease gun does not operate Horn does not sound E-26 E-27 E-28 E-30 E-18 E-19 E-20 E-21 E-22 E-23 E-24 E-25
10
PC600-8
40 Troubleshooting
SEN00447-04
PC600-8
11
SEN00447-04
40 Troubleshooting
Connection table for connector pin numbers

a
(Rev. 2009.04)
The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.
12
PC600-8
40 Troubleshooting
SEN00447-04
PC600-8
13
SEN00447-04
40 Troubleshooting
14
PC600-8
40 Troubleshooting
SEN00447-04
PC600-8
15
SEN00447-04
40 Troubleshooting
16
PC600-8
40 Troubleshooting
SEN00447-04
PC600-8
17
SEN00447-04
40 Troubleshooting
18
PC600-8
40 Troubleshooting
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PC600-8
19
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20
PC600-8
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PC600-8
21
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40 Troubleshooting
22
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40 Troubleshooting
SEN00447-04
PC600-8
23
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26
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30
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31
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32
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33
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34
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35
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36
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37
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38
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39
SEN00447-04
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40
PC600-8
40 Troubleshooting
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PC600-8
41
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42
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PC600-8
43
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44
PC600-8
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45
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46
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47
SEN00447-04
40 Troubleshooting
T- branch box and T- branch adapter table

a
(Rev. 2009.03)
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.
Number of pins T-adapter kit 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4101 q q 1 2 3 4 6 8 12 14 16 1 2 3 4 M2P M3P M4P X2P X3P X4P SW6P SW8P SW12P SW14P SW16P q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q 799-601-4201 Identification symbol Out of kit q q q 24 24 17 17 5 10 5 17 19 14 5 13 17 21 9 2 3 4 8 8 12 16 MS-24P MS-24P MS-17P MS-17P MS-5P MS-10P MS-5P MS-17P MS-19P MS-14P MIC-5P MIC-13P MIC-17P MIC-21P MIC-9P ECONO2P ECONO3P ECONO4P ECONO8P DLI-8P DLI-12P DLI-16P q q q q q q q q q q q q q q q q 60 q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
Part No.
Part name
799-601-2600 T-box (for ECONO) 799-601-3100 T-box (for MS) 799-601-3200 T-box (for MS) 799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS) 799-601-3420 Adapter for BENDIX (MS) 799-601-3430 Adapter for BENDIX (MS) 799-601-3440 Adapter for BENDIX (MS) 799-601-3450 Adapter for BENDIX (MS) 799-601-3460 Adapter for BENDIX (MS) 799-601-3510 Adapter for BENDIX (MS) 799-601-3520 Adapter for BENDIX (MS) 799-601-3530 Adapter for BENDIX (MS) 799-601-2910 Adapter for BENDIX (MS) 799-601-3470 Case 799-601-2710 Adapter for MIC 799-601-2720 Adapter for MIC 799-601-2730 Adapter for MIC 799-601-2740 Adapter for MIC 799-601-2950 Adapter for MIC 799-601-2750 Adapter for ECONO 799-601-2760 Adapter for ECONO 799-601-2770 Adapter for ECONO 799-601-2780 Adapter for ECONO 799-601-2790 Adapter for ECONO 799-601-2810 Adapter for DLI 799-601-2820 Adapter for DLI 799-601-2830 Adapter for DLI 799-601-2840 Extension cable (ECONO type) 799-601-2850 Case 799-601-4350 T-box (for DRC 60, ECONO) 799-601-4360 Case 799-601-7010 Adapter for X (T-adapter) 799-601-7020 Adapter for X 799-601-7030 Adapter for X 799-601-7040 Adapter for X 799-601-7050 Adapter for SWP 799-601-7060 Adapter for SWP 799-601-7310 Adapter for SWP 799-601-7070 Adapter for SWP 799-601-7320 Adapter for SWP 799-601-7080 Adapter for M (T-adapter) 799-601-7090 Adapter for M 799-601-7110 Adapter for M 799-601-7120 Adapter for M
21 37 37
q q
12 ECONO12P q q
12 ECONO12P q q
48
PC600-8
40 Troubleshooting
SEN00447-04
T-adapter kit 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4101 799-601-4201 Identification symbol Out of kit q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q 10 12 14 18 20 5 6 2 2 2 3 4 6 8 8 8 8 12 12 12 12 8 14 20 21 9 16 21 23 31 24 07-10 07-12 07-14 07-18 07-20 REL-5P REL-6P DTM2 DT2 DT3 DT4 DT6 DT8GR DT8B DT8G DT8BR DT12GR DT12B DT12G DT12BR D18-8 D18-14 D18-20 D18-21 D24-9 D24-16 D24-21 D24-23 D24-31 q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
Part No.
Part name
Number of pins
799-601-7130 Adapter for M 799-601-7340 Adapter for M 799-601-7140 Adapter for S 799-601-7150 Adapter for S (White) 799-601-7160 Adapter for S (Blue) 799-601-7170 Adapter for S (Blue) 799-601-7330 Adapter for S (White) 799-601-7350 Adapter for S (White) 799-601-7180 Adapter for AMP040 799-601-7190 Adapter for AMP040 799-601-7210 Adapter for AMP040 799-601-7220 Adapter for AMP040 799-601-7230 Short connector for X 799-601-7240 Case 799-601-7270 Case 799-601-7510 Adapter for 070 799-601-7520 Adapter for 070 799-601-7530 Adapter for 070 799-601-7540 Adapter for 070 799-601-7550 Adapter for 070 799-601-7360 Adapter for relay 799-601-7370 Adapter for relay 799-601-7380 Adapter for JFC 799-601-9010 Adapter for DTM 799-601-9020 Adapter for DT 799-601-9030 Adapter for DT 799-601-9040 Adapter for DT 799-601-9050 Adapter for DT 799-601-9060 Adapter for DT (Gray) 799-601-9070 Adapter for DT (Black) 799-601-9080 Adapter for DT (Green) 799-601-9090 Adapter for DT (Brown) 799-601-9110 Adapter for DT (Gray) 799-601-9120 Adapter for DT (Black) 799-601-9130 Adapter for DT (Green) 799-601-9140 Adapter for DT (Brown) 799-601-9210 Adapter for HD30-18 799-601-9220 Adapter for HD30-18 799-601-9230 Adapter for HD30-18 799-601-9240 Adapter for HD30-18 799-601-9250 Adapter for HD30-24 799-601-9260 Adapter for HD30-24 799-601-9270 Adapter for HD30-24 799-601-9280 Adapter for HD30-24 799-601-9290 Adapter for HD30-24 799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO) 799-601-9330 Case
6 8 8 10 12 16 16 12 8 12 16 20 2
M6P M8P S8P S10P S12P S16P S16PW S12PW A8P A12P A16P A20P
q q q
PC600-8
49
SEN00447-04
T-adapter kit 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100
40 Troubleshooting
Number of pins
799-601-9200
799-601-9300
799-601-4101 q q
799-601-4201
Part No.
Part name
Identification symbol
799-601-9340 Case 799-601-9350 Adapter for DRC 799-601-9360 Adapter for DRC 799-601-9410* Socket for engine (CRI-T2) Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor 799-601-9430* Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV 40 24 2 3 2 3 2 2 2 3 3 3 4 3 3 3 2 3 3 4 3 3 3 2 4 4 50 60 60 121 16 16 26 2, 3, 4, DRC-40 DRC-24 G A3 P 1,2,3 S C A ITT3N FCIN FCIG FCIB 4160 4180 1,2,3L 1,2,3,4C 1,2,3A 1,2,3B 1,2,3,G 2,PA 1,2,3,4T DTP4 DRC50 DRC60 HST16A HST16B HST26A
q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
799-601-9440* Socket for engine (CRI-T2) 795-799-5520* Socket for engine (HPI-T2) Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor 795-799-5540* Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 795-799-5470 Cable for engine (HPI-T2) 795-799-5480 Cable for engine (HPI-T2) 799-601-4110 Adapter for engine (140-T3) PIM 799-601-4130 Adapter for engine (CRI-T3) NE, CAM 799-601-4140 Adapter for engine (CRI-T3) Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch 799-601-4180 Adapter for engine (CRI-T3) PEVA Socket for engine (CRI-T3) 799-601-4190* Commonrail pressure 799-601-4230* Socket for engine (CRI-T3) Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 799-601-4250* Socket for engine (CRI-T3) PIM 799-601-4330* Socket for engine (CRI-T3) G Socket for engine (CRI-T3) 799-601-4340* Pump actuator 799-601-4380* Socket for engine (CRI-T3)(95) Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 799-601-4211 Adapter for controller (ENG) 799-601-4220 Adapter for controller (ENG) 799-601-4390* Socket for controller (95 ENG) 799-601-4280* Box for controller (PUMP) 799-601-9720 Adapter for controller (HST) 799-601-9710 Adapter for controller (HST) 799-601-9730 Adapter for controller (HST) 799-601-9890 Multi-adapter for DT2 4 and DTM2
q q q q q q
* Shows not T-adapter but socket.
50
PC600-8
Out of kit
40 Troubleshooting
SEN00447-04
PC600-8
51
SEN00447-04
40 Troubleshooting
52
SEN00448-02
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
40 Troubleshooting
Troubleshooting by failure code (Display of code), Part 1
Failure code [A000N1] Eng. Hi Out of Std ...................................................................................................... 3 Failure code [AA10NX] Aircleaner clogging ................................................................................................... 4 Failure code [AB00KE] Charge Voltage Low .................................................................................................. 6 Failure code [B@BAZG] Eng. Oil Press. Low ................................................................................................ 8 Failure code [B@BAZK] Eng. Oil Level Low ................................................................................................ 10 Failure code [B@BCNS] Eng. Water Overheat .............................................................................................11 Failure code [B@BCZK] Eng. Water Lvl Low ............................................................................................... 12 Failure code [B@HANS] Hydr. Oil Overheat ................................................................................................ 14 Failure code [CA111] ECM Critical Internal Failure ...................................................................................... 15 Failure code [CA115] Eng Ne and Bkup Speed Sens Error.......................................................................... 16 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................... 18 Failure code [CA123] Chg Air Press Sensor Low Error................................................................................ 20 Failure code [CA131] Throttle Sensor High Error ......................................................................................... 22 Failure code [CA132] Throttle Sensor Low Error.......................................................................................... 24 Failure code [CA135] Eng Oil Press Sensor High Error ............................................................................... 26 Failure code [CA141] Eng Oil Press Sensor Low Error ................................................................................ 28 Failure code [CA144] Coolant Temp Sens High Error .................................................................................. 30 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................... 32 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................... 34 Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................ 36
PC600-8
SEN00448-02
40 Troubleshooting
Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................................... 36 Failure code [CA221] Ambient Press Sens High Error ................................................................................. 38 Failure code [CA222] Ambient Press Sens Low Error.................................................................................. 40 Failure code [CA227] Sens Supply 2 Volt High Error ................................................................................... 42 Failure code [CA234] Eng Overspeed .......................................................................................................... 44 Failure code [CA238] Ne Speed Sens Supply Volt Error .............................................................................. 45 Failure code [CA263] Fuel Temp Sensor High Error .................................................................................... 46 Failure code [CA265] Fuel Temp Sensor Low Error ..................................................................................... 48 Failure code [CA271] IMV/PCV1 Short Error................................................................................................ 49 Failure code [CA272] IMV/PCV1 Open Error ............................................................................................... 50 Failure code [CA273] PCV2 Short Error ....................................................................................................... 51 Failure code [CA274] PCV2 Open Error....................................................................................................... 52
PC600-8
40 Troubleshooting
SEN00448-02
Failure code [A000N1] Eng. Hi Out of Std

Action code Failure content Failure code A000N1 Failure phenomenon Eng. Hi Out of Std (Mechanical monitor system)
Engine speed higher than 2,500 rpm is detected while the engine is running.
Response from None in particular. controller Phenomenon occurring on machine Relative information If the machine is used as it is, the engine may be damaged. Input from the engine speed sensor (rpm) can be checked in the monitoring function. (Code No. 01002: Engine speed) Cause Presumed cause and standard value in normalcy Engine overrun 1 (While system is normal) 2 3 Standard value in normalcy and references for troubleshooting Check for external and internal causes for abnormal rise of the engine high idle speed, then carry out troubleshooting for the mechanical system of the engine.
Engine Ne sensor system If failure code [CA238] is displayed, carry out troubleshooting for it. defective Engine G sensor system defective If failure code [CA778] is displayed, carry out troubleshooting for it. a Turn the engine starting switch ON for the preparations, and keep the engine running during the troubleshooting. Monitoring 010006 Engine speed Engine High idle Engine speed 1,900 2,000 rpm
Engine controller defective
PC600-8
SEN00448-02 Failure code [AA10NX] Aircleaner clogging

Action code Failure content Failure code AA10NX Failure phenomenon Aircleaner clogging (Machine monitor system)
40 Troubleshooting
The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine is running.
Response from None in particular. controller Phenomenon occurring on machine Relative information If the machine is used as it is, the engine may be damaged. If the air cleaner clogging monitor on the machine monitor lights up in red while the engine is running, this failure code is recorded. Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function. (Code No. 04501: Monitor input 1) Cause 1 Air cleaner clogged (While system is normal) Standard value in normalcy and references for troubleshooting Check the air cleaner. If it is clogged, clean or replace it. 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. P23 (male) Between (1) and (2) Air cleaner Normal Clogged Resistance value Max. 1 z Min. 1 Mz
Presumed cause and standard value in normalcy
Air cleaner clogging 2 switch defective (Internal disconnection)
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CM02 (female) (5) and P23 (female) (1) Wiring harness between P23 (female) (2) and grounding Resistance value Resistance value Max. 1 z Max. 1 z
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. 4 Machine monitor defective CM02 Between (5) and grounding Air cleaner Normal Clogged Voltage Max. 1 V 20 30 V
PC600-8
40 Troubleshooting
SEN00448-02
Electrical circuit diagram related to air cleaner clogging switch
PC600-8
SEN00448-02 Failure code [AB00KE] Charge Voltage Low

Action code Failure content Failure code AB00KE Failure phenomenon Charge Voltage Low (Machine monitor system)
40 Troubleshooting
Signal voltage from alternator is Max. 20 V while the engine is running.
Response from None in particular. controller Phenomenon occurring on machine Relative information If the machine is used as it is, the battery may not be charged. If the charge level monitor on the machine monitor lights up in red while the engine is running, this failure code is recorded. Input from the alternator (Voltage, ON or OFF) can be checked in the monitoring function. (Code No. 04300: Charge voltage, 04501: Monitor input 2) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 1 Alternator defective (Internal defect) Alternator Between terminal R and grounding Engine Above low idle Voltage 27.5 29.5 V
If the voltage is abnormal, check the belt tension too. Presumed cause and standard value in normalcy Disconnection of wiring harness 2 (Disconnection or defective contact with connector) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CM02 (female) (11) and alternator terminal R Resistance value Max. 1 z
Grounding fault of wiring harness 3 (Contact with grounding circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CM02 (female) (11) and alternator terminal R, or between CM02 (female) (11), D01, J01, and starting switch terminal BR, or between CM02 (female) (11), battery relay terminal BR and grounding Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 4 Machine monitor defective CM02 Between (11) and grounding Engine Above low idle Voltage 27.5 29.5 V
PC600-8
40 Troubleshooting
SEN00448-02
Electrical circuit diagram related to engine preheating, starting, charging
PC600-8
SEN00448-02 Failure code [B@BAZG] Eng. Oil Press. Low

Action code Failure content Failure code B@BAZG Failure phenomenon Eng. Oil Press. Low (Machine monitor system)
40 Troubleshooting
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. If cause of failure disappears, system resets itself. controller Phenomenon occurring on machine Relative information Input state (Pressure) from engine oil pressure sensor can be checked with monitoring function. (Code 37200: Engine oil pressure) Cause Defective sensor power 1 supply system Defective pressure sensor (Internal defect) Standard value in normalcy and references for troubleshooting If failure code [CA227] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 2 POIL Between (1) (2) Between (3) (2) Source voltage 4.5 5.5 V 0.5 4.5 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Presumed cause and standard value in normalcy Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between ENG (female) (13) POIL (female) (3) Wiring harness between ENG (female) (37) POIL (female) (1) Wiring harness between ENG (female) (47) POIL (female) (2) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning Ground fault in wiring starting switch ON. 4 harness Wiring harness between ENG (female) (13) POIL (Contact with GND circuit) Resistance Min. 1 Mz (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ENG (female) (13) POIL (female) (3) Wiring harness between ENG (female) (37) POIL (female) (1) ENG CE01 Between (37) (47) Between (13) (47) Voltage Voltage Max. 1 V Max. 1 V
Hot short (Short circuit 5 with 24V circuit) in wiring harness
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 6 Defective engine controller Voltage 4.5 5.5 V 0.5 4.5 V
PC600-8
40 Troubleshooting
SEN00448-02
Electrical circuit diagram related to Eng. Oil Press. Low
PC600-8
SEN00448-02 Failure code [B@BAZK] Eng. Oil Level Low

Action code Failure content Failure code B@BAZK Failure phenomenon Eng. Oil Level Low (Mechanical system)
40 Troubleshooting
The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the engine is stopped.
Response from None in particular. controller Phenomenon occurring on machine Relative information If the machine is used as it is, the engine may be damaged. If the engine oil level monitor on the machine monitor lights up in red while the engine is running, this failure code is recorded. Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function. (Code No. 04501: Monitor input 2) Cause 1 Engine oil level low (While system is normal) Standard value in normalcy and references for troubleshooting Check the oil level in the engine oil pan. If it is low, add oil. (If it is reduced frequently, find out the cause.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. P44 (male) Between (1) and grounding Engine oil level Normal level Below normal level Resistance value Max. 1 z Min. 1 Mz
Engine oil level switch 2 defective (Internal disconnection) Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CM02 (female) (8) and P44 (female) (1) Resistance value Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Machine monitor defective CM02 Between (8) and grounding Engine oil level Normal level Below normal level Voltage Max. 1 V 20 30 V
Electrical circuit diagram related to engine oil level switch
10
PC600-8
40 Troubleshooting
SEN00448-02
Failure code [B@BCNS] Eng. Water Overheat

Action code Failure content Failure code B@BCNS Failure phenomenon Eng. Water Overheat (Mechanical system)
The signal circuit of the engine water high temperature sensor detected temperature above 105C.
Response from None in particular. controller Phenomenon occurring on machine Relative information If the machine is used as it is, the engine may be damaged. If the engine coolant temperature monitor on the machine monitor lights up in red while the engine is running, this failure code is recorded. Input from the engine coolant high temperature sensor (coolant temperature and voltage) can be checked in the monitoring function. (Code No. 04107: Engine coolant temperature, 04105: Engine coolant temperature sensor voltage) Cause Presumed cause and standard value in normalcy 1 Engine overheated (While system is normal) Standard value in normalcy and references for troubleshooting Check the engine for overheating. If it has been overheated, find out the cause and check the engine for damage, then repair. Carry out troubleshooting for "E-12 Display of engine coolant temperature gauge on machine monitor is abnormal" in E-mode. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. ENG (female) Between (15) and (38) Engine water temperature 105C Resistance value 3.28 kz
Engine coolant 2 temperature sensor system defective Engine controller defective
Electrical circuit diagram related to engine coolant temperature sensor
PC600-8
11
SEN00448-02 Failure code [B@BCZK] Eng. Water Lvl Low

Action code Failure content Failure code B@BCZK Failure phenomenon Eng. Water Lvl Low (Machine monitor system)
40 Troubleshooting
The signal circuit of the radiator coolant level switch is opened (disconnected from grounding) while the engine is running.
Response from None in particular. controller Phenomenon occurring on machine Relative information If the machine is used as it is, the engine will overheat. If the radiator coolant level monitor on the machine monitor lights up in red while the engine is stopped (the starting switch is at the ON position), this failure code is recorded. Input from the radiator coolant level switch (ON or OFF) can be checked in the monitoring function. (Code No. 04500: Monitor input 1) Cause 1 Standard value in normalcy and references for troubleshooting
Sub-tank coolant level low Check the radiator sub-tank coolant level. If it is low, add coolant. (If it is reduced fre(While system is normal) quently, find out the cause.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. P24 (male) Between (1) and (2) Sub-tank coolant level Within normal level Below LOW level Resistance value Max. 1 z Min. 1 Mz
Radiator coolant level 2 switch defective (Internal disconnection)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CM02 (female) (3) and P24 (female) (1) Wiring harness between P24 (female) (2) and grounding Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Machine monitor defective CM02 Between (3) and grounding Sub-tank coolant level Within normal level Below LOW level Voltage Max. 1 V 20 30 V
12
PC600-8
40 Troubleshooting
SEN00448-02
Electrical circuit diagram related to radiator coolant level switch
PC600-8
13
SEN00448-02 Failure code [B@HANS] Hydr. Oil Overheat

Action code Failure content Failure code B@HANS Failure phenomenon Hydr. Oil Overheat (Machine monitor system)
40 Troubleshooting
The signal of the hydraulic oil temperature sensor rises above 102C while the engine is running.
Response from None in particular. controller Phenomenon occurring on machine Relative information If the machine is used as it is, the hydraulic equipment may be damaged. If the hydraulic oil temperature monitor on the machine monitor lights up in red while the engine is running, this failure code is recorded. 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) Cause 1 Hydraulic oil overheated (While system is normal) Standard value in normalcy and references for troubleshooting Check the hydraulic oil for overheating. If it has been overheated, find out the cause and check the hydraulic equipment for damage, then repair. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. P22 (male) Between (1) and (2) Between (1) and grounding Grounding fault of wiring harness 3 (Contact with grounding circuit) Hydraulic oil temperature 10 100C Resistance value 90 3.5 kz Min. 1 Mz
Hydraulic oil temperature 2 sensor defective (Internal short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CM02 (female) (12) and P22 (female) (1) and grounding Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Machine monitor defective CM02 Between (12) and (13) Between (12) and grounding 10 100C Hydraulic oil temperature Resistance value 90 3.5 kz Min. 1 Mz
Electrical circuit diagram related to hydraulic oil temperature sensor
14
PC600-8
40 Troubleshooting
SEN00448-02
Failure code [CA111] ECM Critical Internal Failure

Action code E10 Contents of trouble Action of controller Failure code CA111 None in particular. Trouble ECM Critical Internal Failure (Engine controller system)
Abnormality occurred in controller.
Problem that appears Engine runs normally but it may stop during operation or may not be able to start. on machine Related information Cause 1 Defective circuit breaker No.7 Standard value in normal state/Remarks on troubleshooting Check circuit breaker No.7 directly for defect. (If circuit breaker is turned OFF, circuit probably has ground fault.)
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between CE03 2 Resistance Max. 1 z ing or defective contact in (female) (3) battery (B) connector) Wiring harness between CE03 Resistance Max. 1 z (female) (1) chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between CE03 circuit) (female) (3) battery (B) and chassis Resistance Max. 1 z ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CE03 Between (3) (1) Voltage 20 30 V
4 Defective engine controller
Circuit diagram related to controller power supply
PC600-8
15
SEN00448-02 Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Action code E10 Contents of trouble Action of controller Failure code CA115 None in particular. Trouble Eng Ne and Bkup Speed Sens Error (Engine controller system)
40 Troubleshooting
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 Cause 1 2 Possible causes and standard value in normal state 3 4 5 Standard value in normal state/Remarks on troubleshooting
Defective Ne speed sensor Carry out troubleshooting for Failure code [CA689]. system Defective Bkup speed senCarry out troubleshooting for Failure code [CA778]. sor system Defective mount of Ne speed sensor Defective mount of Bkup speed sensor Defective connection (Wrong connection) Check mount of Ne speed sensor directly for defect (defective installation of sensor, internal trouble of flywheel, etc.) Check mount of Bkup speed sensor directly for defect (defective installation of sensor, internal trouble of supply pump, etc.) Check Ne speed sensor and Bkup speed sensor directly for defective connection (wrong connection). If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
16
PC600-8
40 Troubleshooting
SEN00448-02
PC600-8
17
SEN00448-02 Failure code [CA122] Chg Air Press Sensor High Error
Action code E11 Contents of trouble Action of controller Failure code Chg Air Press Sensor High Error Trouble (Engine controller system) CA122 Signal voltage in charge pressure sensor circuit is abnormally high. Fixes charge pressure (400 kPa {4.1 kg/cm2}) and continues operation.
40 Troubleshooting
Problem that appears Acceleration performance of engine drops. on machine Related information Signal voltage of boost pressure sensor can be checked with monitoring function. (Code: 36501 Boost pressure sensor voltage) Cause Defective sensor power 1 supply system Standard value in normal state/Remarks on troubleshooting If failure code [CA187] or [CA227] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. PIM Voltage Between (1) (2) Power supply 4.75 5.25 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. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) PIM (female) (1) and between Resistance Min. 1 Mz ENG (female) (47) PIM (female) (2) Wiring harness between ENG (female) (37) PIM (female) (1) and between Resistance Min. 1 Mz ENG (female) (44) PIM (female) (3) Wiring harness between ENG (female) (47) PIM (female) (3) and between Resistance Min. 1 Mz ENG (female) (44) PIM (female) (3) a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Wiring harness between ENG (female) (37) PIM (female) (1) and chassis Voltage Max. 1 V ground Wiring harness between ENG (female) (47) PIM (female) (2) and chassis Voltage Max. 1 V ground Wiring harness between ENG (female) (44) PIM (female) (3) and chassis Voltage Max. 1 V ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG Voltage Between (37) (47) Power supply 4.75 5.25 V
Defective charge pres2 sure sensor (Internal trouble)
Short circuit in wiring har3 ness (with another wiring harness)
Hot short (Short circuit 4 with 24V circuit) in wiring harness
Defective engine controller
18
PC600-8
40 Troubleshooting
SEN00448-02
Circuit diagram related to charge pressure sensor
PC600-8
19
SEN00448-02 Failure code [CA123] Chg Air Press Sensor Low Error
Action code E11 Contents of trouble Action of controller Failure code CA123 Trouble Chg Air Press Sensor Low Error (Engine controller system)
40 Troubleshooting
Signal voltage in charge pressure sensor circuit is abnormally low. Fixes charge pressure (400 kPa {4.1 kg/cm2}) and continues operation.
Problem that appears Acceleration performance of engine drops. on machine Related information Possible causes and standard value in normal state Signal voltage of boost pressure sensor can be checked with monitoring function. (Code: 36501 Boost pressure sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure Code [CA122].
20
PC600-8
40 Troubleshooting
SEN00448-02
PC600-8
21
SEN00448-02 Failure code [CA131] Throttle Sensor High Error

Action code E14 Contents of trouble Action of controller Failure code CA131 Trouble Throttle Sensor High Error (Engine controller system)
40 Troubleshooting
Throttle sensor circuit has high error. Continues operation by setting throttle angle with signal other than throttle sensor signal. If this error is detected while engine is running, controller keeps signal of fuel control dial just before error is detected.
Problem that appears Engine speed may not be controlled. on machine Related information Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial voltage) Cause 1 Defective sensor power supply system Standard value in normal state/Remarks on troubleshooting If failure code [CA2185] or [CA2186] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2 Defective fuel control dial (Internal defect) P20 (male) Between (1) (3) Between (2) (1) Between (2) (3) Resistance 4.0 6.0 kz 0.25 5.0 kz 0.25 5.0 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (22) P20 (female) (1) and between CE02 (female) (9) P20 (female) (2) Wiring harness between CE02 (female) (22) P20 (female) (1) and between CE02 (female) (23) P20 (female) (3) Wiring harness between CE02 (female) (23) P20 (female) (3) and between CE02 (female) (9) P20 (female) (2) Resistance Min. 1 Mz
Short circuit in wiring har3 ness (with another wiring harness)
Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (short circuit with 4 24V circuit) in wiring harness Wiring harness between CE02 (female) (22) P20 (female) (1) Wiring harness between CE02 (female) (9) P20 (female) (2) Wiring harness between CE02 (female) (23) P20 (female) (3) Voltage Voltage Voltage Max. 1 V Max. 1 V Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller CE02 Between (22) (23) Between (9) (23) Power supply Signal Voltage 4.75 5.25 V 0.5 4.5 V
22
PC600-8
40 Troubleshooting
SEN00448-02
Circuit diagram related to throttle sensor of fuel control dial type
PC600-8
23
SEN00448-02 Failure code [CA132] Throttle Sensor Low Error

Action code E14 Contents of trouble Action of controller Failure code CA132 Trouble Throttle Sensor Low Error (Engine controller system)
40 Troubleshooting
Signal voltage in throttle sensor circuit is abnormally low. Sets throttle angle with signal other than throttle signal and continues operation.
Problem that appears on machine Related information If this error is detected while engine is running, controller keeps signal of fuel control dial just before error is detected. (Code: 03000 Fuel control dial voltage) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure Code [CA131].
24
PC600-8
40 Troubleshooting
SEN00448-02
PC600-8
25
SEN00448-02 Failure code [CA135] Eng Oil Press Sensor High Error
40 Troubleshooting
Action code Failure code Eng Oil Press Sensor High Error Trouble (Engine controller system) E15 CA135 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. Problem that appears on machine Signal voltage of oil pressure sensor can be checked with monitoring function. Related information (Code: 37201 Oil pressure sensor voltage) Cause Defective sensor power supply system Standard value in normal state/Remarks on troubleshooting If failure code [CA187] or [CA227] is indicated, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. POIL Voltage Defective oil pressure 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. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) POIL (female) (1) and between Resistance Min. 1 Mz ENG (female) (47) POIL (female) (2) Short circuit in wiring harness (with another Wiring harness between ENG (female) wiring harness) (37) POIL (female) (1) and between Resistance Min. 1 Mz ENG (female) (13) POIL (female) (3) Wiring harness between ENG (female) (47) POIL (female) (2) and between Resistance Min. 1 Mz ENG (female) (13) POIL (female) (3) a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Wiring harness between ENG (female) Voltage Max. 1 V Hot short (Short circuit (37) POIL (female) (1) with 24V circuit) in wirWiring harness between ENG (female) ing harness Voltage Max. 1 V (47) POIL (female) (2) Wiring harness between ENG (female) Voltage Max. 1 V (13) POIL (female) (3) a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective engine controller ENG Voltage Between (37) (47) Power supply 4.75 5.25 V
26
PC600-8
40 Troubleshooting
SEN00448-02
Circuit diagram related to oil pressure sensor
PC600-8
27
SEN00448-02 Failure code [CA141] Eng Oil Press Sensor Low Error
Action code E15 Contents of trouble Action of controller Failure code CA141 Trouble Eng Oil Press Sensor Low Error (Engine controller system)
40 Troubleshooting
Signal voltage in oil pressure sensor circuit is abnormally low. Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
Problem that appears on machine Related information Possible causes and standard value in normal state Signal voltage of oil pressure sensor can be checked with monitoring function. (Code: 37201 Oil pressure sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA135].
28
PC600-8
40 Troubleshooting
SEN00448-02
PC600-8
29
SEN00448-02 Failure code [CA144] Coolant Temp Sens High Error

Action code E15 Contents of trouble Action of controller Failure code CA144 Trouble Coolant Temp Sens High Error (Engine controller system)
40 Troubleshooting
Signal voltage in coolant temperature sensor circuit is abnormally high. Fixes coolant temperature (90C) and continues operation.
Problem that appears on machine Related information Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105 Coolant temperature sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective coolant tempera1 ture sensor (Internal trouCoolant TWTR (male) Resistance ble) temperature Between (A) (B) 10 100C 0.6 20 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (15) TWTR (female) (A) connector) Wiring harness between ENG Resistance Max. 1 z (female) (38) TWTR (female) (B) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between ENG circuit) (female) (15) TWTR (female) (A) Resistance Min. 1 Mz and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ENG (female) Between (15) (38) Coolant temperature 10 100C Resistance 0.6 20 kz
30
PC600-8
40 Troubleshooting
SEN00448-02
Circuit diagram related to coolant temperature sensor
PC600-8
31
SEN00448-02 Failure code [CA145] Coolant Temp Sens Low Error

Action code E15 Contents of trouble Action of controller Failure code CA145 Trouble Coolant Temp Sens Low Error (Engine controller system)
40 Troubleshooting
Signal voltage in coolant temperature sensor circuit is abnormally low. Fixes coolant temperature (90C) and continues operation.
Problem that appears on machine Related information Possible causes and standard value in normal state Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105 Coolant temperature sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA144].
32
PC600-8
40 Troubleshooting
SEN00448-02
PC600-8
33
SEN00448-02 Failure code [CA153] Chg Air Temp Sensor High Error
Action code E15 Contents of trouble Action of controller Failure code CA153 Trouble Chg Air Temp Sensor High Error (Engine controller system)
40 Troubleshooting
Signal voltage in charge temperature sensor circuit is abnormally high. Fixes charge temperature (intake air temperature) (70C) and continues operation.
Problem that appears on machine Related information Signal voltage of boost temperature sensor can be checked with monitoring function. (Code: 18501 Boost temperature sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TIM (male) Defective charge tempera1 ture sensor (Internal trouble) Intake air temperature 0C Between (A) (B) 25C 40C 100C Between (A) chassis ground All range Resistance 29 36 kz 9 11 kz 4.9 5.8 kz 600 700 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (23) TIM (female) (A) connector) Wiring harness between ENG Resistance Max. 1 z (female) (47) TIM (female) (B) Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between ENG circuit) (female) (23) TIM (female) (A) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) 4 Defective engine controller Between (23) (47) Intake air temperature 0C 25C 40C 100C Resistance 29 36 kz 9 11 kz 4.9 5.8 kz 600 700 z
34
PC600-8
40 Troubleshooting
SEN00448-02
Circuit diagram related to charge temperature sensor
PC600-8
35
SEN00448-02 Failure code [CA154] Chg Air Temp Sensor Low Error
Action code E15 Contents of trouble Action of controller Failure code CA154 Trouble Chg Air Temp Sensor Low Error (Engine controller system)
40 Troubleshooting
Signal voltage in charge temperature sensor circuit is abnormally low. Fixes charge temperature (intake air temperature) (70C) and continues operation.
Problem that appears on machine Related information Possible causes and standard value in normal state Signal voltage of boost temperature sensor can be checked with monitoring function. (Code: 18501 Boost temperature sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA153].
Failure code [CA187] Sens Supply 2 Volt Low Error

Action code E15 Contents of trouble Failure code CA187 Trouble Sens Supply 2 Volt Low Error (Engine controller system)
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. 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.
Action of controller
Problem that appears Output drops. on machine Related information Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA227].
36
PC600-8
40 Troubleshooting
SEN00448-02
PC600-8
37
SEN00448-02 Failure code [CA221] Ambient Press Sens High Error

Action code E15 Contents of trouble Action of controller Failure code CA221 Trouble Ambient Press Sens High Error (Engine controller system)
40 Troubleshooting
Signal voltage in atmospheric pressure sensor circuit is abnormally high. Sets atmospheric pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Problem that appears Output drops. on machine Related information Signal voltage of atmospheric pressure sensor can be checked with monitoring function. (Code: 37401 Atmospheric pressure sensor voltage) Cause Defective sensor power 1 supply system Standard value in normal state/Remarks on troubleshooting If failure code [CA187] or [CA227] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective atmospheric 2 pressure sensor (Internal trouble) PAMB Between (1) (2) Between (3) (2) Power supply Signal Voltage 4.75 5.25 V 0.5 4.5 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) PAMB (female) (1) and between Resistance Min. 1 Mz Short circuit in wiring har- ENG (female) (38) PAMB (female) (2) 3 ness (with another wiring Wiring harness between ENG (female) harness) (33) PAMB (female) (1) and between Resistance Min. 1 Mz ENG (female) (3) PAMB (female) (3) Wiring harness between ENG (female) (38) PAMB (female) (2) and between ENG (female) (3) PAMB (female) (3) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Wiring harness between ENG (female) (33) PAMB (female) (1) and chassis ground Voltage Max. 1 V
Hot short (Short circuit 4 with 24V circuit) in wiring Wiring harness between ENG (female) harness (38) PAMB (female) (2) and chassis ground Wiring harness between ENG (female) (3) PAMB (female) (3) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG Between (33) (38) Between (3) (38) Voltage 4.75 5.25 V 0.5 4.5 V
38
PC600-8
40 Troubleshooting
SEN00448-02
Circuit diagram related to atmospheric pressure sensor
PC600-8
39
SEN00448-02 Failure code [CA222] Ambient Press Sens Low Error

Action code E15 Contents of trouble Action of controller Failure code CA222 Trouble Ambient Press Sens Low Error (Engine controller system)
40 Troubleshooting
Signal voltage in atmospheric pressure sensor circuit is abnormally low. Sets atmospheric pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Problem that appears Output drops. on machine Related information Possible causes and standard value in normal state Signal voltage of atmospheric pressure sensor can be checked with monitoring function. (Code: 37401 Atmospheric pressure sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA221].
40
PC600-8
40 Troubleshooting
SEN00448-02
PC600-8
41
SEN00448-02 Failure code [CA227] Sens Supply 2 Volt High Error

Action code E15 Contents of trouble
40 Troubleshooting
Action of controller
Failure code Sens Supply 2 Volt High Error Trouble (Engine controller system) CA227 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. Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues 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. Limits output of bypass valve lift sensor and closes EGR valve and bypass valve.
Problem that appears Output drops. on machine Related information Cause Standard value in normal state/Remarks on troubleshooting 1 Defective related system If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Bkup speed sensor Oil pressure sensor Atmospheric Disconnect devices at right in order. If error pressure sensor code disappears when Charge presa device is disconsure sensor nected, that device EGR inlet preshas a defect in it. sure sensor EGR valve lift sensor Common rail pressure sensor G connector POIL connector PAMB PIM connector PEVA connector SEGR connector PFUEL connector
Defective sensor (Internal trouble)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness Wiring harness between ENG (female) 3 (with another wiring har- (37) each sensor (female) and between Resistance Min. 1 Mz ness) ENG (female) (47) each sensor (female) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit Wiring harness between ENG (female) (37) Voltage Max. 1 V 4 with 24V circuit) in wiring each sensor (female) and chassis ground harness Wiring harness between ENG (female) (47) Voltage Max. 1 V each sensor (female) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine control5 ler ENG Voltage Between (37) (47) 4.75 5.25 V
42
PC600-8
40 Troubleshooting
SEN00448-02
Circuit diagram related to sensor power supply 2 (5 V)
PC600-8
43
SEN00448-02 Failure code [CA234] Eng Overspeed

Action code Contents of trouble Action of controller Failure code CA234 Trouble Eng Overspeed (Engine controller system)
40 Troubleshooting
Engine speed is above operating range. Limits fuel injection rate until engine speed lowers to operating range.
Problem that appears Engine speed fluctuates. on machine Related information Cause Possible causes and standard value in normal state 1 Defective related system 2 Improper way of use 3 Defective engine controller Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. Way of use may be improper. Teach proper way of use to operator. If causes 1 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
44
PC600-8
40 Troubleshooting
SEN00448-02
Failure code [CA238] Ne Speed Sens Supply Volt Error

Action code E15 Contents of trouble Action of controller Failure code CA238 Trouble Ne Speed Sens Supply Volt Error (Engine controller system)
Abnormality occurred in Ne speed sensor power supply (5 V) circuit. 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). Related information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective Ne speed sen- Disconnect devices at right in order. If error code disapsor (Internal trouble) Ne speed pears when a device is dissensor connected, that device has a defect in it.
NE connector
Disconnection in wiring harness (Disconnection Wiring harness between ENG (female) 2 in wiring or defective con- (16) NE (female) (1) tact in connector) Wiring harness between ENG (female) (48) NE (female) (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Max. 1 z Resistance Max. 1 z
Ground fault in wiring 3 harness (Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) Resistance Min. 1 Mz (16) NE (female) (1) and chassis ground Wiring harness between ENG (female) Resistance Min. 1 Mz (48) NE (female) (2) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har4 ness (with another wiring Wiring harness between ENG (female) harness) (16) NE (female) (1) and between ENG Resistance Min. 1 Mz (female) (48) NE (female) (2) Defective engine control5 ler a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ENG Between (16) (48) Voltage 4.75 5.25 V
Circuit diagram related to Ne speed sensor power supply
PC600-8
45
SEN00448-02 Failure code [CA263] Fuel Temp Sensor High Error

Action code E15 Contents of trouble Action of controller Failure code CA263 Trouble Fuel Temp Sensor High Error (Engine controller system)
40 Troubleshooting
Signal voltage in fuel temperature sensor circuit is abnormally high. Fixes fuel temperature (90C) and continues operation.
Problem that appears on machine Related information Signal voltage of fuel temperature sensor can be checked with monitoring function. (Code: 14201 fuel temperature sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TFUEL (male) Between (A) (B) Fuel temperature 10 100C Resistance 0.6 20 kz
Defective fuel temperature sensor (Internal trouble)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (30) TFUEL (female) (A) connector) Wiring harness between ENG Resistance Max. 1 z (female) (47) TFUEL (female) (B) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between ENG circuit) Resistance Min. 1 Mz (female) (30) TFUEL (female) (A) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ENG (female) Between (30) (47) Fuel temperature 10 100C Resistance 0.6 20 kz
46
PC600-8
40 Troubleshooting
SEN00448-02
Circuit diagram related to fuel temperature sensor
PC600-8
47
SEN00448-02 Failure code [CA265] Fuel Temp Sensor Low Error

Action code E15 Contents of trouble Action of controller Failure code CA265 Trouble Fuel Temp Sensor Low Error (Engine controller system)
40 Troubleshooting
Signal voltage in fuel temperature sensor circuit is abnormally low. Fixes fuel temperature (90C) and continues operation.
Problem that appears on machine Related information Possible causes and standard value in normal state Signal voltage of fuel temperature sensor can be checked with monitoring function. (Code: 14201 fuel temperature sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA263].
48
PC600-8
40 Troubleshooting
SEN00448-02
Failure code [CA271] IMV/PCV1 Short Error

Action code E11 Contents of trouble Action of controller Failure code CA271 None in particular. Trouble IMV/PCV1 Short Error (Engine controller system)
There is short circuit in PCV1 circuit of supply pump.
Problem that appears on machine Related information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective supply pump PCV1 (Internal trouble) PCV1 (male) Between (1) (2) Between (1), (2) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (4) PCV1 (female) (1) and Resistance Min. 1 Mz 2 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (5) PCV1 (female) (2) and Resistance Min. 1 Mz chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage Voltage Max. 1 V Max. 1 V
Hot short (Short circuit with Wiring harness between ENG 3 24V circuit) in wiring har(female) (4) PCV1 (female) (1) ness Wiring harness between ENG (female) (5) PCV1 (female) (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ENG (female) Between (4) (5) Between (4), (5) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
Circuit diagram related to supply pump PCV1
PC600-8
49
SEN00448-02 Failure code [CA272] IMV/PCV1 Open Error

Action code E11 Contents of trouble Action of controller Failure code CA272 None in particular. Trouble IMV/PCV1 Open Error (Engine controller system)
40 Troubleshooting
There is disconnection in PCV1 circuit of supply pump.
Problem that appears on machine Related information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective supply pump 1 PCV1 (Internal disconnection) PCV1 (male) Between (1) (2) Between (1), (2) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (4) PCV1 (female) (1) connector) Wiring harness between ENG Resistance Max. 1 z (female) (5) PCV1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (4) PCV1 (female) (1) and Resistance Min. 1 Mz 3 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (5) PCV1 (female) (2) and Resistance Min. 1 Mz chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ENG (female) Between (4) (5) Between (4), (5) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
50
PC600-8
40 Troubleshooting
SEN00448-02
Failure code [CA273] PCV2 Short Error

Action code E11 Contents of trouble Action of controller Failure code CA273 None in particular. Trouble PCV2 Short Error (Engine controller system)
There is short circuit in PCV2 circuit of supply pump.
Problem that appears on machine Related information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective supply pump PCV2 (Internal trouble) PCV2 (male) Between (1) (2) Between (1), (2) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (9) PCV2 (female) (1) and Resistance Min. 1 Mz 2 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (10) PCV2 (female) (2) and Resistance Min. 1 Mz chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ENG Hot short (Short circuit with (female) (9) PCV2 (female) (1) and 3 24V circuit) in wiring harchassis ground ness Wiring harness between ENG (female) (10) PCV2 (female) (2) and chassis ground Voltage Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ENG (female) Between (9) (10) Between (9), (10) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
PC600-8
51
SEN00448-02 Failure code [CA274] PCV2 Open Error

Action code E11 Contents of trouble Action of controller Failure code CA274 None in particular. Trouble PCV2 Open Error (Engine controller system)
40 Troubleshooting
There is disconnection in PCV2 circuit of supply pump.
Problem that appears on machine Related information Cause Defective supply pump 1 PCV2 (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV2 (male) Between (1) (2) Resistance 2.3 5.3 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (9) PCV2 (female) (1) connector) Wiring harness between ENG Resistance Max. 1 z (female) (10) PCV2 (female) (2) Possible causes and standard value in normal state a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (9) PCV2 (female) (1) and Resistance Min. 1 Mz 3 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (10) PCV2 (female) (2) and Resistance Min. 1 Mz chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller ENG (female) Between (9) (10) Between (9), (10) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
52
PC600-8
40 Troubleshooting
SEN00448-02
PC600-8
53
SEN00448-02
40 Troubleshooting
54
SEN00449-02
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
40 Troubleshooting
Failure code [CA322] Inj #1 (L#1) Open/Short Error............................................................................................ 4 Failure code [CA323] Inj #5 (L#5) Open/Short Error............................................................................................ 6 Failure code [CA324] Inj #3 (L#3) Open/Short Error............................................................................................ 8 Failure code [CA325] Inj #6 (L#6) Open/Short Error.......................................................................................... 10 Failure code [CA331] Inj #2 (L#2) Open/Short Error.......................................................................................... 12 Failure code [CA332] Inj #4 (L#4) Open/Short Error.......................................................................................... 14 Failure code [CA342] Calibration Code Incompatibility...................................................................................... 16 Failure code [CA351] Injectors Drive Circuit Error ............................................................................................. 17 Failure code [CA352] Sens Supply 1 Volt Low Error ......................................................................................... 19 Failure code [CA386] Sens Supply 1 Volt High Error......................................................................................... 20 Failure code [CA441] Battery Voltage Low Error ............................................................................................... 22 Failure code [CA442] Battery Voltage High Error............................................................................................... 22 Failure code [CA449] Rail Press Very High Error .............................................................................................. 23 Failure code [CA451] Rail Press Sensor High Error .......................................................................................... 24 Failure code [CA452] Rail Press Sensor Low Error ........................................................................................... 26 Failure code [CA553] Rail Press High Error ...................................................................................................... 26 Failure code [CA554] Rail Press Sensor In Range Error ................................................................................... 27 Failure code [CA559] Rail Press Low Error ....................................................................................................... 28 Failure code [CA689] Eng Ne Speed Sensor Error............................................................................................ 32 Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................................................ 34
PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA757] All Persistent Data Lost Error .......................................................................................... 35 Failure code [CA778] Engine Bkup Speed Sensor Error ................................................................................... 36 Failure code [CA1228] EGR Valve Servo Error 1 .............................................................................................. 38 Failure code [CA1625] EGR Valve Servo Error 2 .............................................................................................. 39 Failure code [CA1626] BP Valve Sol Current High Error ................................................................................... 40 Failure code [CA1627] BP Valve Sol Current Low Error .................................................................................... 42 Failure code [CA1628] Bypass Valve Servo Error 1........................................................................................... 43 Failure code [CA1629] Bypass Valve Servo Error 2........................................................................................... 44 Failure code [CA1631] BP Valve Pos Sens High Error ...................................................................................... 45 Failure code [CA1632] BP Valve Pos Sens Low Error ....................................................................................... 47 Failure code [CA1633] KOMNET Datalink Timeout Error .................................................................................. 48 Failure code [CA1642] EGR Inlet Press Sens Low Error ................................................................................... 51 Failure code [CA1653] EGR Inlet Press Sens High Error .................................................................................. 52 Failure code [CA2185] Throt Sens Sup Volt High Error ..................................................................................... 54 Failure code [CA2186] Throt Sens Sup Volt Low Error...................................................................................... 56 Failure code [CA2249] Rail Press Very Low Error ............................................................................................. 57 Failure code [CA2271] EGR Valve Pos Sens High Error ................................................................................... 58 Failure code [CA2272] EGR Valve Pos Sens Low Error .................................................................................... 60 Failure code [CA2351] EGR Valve Sol Current High Error ................................................................................ 62 Failure code [CA2352] EGR Valve Sol Current Low Error ................................................................................. 64 Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................................................ 65 Failure code [CA2556] Grid Htr Relay Volt High Error ....................................................................................... 66
PC600-8
40 Troubleshooting
SEN00449-02
PC600-8
SEN00449-02 Failure code [CA322] Inj #1 (L#1) Open/Short Error

Action code E11 Contents of trouble Action of controller Failure code CA322 None in particular. Trouble Inj #1 (L#1) Open/Short Error (Engine controller system)
40 Troubleshooting
There is disconnection or short circuit in injector #1 circuit.
Problem that appears Output drops. on machine Related information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective injector #1 (Internal trouble) CN1 (male) Between (1) (2) Between (1), (2) chassis ground Resistance 0.4 1.1 z Min. 1M z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG 2 Resistance Max. 1 z ing or defective contact in (female) (45) CN1 (female) (1) connector) Wiring harness between ENG Resistance Max. 1 z (female) (53) CN1 (female) (2) Possible causes and standard value in normal state a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG Ground fault in wiring har(female) (45) CN1 (female) (1) and 3 ness (Short circuit with GND chassis ground circuit) Wiring harness between ENG (female) (53) CN1 (female) (2) and chassis ground 4 Defective another cylinder injector or wiring harness Resistance Min. 1 Mz
If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ENG (female) Between (45) (53) Between (45), (53) chassis ground
Resistance 0.4 1.1 z Min. 1 Mz
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to injector #1
PC600-8

40 Troubleshooting
Problem that appears Output drops. on machine Related information Different machine models may have different connector Nos. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective injector #5 (Internal trouble) CN5 (male) Between (1) (2) Between (1), (2) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
PC600-8
40 Troubleshooting
SEN00449-02
PC600-8

40 Troubleshooting
Problem that appears Output drops. on machine Related information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective injector #3 (Internal trouble) CN3 (male) Between (1) (2) Between (1), (2) chassis ground Resistance 0.4 1.1 z Min. 1M z
Resistance 0.4 1.1 z Min. 1M z
PC600-8
40 Troubleshooting
SEN00449-02
PC600-8

40 Troubleshooting
Problem that appears Output drops. on machine Related information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective injector #6 (Internal trouble) CN6 (male) Between (1) (2) Between (1), (2) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
10
PC600-8
40 Troubleshooting
SEN00449-02
PC600-8
11

40 Troubleshooting
12
PC600-8
40 Troubleshooting
SEN00449-02
PC600-8
13

40 Troubleshooting
14
PC600-8
40 Troubleshooting
SEN00449-02
PC600-8
15
SEN00449-02 Failure code [CA342] Calibration Code Incompatibility

Action code E10 Contents of trouble Action of controller Failure code CA342 None in particular. Trouble Calibration Code Incompatibility (Engine controller system)
40 Troubleshooting
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. Related information Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA111].
16
PC600-8
40 Troubleshooting
SEN00449-02
Failure code [CA351] Injectors Drive Circuit Error

Action code E10 Contents of trouble Action of controller Failure code CA351 Trouble Injectors Drive Circuit Error (Engine controller system)
Abnormality occurred in injector drive circuit. Limits output and continues operation (Limits common rail pressure).
Problem that appears Output drops. on machine Related information Cause 1 Defective related system Defective circuit breaker No.7 Standard value in normal state/Remarks on troubleshooting If another failure code (code of abnormality in injector system) is indicated, carry out troubleshooting for it. Check circuit breaker No.7 directly for defect. (If circuit breaker is turned OFF, circuit probably has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between CE03 3 Resistance Max. 1 z ing or defective contact in (female) (3) battery (+) connector) Wiring harness between CE03 Resistance Max. 1 z (female) (1) chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE03 Ground fault in wiring har(female) (3) battery (+) and chassis Resistance Min. 1 Mz 4 ness (Short circuit with GND ground circuit) Wiring harness between CE03 (female) (1) chassis ground and Resistance Min. 1 Mz chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller CE03 Between (3) (1) Voltage 20 30 V
PC600-8
17
SEN00449-02
Circuit diagram related to controller power supply
40 Troubleshooting
18
PC600-8
40 Troubleshooting
SEN00449-02
Failure code [CA352] Sens Supply 1 Volt Low Error

Action code E15 Contents of trouble Action of controller Failure code CA352 Trouble Sens Supply 1 Volt Low Error (Engine controller system)
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).
PC600-8
19
SEN00449-02 Failure code [CA386] Sens Supply 1 Volt High Error

Action code E15 Contents of trouble Action of controller Failure code CA386 Trouble Sens Supply 1 Volt High Error (Engine controller system)
40 Troubleshooting
Signal voltage in sensor power supply (5 V) circuit is abnormally high. Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. Limits output of bypass valve lift sensor and closes EGR valve and bypass valve.
Problem that appears Output drops. on machine Related information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective sensor (Inter2 nal trouble) Disconnect devices at Atmospheric right in order. If error pressure sensor code disappears when a device is disconnected, Bypass valve lift that device has a defect sensor in it. PAMB connector
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
SBP connector
Disconnection in wiring harness (Disconnection 3 in wiring or defective contact in connector) Possible causes and standard value in normal state Ground fault in wiring 4 harness (Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) each sensor (female) (5 V circuit) Resistance Max. 1 z
Wiring harness between ENG (female) Resistance Max. 1 z (38) each sensor (female) (ENG circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) each sensor (female) (5 V circuit) Resistance Min. 1 Mz
Wiring harness between ENG (female) Resistance Min. 1 Mz (38) each sensor (female) (ENG circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) each sensor (female) (5 V circuit) and between ENG (female) (38) each sensor (female) (ENG circuit) Resistance Min. 1 Mz
Short circuit in wiring 5 harness (with another wiring harness)
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine control6 ler ENG Voltage Between (33) (38) 4.75 5.25 V
20
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to sensor power supply 1 (5 V)
PC600-8
21
SEN00449-02 Failure code [CA441] Battery Voltage Low Error

Action code E10 Contents of trouble Action of controller Failure code CA441 None in particular. Trouble Battery Voltage Low Error (Engine controller system)
40 Troubleshooting
Power supply voltage is abnormally low.
Problem that appears Engine continues operation normally, but it may stop during operation or may not be able to on machine start. Related information Possible causes and standard value in normal state Signal voltage of power supply voltage can be checked with monitoring function. (Code: 03200 Power supply voltage) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA111].
Failure code [CA442] Battery Voltage High Error

Action code E10 Contents of trouble Action of controller Failure code CA442 None in particular. Trouble Battery Voltage High Error (Engine controller system)
Power supply voltage is abnormally high.
22
PC600-8
40 Troubleshooting
SEN00449-02
Failure code [CA449] Rail Press Very High Error

Action code E11 Contents of trouble Action of controller Failure code CA449 Trouble Rail Press Very High Error (Engine controller system)
Common rail pressure sensor circuit detected abnormally high pressure (level 2). Limits output and continues operation (Limits common rail pressure).
Problem that appears Output drops. on machine Related information Possible causes and standard value in normal state Signal voltage of common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA553].
PC600-8
23
SEN00449-02 Failure code [CA451] Rail Press Sensor High Error

Action code E11 Contents of trouble Action of controller Failure code CA451 Trouble Rail Press Sensor High Error (Engine controller system)
40 Troubleshooting
Signal voltage in common rail pressure sensor circuit is abnormally high. Limits output and continues operation (Limits common rail pressure).
Problem that appears Output drops. on machine Related information Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure voltage) Cause 1 Defective sensor power supply Standard value in normal state/Remarks on troubleshooting If failure code [CA352] or [CA386] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. PFUEL Defective common rail 2 pressure sensor (Internal trouble) Between (1) (3) Between (2) (3) Power supply Signal Voltage 4.75 5.25 V 0.25 4.6 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection 3 in wiring or defective contact in connector) Wiring harness between ENG (female) (37) PFUEL (female) (1) Wiring harness between ENG (female) (25) PFUEL (female) (2) Wiring harness between ENG (female) (47) PFUEL (female) (3) Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) PFUEL (female) (1) and between Resistance Min. 1 Mz Short circuit in wiring har- ENG (female) (25) PFUEL (female) (2) 4 ness (with another wiring Wiring harness between ENG (female) harness) (37) PFUEL (female) (1) and between Resistance Min. 1 Mz ENG (female) (47) PFUEL (female) (3) Wiring harness between ENG (female) (25) PFUEL (female) (2) and between Resistance Min. 1 Mz ENG (female) (47) PFUEL (female) (3) a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 5 Defective engine controller ENG Between (37) (47) Between (25) (47) Voltage 4.75 5.25 V 0.25 4.6 V
24
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to common rail pressure sensor
PC600-8
25
SEN00449-02 Failure code [CA452] Rail Press Sensor Low Error

Action code E11 Contents of trouble Action of controller Failure code CA452 Trouble Rail Press Sensor Low Error (Engine controller system)
40 Troubleshooting
Signal voltage in common rail pressure sensor circuit is abnormally low. Limits output and continues operation (Limits common rail pressure).
Problem that appears Output drops. on machine Related information Possible causes and standard value in normal state Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure voltage) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA451].
Failure code [CA553] Rail Press High Error

Action code E15 Contents of trouble Action of controller Failure code CA553 None in particular. Trouble Rail Press High Error (Engine controller system)
Common rail pressure sensor circuit detected abnormally high pressure (level 1).
Problem that appears Output drops. on machine Related information Signal voltage of common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) Cause 1 Defective related system 2 Use of improper fuel Defective electrical system 3 of common rail pressure sensor Defective mechanical sys4 tem of common rail pressure sensor 5 Defective overflow valve Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. Check fuel used directly (for high viscosity). Common rail pressure sensor may have electric trouble. Carry out troubleshooting for code [CA451]. Check mechanical system of common rail pressure sensor directly. Check overflow valve directly for broken spring, worn seat, and stuck ball. Check pressure limiter directly for mechanical defect.
6 Clogging of overflow piping Check overflow piping directly for clogging. 7 Defective pressure limiter
26
PC600-8
40 Troubleshooting
SEN00449-02
Failure code [CA554] Rail Press Sensor In Range Error

Action code Contents of trouble Action of controller Failure code CA554 Trouble Rail Press Sensor In Range Error (Engine controller system)
In-range error occurred in common rail pressure sensor circuit. Limits output and continues operation (Limits common rail pressure).
PC600-8
27
SEN00449-02 Failure code [CA559] Rail Press Low Error

Action code E15 Contents of trouble Action of controller Failure code CA559 Trouble Rail Press Low Error (Engine controller system)
40 Troubleshooting
Supply pump does not feed fuel (level 1). Limits common rail pressure.
Problem that appears Output drops. on machine Related information Cause 1 Defective related system 2 Use of improper fuel Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. 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 Adjusting, Testing fuel pressure. Pressure in fuel low-pressure circuit Min. 0.15 MPa {Min. 1.5 kg/cm2}
Defective low-pressure circuit device
4 Clogging of filter/strainer 5 Defective electrical system of supply pump PCV
a For contents of troubleshooting, see Note 2. Supply pump PCV may have electric trouble. Carry out troubleshooting for following codes; [CA271], [CA272], [CA273], [CA274].
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring sure sensor harness for damage. a For testing of leakage from pressure limiter, see Testing 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. Speed at rated operation Return (Spill) limit from injector 960 cc/min 1,020 cc/min 1,080 cc/min 1,140 cc/min 1,200 cc/min
7 Defective pressure limiter
8 Defective injector
1,600 rpm 1,700 rpm 1,800 rpm 1,900 rpm 2,000 rpm
9 Defective supply pump
If causes 1 8 are not detected, supply pump may be defective.
<How to use check sheet> Carry out the above troubleshooting and take a record of the contents of the attached Check sheet for no-pressure feed.
28
PC600-8
40 Troubleshooting
SEN00449-02
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
29
SEN00449-02
Check sheet for no-pressure feed
Model Machine serial No. Engine Engine serial No. A. Visual check 1 Fuel leakage to outside 2 Clogging of fuel tank breather # # Work No. Date of check Service meter Worker's name /
40 Troubleshooting
/ h
Good NG
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) 3 Check of failure code / / / / Check of monitoring information Standard value Code Displayed item Checking condition Unit Measured value (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 presMPa 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 Measured value Function Reduced cylinder Checking condition Unit (Reference value) No. 1 cylinder Low idle rpm No. 2 cylinder Low idle rpm 5 No. 3 cylinder Low idle rpm *10 No. 4 cylinder Low idle rpm No. 5 cylinder Low idle rpm No. 6 cylinder Low idle rpm Standard value (Reference value) MPa Min. 0.15 MPa {kg/cm2} {Min. 1.5 kg/cm2} Unit
Good NG
Good NG
Good NG
C. Check of fuel circuit pressure 6 Fuel low-pressure circuit presHigh idle sure
Checking condition
Measured value
Good NG
D. Check of strainers and filters 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 Checking condition return rate Leakage through pressure lim11 At rated output (pump relief) iter Equivalent to rating 1,600 rpm Equivalent to rating 1,700 rpm 12 Return rate from injector Equivalent to rating 1,800 rpm Equivalent to rating 1,900 rpm Equivalent to rating 2,000 rpm Standard value (Reference value) Max. 10 960 1,020 1,080 1,140 1,200 Speed:
Good NG
Unit cc/min cc/min cc/min cc/min cc/min cc/min
Measured value
Good NG
Return rate:
30
PC600-8
40 Troubleshooting
SEN00449-02
*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
31
SEN00449-02 Failure code [CA689] Eng Ne Speed Sensor Error

Action code E11 Contents of trouble Action of controller Failure code CA689 Trouble Eng Ne Speed Sensor Error (Engine controller system)
40 Troubleshooting
Abnormality occurred in engine Ne speed sensor circuit. 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). Related information Cause 1 Defective sensor power supply system Standard value in normal state/Remarks on troubleshooting If failure code [CA238] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector) Wiring harness between ENG (female) (16) NE (female) (1) Wiring harness between ENG (female) (48) NE (female) (2) Wiring harness between ENG (female) (27) NE (female) (3) Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (16) NE (female) (1) and chassis ground Wiring harness between ENG (female) (48) NE (female) (2) and chassis ground Wiring harness between ENG (female) (27) NE (female) (3) and chassis ground Resistance Min. 1 Mz
Ground fault in wiring 3 harness (Short circuit with GND circuit) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (16) NE (female) (1) and between Short circuit in wiring har- ENG (female) (48) NE (female) (2) 4 ness (with another wiring Wiring harness between ENG (female) harness) (16) NE (female) (1) and between ENG (female) (27) NE (female) (3) Wiring harness between ENG (female) (48) NE (female) (2) and between ENG (female) (27) NE (female) (3) 5 Defective engine Ne speed sensor Resistance Min. 1 Mz
If causes 1 4 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
If causes 1 4 are not detected, engine controller may be defecDefective engine controltive. (Since trouble is in system, troubleshooting cannot be carler ried out.)
32
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to engine Ne speed sensor
PC600-8
33
SEN00449-02 Failure code [CA731] Eng Bkup Speed Sens Phase Error
Action code E11 Contents of trouble Action of controller Failure code CA731 Trouble Eng Bkup Speed Sens Phase Error (Engine controller system)
40 Troubleshooting
Engine Bkup sensor circuit detected abnormality in phase. 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). Related information Cause Possible causes and standard value in normal state 1 2 Standard value in normal state/Remarks on troubleshooting
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out troublesensor system shooting for failure code [CA698]. Defective engine Bkup speed sensor system Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure code [CA778].
34
PC600-8
40 Troubleshooting
SEN00449-02
Failure code [CA757] All Persistent Data Lost Error

Action code E10 Contents of trouble Action of controller Failure code CA757 None in particular. Trouble All Persistent Data Lost Error (Engine controller system)
All data in engine controller are lost.
PC600-8
35
SEN00449-02 Failure code [CA778] Engine Bkup Speed Sensor Error

Action code E11 Contents of trouble Action of controller Failure code CA778 Trouble Engine Bkup Speed Sensor Error (Engine controller system)
40 Troubleshooting
Abnormality occurred in engine Bkup speed sensor circuit. Operates with signals of Ne speed sensor. Limits output and continues operation.
Output drops. 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). Related information Cause Defective sensor power 1 supply system Standard value in normal state/Remarks on troubleshooting If failure code [CA187] or [CA227] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector) Wiring harness between ENG (female) (37) G (female) (1) Wiring harness between ENG (female) (47) G (female) (2) Wiring harness between ENG (female) (26) G (female) (3) Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) G (female) (1) and chassis ground Wiring harness between ENG (female) (47) G (female) (2) and chassis ground Wiring harness between ENG (female) (26) G (female) (3) and chassis ground Resistance Min. 1 Mz
Ground fault in wiring 3 harness (Short circuit with GND circuit) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) G (female) (1) and between ENG Resistance Min. 1 Mz Short circuit in wiring har- (female) (47) G (female) (2) 4 ness (with another wiring Wiring harness between ENG (female) harness) (37) G (female) (1) and between ENG Resistance Min. 1 Mz (female) (26) G (female) (3) Wiring harness between ENG (female) (47) G (female) (2) and between ENG Resistance Min. 1 Mz (female) (26) G (female) (3) 5 Defective engine Bkup speed sensor If causes 1 4 are not detected, engine Bkup speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
If causes 1 5 are not detected, engine controller may be defecDefective engine controltive. (Since trouble is in system, troubleshooting cannot be carler ried out.)
36
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to engine Bkup speed sensor
PC600-8
37
SEN00449-02 Failure code [CA1228] EGR Valve Servo Error 1

Action code E15 Contents of trouble Action of controller Failure code CA1228 Trouble EGR Valve Servo Error 1 (Engine controller system)
40 Troubleshooting
Abnormality (level 1) occurred in EGR valve servo. Performs open control.
Problem that appears on machine Related information Cause 1 Defective related system Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a For measurement of EGR valve drive pressure, see Testing and adjusting, Testing EGR valve and bypass valve drive oil pressure 2 Improper EGR valve drive pressure Engine speed Low idle High idle EGR valve drive pressure Min.1.18 MPa {Min.12 kg/cm2} Min.1.43 MPa {Min.14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 4 and 5. a For check of engine oil pressure, see Testing and adjusting, Testing engine oil pressure. Possible causes and standard value in normal state Engine speed 3 Defective engine oil pressure system (main circuit) Low idle High idle Engine oil pressure Min.0.08 MPa {Min.0.8 kg/cm2} Min.0.21 MPa {Min.2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting of engine (S-12 Oil pressure lowers). 4 5 6 Defective oil pump for EGR Check oil pump and relief valve for EGR valve circuit directly. valve Defective oil feed piping for Check oil feed piping for EGR valve circuit directly. EGR valve Defective oil return piping for EGR valve Check oil return piping for EGR valve circuit directly. Check mechanical section of EGR valve directly. If causes 1 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
7 Defective EGR valve 8 Defective engine controller
38
PC600-8
40 Troubleshooting
SEN00449-02
Failure code [CA1625] EGR Valve Servo Error 2

Action code E11 Contents of trouble Action of controller Failure code CA1625 Trouble EGR Valve Servo Error 2 (Engine controller system)
Abnormality (level 2) occurred in EGR valve servo. Limits output and continues operation. Closes EGR valve and bypass valve.
PC600-8
39
SEN00449-02 Failure code [CA1626] BP Valve Sol Current High Error

Action code E11 Contents of trouble Action of controller Failure code CA1626 Trouble BP Valve Sol Current High Error (Engine controller system)
40 Troubleshooting
There is short circuit in drive circuit of bypass valve solenoid. Limits output and continues operation. Closes EGR valve and bypass valve.
Problem that appears Output drops. on machine Related information Cause Defective bypass valve 1 solenoid (Internal trouble) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BP (male) Between (1) (2) Resistance 10 21 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between ENG (female) 2 Resistance Max. 1 z in wiring or defective con- (31) BP (female) (1) tact in connector) Wiring harness between ENG (female) Resistance Max. 1 z (11) BP (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Ground fault in wiring 3 harness (Short circuit with GND circuit) Wiring harness between ENG (female) (31) BP (female) (1) and chassis ground Wiring harness between ENG (female) (11) BP (female) (2) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ENG (female) Hot short (Short circuit (31) BP (female) (1) and chassis 4 with 24V circuit) in wiring ground harness Wiring harness between ENG (female) (11) BP (female) (2) and chassis ground Voltage Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine control5 ler ENG (female) Resistance Between (31) (11) 10 21 z
40
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to bypass valve solenoid & lift sensor
PC600-8
41
SEN00449-02 Failure code [CA1627] BP Valve Sol Current Low Error

Action code E11 Contents of trouble Action of controller Failure code CA1627 Trouble BP Valve Sol Current Low Error (Engine controller system)
40 Troubleshooting
There is disconnection in drive circuit of bypass valve solenoid. Limits output and continues operation. Closes EGR valve and bypass valve.
42
PC600-8
40 Troubleshooting
SEN00449-02
Failure code [CA1628] Bypass Valve Servo Error 1

Action code E15 Contents of trouble Action of controller Failure code CA1628 Trouble Bypass Valve Servo Error 1 (Engine controller system)
Abnormality (level 1) occurred in bypass valve servo. Performs open control.
Problem that appears on machine Related information Cause 1 Defective related system Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a For measurement of bypass valve drive pressure, see Testing and adjusting, Testing EGR valve and bypass valve drive oil pressure Engine speed 2 Improper bypass valve drive pressure Low idle High idle Bypass valve drive pressure Min.1.18 MPa {Min.12 kg/cm2} Min.1.43 MPa {Min.14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 4 and 5. Possible causes and standard value in normal state a For check of engine oil pressure, see TESTING AND ADJUSTING, Testing engine oil pressure. Engine 3 Defective engine oil pressure system (main circuit) Low idle High idle Engine oil pressure Min.0.08 MPa {Min.0.8 kg/cm2} Min.0.21 MPa {Min.2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting for mechanical system (S-12 Oil pressure lowers). 4 5 6 Defective oil pump for bypass valve Check oil pump and relief valve for bypass valve circuit directly.
Defective oil feed piping for Check oil feed piping for bypass valve circuit directly. bypass valve Defective oil return piping for bypass valve Check oil return piping for bypass valve circuit directly. Check mechanical section of bypass valve directly. If causes 1 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
7 Defective bypass valve 8 Defective engine controller
PC600-8
43
SEN00449-02 Failure code [CA1629] Bypass Valve Servo Error 2

Action code E11 Contents of trouble Action of controller Failure code CA1629 Trouble Bypass Valve Servo Error 2 (Engine controller system)
40 Troubleshooting
Abnormality (level 2) occurred in bypass valve servo. Limits output and continues operation. Closes EGR valve and bypass valve.
44
PC600-8
40 Troubleshooting
SEN00449-02
Failure code [CA1631] BP Valve Pos Sens High Error

Action code E11 Contents of trouble Action of controller Failure code CA1631 Trouble BP Valve Pos Sens High Error (Engine controller system)
Signal voltage in bypass valve lift sensor circuit is abnormally high. Limits output and continues operation. Closes EGR valve and bypass valve.
Problem that appears Output drops. on machine Related information Signal voltage of bypass valve position sensor can be checked with monitoring function. (Code: 18200 Bypass valve position sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting
Defective sensor power If failure code [CA187] or [CA227] is indicated, carry out trouble1 supply shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective bypass valve 2 lift sensor (Internal trouble) SBP Between (1) (2) Power supply Voltage 4.75 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 3 in wiring or defective contact in connector)
Wiring harness between ENG (female) (33) SBP (female) (1) Wiring harness between ENG (female) (38) SBP (female) (2) Wiring harness between ENG (female) (29) SBP (female) (3), (4)
Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 4 harness (Short circuit with GND circuit) Wiring harness between ENG (female) (33) SBP (female) (1) Wiring harness between ENG (female) (38) SBP (female) (2) Wiring harness between ENG (female) (29) SBP (female) (3), (4) Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) SBP (female) (1) and between ENG Resistance Min. 1 Mz (female) (38) SBP (female) (2) Wiring harness between ENG (female) (33) SBP (female) (1) and between ENG Resistance Min. 1 Mz (female) (29) SBP (female) (3), (4) Wiring harness between ENG (female) (38) SBP (female) (2) and between ENG Resistance Min. 1 Mz (female) (29) SBP (female) (3), (4) Defective engine controller a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG Between (33) (38) Voltage 4.75 5.25 V
PC600-8
45
SEN00449-02
Circuit diagram related to bypass valve solenoid & lift sensor
40 Troubleshooting
46
PC600-8
40 Troubleshooting
SEN00449-02
Failure code [CA1632] BP Valve Pos Sens Low Error

Action code E11 Contents of trouble Action of controller Failure code CA1632 Trouble BP Valve Pos Sens Low Error (Engine controller system)
Signal voltage in bypass valve lift sensor circuit is abnormally low. Limits output and continues operation. Closes EGR valve and bypass valve.
Problem that appears Output drops. on machine Related information Possible causes and standard value in normal state Signal voltage of bypass valve lift sensor can be checked with monitoring function. (Code: 18200 Bypass valve lift sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA1631].
PC600-8
47
SEN00449-02 Failure code [CA1633] KOMNET Datalink Timeout Error

Action code E0E Failure content Failure Code CA1633 Failure phenomenon KOMNET Datalink Timeout Error (Engine controller system)
40 Troubleshooting
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
Cause Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF and hold it in the OFF position during the troubleshooting.
Wiring harness between CM03 (female) (16) and CE02 (female) (47) or between CM03 (female) (16) and CP02 (female) (22) Wiring harness between CM03 (female) (15) and CE02 (female) (46) or between CM03 (female) (15) and CP02 (female) (32)
Resistance value Resistance value
Max. 1 z
Max. 1 z
a Prepare with starting switch OFF and hold it in the OFF position during the troubleshooting. Ground fault of wiring harness 2 (Contact with ground circuit) Between wiring harness between CM03 (female) (16) and CE02 (female) (47) or between CM03 (female) (16) and CP02 (female) (22) or between CM03 (female) (16) and related circuits and ground Between wiring harness between CM03 (female) (15) and CE02 (female) (46) or between CM03 (female) (15) and CP02 (female) (32) or between CM03 (female) (15) and related circuits and ground Resistance value Min. 1 Mz
Resistance value
Min. 1 Mz
a Prepare with starting switch OFF and hold it in the ON position during the troubleshooting. Between wiring harness between CM03 (female) (16) and CE02 (female) (47) or between CM03 (female) (16) and CP02 (female) (22) or between CM03 (female) (16) and related circuits and ground Between wiring harness between CM03 (female) (15) and CE02 (female) (46) or between CM03 (female) (15) and CP02 (female) (32) or between CM03 (female) (15) and related circuits and ground CAN terminal resistor defective
Short-circuiting of wiring 3 harness (Contact with 24 V circuit)
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF and hold it in the OFF position during the troubleshooting. K02 (male), K03 (male) Between (1) and (2) Voltage 40 80 z
Machine monitor, engine 5 controller, or pump controller defective
If causes 1 4 are not detected, machine monitor, engine controller, or pump controller may be defective. (Since trouble is in those devices, troubleshooting cannot be carried out.)
48
PC600-8
40 Troubleshooting
SEN00449-02
Electrical circuit diagram related to CAN communication
PC600-8
49
SEN00449-02
40 Troubleshooting
50
PC600-8
40 Troubleshooting
SEN00449-02
Failure code [CA1642] EGR Inlet Press Sens Low Error

Serial numbers : 30001 30070
Action code E11 Contents of trouble Action of controller Failure code CA1642 EGR Inlet Press Sens Low Error (Engine controller system)
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. Limits output and continues operation.
Problem that appears Output drops. on machine Related information Possible causes and standard value in normal state Signal voltage of EGR inlet pressure sensor can be checked with monitoring function. (Code: 18001 EGR inlet sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA1653].
PC600-8
51
SEN00449-02 Failure code [CA1653] EGR Inlet Press Sens High Error
Serial numbers : 30001 30070
Action code E11 Contents of trouble Action of controller Failure code CA1653 Trouble EGR Inlet Press Sens High Error (Engine controller system)
40 Troubleshooting
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. Limits output and continues operation.
Problem that appears Output drops. on machine Related information Signal voltage of EGR inlet pressure sensor can be checked with monitoring function. (Code: 18001 EGR inlet pressure sensor voltage) Cause 1 Defective sensor power supply Standard value in normal state/Remarks on troubleshooting If failure code [CA187] or [CA227] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective EGR inlet pres2 sure sensor (Internal trouble) PEVA Between (1) (2) Power supply Voltage 4.75 5.25 V
Disconnection in wiring harness (Disconnection 3 in wiring or defective contact in connector)
Wiring harness between ENG (female) (37) PEVA (female) (1) Wiring harness between ENG (female) (47) PEVA (female) (2) Wiring harness between ENG (female) (20) PEVA (female) (3)
Resistance Max. 1 z Resistance Max. 1z
Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 4 harness (Short circuit with GND circuit) Wiring harness between ENG (female) (37) Resistance Min. 1 Mz PEVA (female) (1) and chassis ground Wiring harness between ENG (female) (47) Resistance Min. 1 Mz PEVA (female) (2) and chassis ground Wiring harness between ENG (female) (20) Resistance Min. 1 Mz PEVA (female) (3) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) PEVA (female) (1) and between Short circuit in wiring har- ENG (female) (47) PEVA (female) (2) 5 ness (with another wiring Wiring harness between ENG (female) harness) (37) PEVA (female) (1) and between ENG (female) (20) PEVA (female) (3) Wiring harness between ENG (female) (47) PEVA (female) (2) and between ENG (female) (20) PEVA (female) (3) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective engine control6 ler ENG Voltage Between (37) (47) 4.75 5.25 V
52
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to EGR inlet pressure sensor
PC600-8
53
SEN00449-02 Failure code [CA2185] Throt Sens Sup Volt High Error
Action code E14 Contents of trouble Action of controller Failure code CA2185 Trouble Throt Sens Sup Volt High Error (Engine controller system)
40 Troubleshooting
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.
Problem that appears on machine Related information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 1 Defective accelerator pedal (Internal trouble) Disconnect devices at right in order. If failure code disappears when a device is disconnected, that device has a defect in it.
Fuel control dial
P20 connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Short circuit in wiring 2 harness (with another wiring harness) Wiring harness between CE02 (female) (22) P20 (female) (1) and between CE02 (female) (23) P20 (female) (3) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CE02 (female) (22) P20 (female) (1) and chassis ground Hot short (Short circuit 3 with 24V circuit) in wiring harness Wiring harness between CE02 (female) (23) P20 (female) (3) and chassis ground Voltage Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller CE02 Between (22) (23) Voltage 4.75 5.25 V
54
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to throttle sensor of fuel control dial type
PC600-8
55
SEN00449-02 Failure code [CA2186] Throt Sens Sup Volt Low Error
Action code E14 Contents of trouble Action of controller Failure code CA2186 Trouble Throt Sens Sup Volt Low Error (Engine controller system)
40 Troubleshooting
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low. Sets throttle angle with signal other than throttle sensor signal and continues operation.
Problem that appears on machine Related information Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA2185].
56
PC600-8
40 Troubleshooting
SEN00449-02
Failure code [CA2249] Rail Press Very Low Error

Action code E11 Contents of trouble Action of controller Failure code CA2249 Trouble Rail Press Very Low Error (Engine controller system)
Supply pump does not feed fuel (level 2). Limits common rail pressure.
PC600-8
57
SEN00449-02 Failure code [CA2271] EGR Valve Pos Sens High Error
Action code E11 Contents of trouble Action of controller Failure code CA2271 Trouble EGR Valve Pos Sens High Error (Engine controller system)
40 Troubleshooting
Signal voltage in EGR valve lift sensor circuit is abnormally high. Limits output and continues operation. Closes EGR valve and bypass valve.
Problem that appears Output drops. on machine Related information Signal voltage of EGR valve lift sensor can be checked with monitoring function. (Code: 18101 EGR valve lift sensor voltage) Cause Defective sensor 1 power supply Standard value in normal state/Remarks on troubleshooting If failure code [CA187] or [CA227] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective EGR valve 2 lift sensor (Internal trouble) SEGR Between (1) (2) Power supply Voltage 4.75 5.25V
Disconnection in wiring harness (Disconnec3 tion in wiring or defective contact in connector)
Wiring harness between ENG (female) (37) Resistance Max. 1 z SEGR (female) (1) Wiring harness between ENG (female) (47) Resistance Max. 1 z SEGR (female) (2) Wiring harness between ENG (female) (19) Resistance Max. 1 z SEGR (female) (3), (4) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring 4 harness (Short circuit with GND circuit)
Wiring harness between ENG (female) (37) Resistance Min. 1 Mz SEGR (female) (1) and chassis ground Wiring harness between ENG (female) (47) Resistance Min. 1 Mz SEGR (female) (2) and chassis ground Wiring harness between ENG (female) (19) SEGR (female) (3), (4) and chassis Resistance Min. 1 Mz ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) SEGR (female) (1) and between ENG Resistance Min. 1 Mz (female) (47) SEGR (female) (2) Wiring harness between ENG (female) (37) SEGR (female) (1) and between ENG Resistance Min. 1 Mz (female) (19) SEGR (female) (3), (4) Wiring harness between ENG (female) (47) SEGR (female) (2) and between ENG Resistance Min. 1 Mz (female) (19) SEGR (female) (3), (4)
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG Between (37) (47) Voltage 4.75 5.25 V
58
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to EGR valve solenoid & lift sensor
PC600-8
59
SEN00449-02 Failure code [CA2272] EGR Valve Pos Sens Low Error
Action code E11 Contents of trouble Action of controller Failure code CA2272 Trouble EGR Valve Pos Sens Low Error (Engine controller system)
40 Troubleshooting
Signal voltage in EGR valve lift sensor circuit is abnormally low. Limits output and continues operation. Closes EGR valve and bypass valve.
Problem that appears Output drops. on machine Related information Possible causes and standard value in normal state Signal voltage of EGR valve lift sensor can be checked with monitoring function. (Code: 18101 EGR valve lift sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA2271].
60
PC600-8
40 Troubleshooting
SEN00449-02
PC600-8
61
SEN00449-02 Failure code [CA2351] EGR Valve Sol Current High Error
Action code E11 Contents of trouble Action of controller Failure code CA2351 Trouble EGR Valve Sol Current High Error (Engine controller system)
40 Troubleshooting
There is short circuit in drive circuit of EGR valve solenoid. Limits output and continues operation. Closes EGR valve and bypass valve.
Problem that appears Output drops. on machine Related information Cause Defective EGR valve 1 solenoid (Internal trouble) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. EGR (male) Between (1) (2) Resistance 10 21 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between ENG (female) 2 Resistance Max. 1 z in wiring or defective con- (22) EGR (female) (1) tact in connector) Wiring harness between ENG (female) Resistance Max. 1 z (11) EGR (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Ground fault in wiring 3 harness (Short circuit with GND circuit) Wiring harness between ENG (female) (22) EGR (female) (1) and chassis ground Wiring harness between ENG (female) (11) EGR (female) (2) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ENG (female) Hot short (Short circuit (22) EGR (female) (1) and chassis 4 with 24V circuit) in wiring ground harness Wiring harness between ENG (female) (11) EGR (female) (2) and chassis ground Voltage Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine control5 ler ENG (female) Resistance Between (22) (11) 10 21 z
62
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to EGR valve solenoid & lift sensor
PC600-8
63
SEN00449-02 Failure code [CA2352] EGR Valve Sol Current Low Error
Action code E11 Contents of trouble Action of controller Failure code CA2352 Trouble EGR Valve Sol Current Low Error (Engine controller system)
40 Troubleshooting
There is disconnection in drive current of EGR valve solenoid. Limits output and continues operation. Closes EGR valve and bypass valve.
64
PC600-8
40 Troubleshooting
SEN00449-02
Failure code [CA2555] Grid Htr Relay Volt Low Error

Action code E15 Contents of trouble Action of controller Failure code CA2555 None in particular. Trouble Grid Htr Relay Volt Low Error (Engine controller system)
There is low voltage error in intake air heater relay circuit.
Problem that appears Engine does not start easily at low temperature. on machine Related information Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA2556].
PC600-8
65
SEN00449-02 Failure code [CA2556] Grid Htr Relay Volt High Error
Action code E15 Contents of trouble Action of controller Failure code CA2556 None in particular. Trouble Grid Htr Relay Volt High Error (Engine controller system)
40 Troubleshooting
There is high voltage error in intake air heater relay circuit.
Problem that appears Engine does not start easily at low temperature. on machine Related information Cause Defective intake air 1 heater relay (Internal trouble) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R18 (male) Between (1) (2) Disconnection in wiring harness (Disconnection Wiring harness between CE02 (female) 2 in wiring or defective con- (40) R18 (female) (1) tact in connector) Wiring harness between CE02 (female) (42) R18 (female) (2) Possible causes and standard value in normal state Resistance 200 400 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Max. 1 z Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 3 harness (Short circuit with GND circuit) Wiring harness between CE02 (female) (40) R18 (female) (1) and chassis ground Wiring harness between CE02 (female) (42) R18 (female) (2) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller CE02 Heater relay Under operating condition Under stopping condition Voltage Max. 1 V 20 30 V
Between (40) (42)
66
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to intake air heater
PC600-8
67
SEN00449-02
40 Troubleshooting
68
SEN00450-01
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
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 Failure code [DW7BKA] Fan Reverse Sol. Disc. ............................................................................................... 40
PC600-8
SEN00450-01
40 Troubleshooting
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
PC600-8
40 Troubleshooting
SEN00450-01
PC600-8
SEN00450-01 Failure code [D110KB] Battery Relay Drive S/C

Action code Failure content Failure code D110KB Failure phenomenon Battery Relay Drive S/C (Pump controller system)
40 Troubleshooting
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 machine Relative information There may be a trouble in writing data into the ROM (non-volatile memory) of each controller. Operation of the battery relay (ON or OFF) can be checked in the monitoring function. (Code No. 03700: Controller output 1) Cause Battery relay defective 1 (Internal short-circuiting or grounding fault) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Battery relay (Unit) Between BR and E Between BR and grounding Grounding fault of wiring harness 2 (Contact with grounding circuit) Resistance value Approx. 100 z Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CP03 (female) (4), D01, J01, battery relay terminal BR or between CP03 (female) (4) and starting switch terminal BR or between CP03 (female) (4) and D01 (female) (2) and grounding Resistance value Min. 1 Mz
Pump controller defective
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CP03 (female) Between (4) and grounding Starting switch ON o OFF Voltage 20 30 V (For 0.5 sec)
a S/C: Short circuit
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to battery relay drive
PC600-8
SEN00450-01 Failure code [D163KB] Flash Light Relay S/C

Action code Failure content Failure code D163KB Failure phenomenon Flash Light Relay S/C (Pump controller system)
40 Troubleshooting
Abnormal current flowed in the flash light relay circuit (the primary circuit of the relay), when power is 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 machine Relative information The flash light does not flash. Operation of the flash light relay circuit (the primary side of the relay) (ON or OFF) can be checked in the monitoring function. (Code No. 03701: Controller output 2) This error code detects abnormality on the primary (coil) side of the flash light relay and cannot detect abnormality on the secondary (contact) side. Cause Standard value in normalcy and references for troubleshooting
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Flash light relay defective 1 (Internal short-circuiting) R10 (male) Resistance value Presumed cause and standard value in normalcy Between (1) and (2) Grounding fault of wiring harness 2 (Contact with grounding circuit) 250 350 z a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CP03 (female) (18) and R10 (female) (1) and grounding Resistance valve Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Pump controller defective CP03 Between (18) and grounding Horn switch ON OFF Voltage 20 30 V Max. 1 V (at constant cycle, 5 seconds) Max. 1 V
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to horn and flash light
PC600-8
SEN00450-01 Failure code [D195KB] Step Light Relay S/C

Action code Failure content Failure code D195KB Failure phenomenon Step Light Relay S/C (Pump controller system)
40 Troubleshooting
Abnormal current flowed in the step light relay circuit (the primary circuit of the relay), when power is supplied to the circuit.
Power to the step light relay circuit is switched OFF. 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 machine Relative information Step light does not light up. Operation of the step light relay circuit (the primary side of the relay) (ON or OFF) can be checked in the monitoring function. (Code No. 03701: Controller output 2) This error code detects abnormality on the primary (coil) side of the step light relay and cannot detect abnormality on the secondary (contact) side. Cause Step light relay defective (Internal short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R09 (male) Between (2) and (1) Grounding fault of wiring harness 2 (Contact with grounding circuit) Resistance value 250 350 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CP02 (female) (19) and R09 (female) (2) and grounding Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 3 Pump controller defective CP02 Between (19) and grounding Step light switch ON OFF Voltage 20 30 V (Kept for 60 sec) Max. 1 V
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to step light
PC600-8
SEN00450-01 Failure code [DA25KP] Press. Sensor Power Abnormality

Action code Failure content Failure code DA25KP Failure phenomenon Press. Sensor Power Abnormality (Pump controller system)
40 Troubleshooting
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. controller If cause of failure disappears, system resets itself. Phenomenon occurring on machine Relative information The pressure sensor signal is not input normally. The error code of abnormality in the pressure sensor is displayed, too. Cause Standard value in normalcy and references for troubleshooting a Disconnect the connector when the engine starting switch is in OFF, and hold it in the ON position during the troubleshooting. Pressure sensor 1 defective (Internal short-circuiting) Presumed cause and standard value in normalcy Disconnect the parts shown at right in order. If the error code goes off when one of those parts is disconnected, that part is defective. Front pump pressure sensor Rear pump pressure sensor Connector P25
Connector P26
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit) Between wiring harness between CP01 (female) (22), A06, and P25 (female) (B) and grounding [Front pump pressure sensor system] Between wiring harness between CP01 (female) (22), A06, and P26 (female) (B) and grounding [Rear pump pressure sensor system] Resistance value Resistance value Min. 1 Mz
Min. 1 Mz
3 Pump controller defective
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CP01 Between (22) and (10) Voltage 4.5 5.5 V
10
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to pressure sensor power supply
PC600-8
11
SEN00450-01 Failure code [DA2SKQ] Model Selection Abnormality

Action code Failure content Failure code DA2SKQ Failure phenomenon Model Selection Abnormality (Pump controller system)
40 Troubleshooting
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 machine Relative information None in particular with PC600 model Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring function. (Code No. 00200: Controller Model Code) a Input of model selecting signals (ON or OFF) can be confirmed in the monitoring function. (Code No. 02201: Switch Input 2) Cause Model selection connector defective 1 (Internal disconnection or short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S30 (male) Between (2) , (3), (4) and (8) Between (1) and (8) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Resistance value Min. 1 Mz Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CP02 (female) (37) and S30 (male) (1) Between wiring harness between S30 (male) (8) to J05 , A07, J14, J15 and grounding Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 3 (Contact with grounding circuit) Between wiring harness between CP02 (female) (27) and S30 (male) (2) and grounding Between wiring harness between CP02 (female) (17) and S30 (male) (3) and grounding Between wiring harness between CP02 (female) (7) and S30 (male) (4) and grounding Resistance value Resistance value Resistance value Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Pump controller defective CP02 Between (7), (17), (27) and grounding Between (37) and grounding Voltage 20 30 V Max. 1 V
12
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to model selection connector (for pump controller)
PC600-8
13
SEN00450-01 Failure code [DA80MA] Auto. Lub Abnormal

a This failure code is applicable only when the auto grease device is installed.
40 Troubleshooting
14
PC600-8
40 Troubleshooting
SEN00450-01
PC600-8
15
SEN00450-01 Failure code [DA2RMC] Pump Comm. Abnormality

Action code E0E Failure content Failure code DA2RMC Failure phenomenon Pump Comm. Abnormality (Pump controller system)
40 Troubleshooting
The pump controller detected communication failure in the CAN communication circuit to the machine 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%. controller When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information The output lowers (The pump absorption torque is reduced). If the working load increases, the engine may stall. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CM03 (female) (16) and CE02 (female) (47) or between CM03 (female) (16) and CP02 (female) (22) Wiring harness between CM03 (female) (15) and CE02 (female) (46) or between CM03 (female) (15) and CP02 (female) (32) Resistance value Resistance value Max. 1 z
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit) Between wiring harness between CM03 (female) (16) and CE02 (female) (47) or between CM03 (female) (16) and CP02 (female) (22) or between CM03 (female) (16) and related circuits and grounding Between wiring harness between CM03 (female) (15) and CE02 (female) (46) or between CM03 (female) (15) and CP02 (female) (32) or between CM03 (female) (15) and related circuits and grounding Resistance value Min. 1 Mz
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness (Contact with 24 V circuit) Between wiring harness between CM03 (female) (16) and CE02 (female) (47) or between CM03 (female) (16) and CP02 (female) (22) or between CM03 (female) (16) and related circuits and grounding Between wiring harness between CM03 (female) (15) and CE02 (female) (46) or between CM03 (female) (15) and CP02 (female) (32) or between CM03 (female) (15) and related circuits and grounding Voltage Max. 1 V
Voltage
Max. 1 V
CAN terminal resistor defective
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. K02 (male), K03 (male) Between (A) and (B) Resistance value 120 12 z
If causes 1 4 are not detected, machine monitor, engine controller, or pump controlMonitor panel, ler may be defective. (Since trouble is in those devices, troubleshooting cannot be 5 engine controller, or pump controller defective carried out.)
16
PC600-8
40 Troubleshooting
SEN00450-01
PC600-8
17
SEN00450-01 Failure code [DAFRMC] Monitor Comm. Abnormality

Action code E0E Failure content Failure code DAFRMC Failure phenomenon Monitor Comm. Abnormality (Machine monitor system)
40 Troubleshooting
The machine monitor detected communication failure in the CAN communication circuit to the engine 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 occurring on machine Relative information The output lowers (The pump absorption torque is reduced). If the working load increases, the engine may stall. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CM03 (female) (16) and CE02 (female) (47) or between CM03 (female) (16) and CP02 (female) (22) Wiring harness between CM03 (female) (15) and CE02 (female) (46) or between CM03 (female) (15) and CP02 (female) (32) Resistance value Resistance value Max. 1 z
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit) Between wiring harness between CM03 (female) (16) and CE02 (female) (47) or between CM03 (female) (16) and CP02 (female) (22) or between CM03 (female) (16) and related circuits and grounding Between wiring harness between CM03 (female) (15) and CE02 (female) (46) or between CM03 (female) (15) and CP02 (female) (32) or between CM03 (female) (15) and related circuits and grounding Resistance value Min. 1 Mz
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness (Contact with 24 V circuit) Between wiring harness between CM03 (female) (16) and CE02 (female) (47) or between CM03 (female) (16) and CP02 (female) (22) or between CM03 (female) (16) and related circuits and grounding Between wiring harness between CM03 (female) (15) and CE02 (female) (46) or between CM03 (female) (15) and CP02 (female) (32) or between CM03 (female) (15) and related circuits and grounding Voltage Max. 1 V
Voltage
Max. 1 V
CAN terminal resistor defective
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. K02 (male), K03 (male) Between (A) and (B) Voltage 120 12 z
Machine monitor, engine 5 controller, or pump controller defective
If causes 1 4 are not detected, machine monitor, engine controller, or pump controller may be defective. (Since trouble is in those devices, troubleshooting cannot be carried out.)
18
PC600-8
40 Troubleshooting
SEN00450-01
PC600-8
19
SEN00450-01 Failure code [DGE5KY] Ambi. Temp. Sensor S/C

Action code Failure content Failure code DGE5KY Failure phenomenon Ambi. Temp. Sensor S/C (Pump controller system)
40 Troubleshooting
Abnormal current flowed in ambient temperature sensor circuit.
Response from None in particular. controller If cause of failure disappears, system resets itself. Phenomenon occurring on machine Relative information Fan rotation speed rises. Cause Defective ambient temperature sensor Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P29 (male) Between (1) (2) Presumed cause and standard value in normalcy Ambient temperature 20C Resistance 4 6 kz
Disconnection in wiring harness (Disconnection Wiring harness between CP01 (female) (9) P29 2 in wiring or defective con- (female) (1) tact in connector) Wiring harness between CP01 (female) (10) P29 (female) (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Resistance Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out Hot short (Short circuit troubleshooting. 3 with 24 V circuit) in wiring Wiring harness between CP01 (female) (9) P29 harness Voltage Max. 1 V (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P29 (male) Between (1) (2) Ambient temperature 20C Resistance 4 6 kz
4 Defective pump controller
Circuit diagram related to ambient temperature sensor
20
PC600-8
40 Troubleshooting
SEN00450-01
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C

Action code Failure content Failure code DGH2KB Failure phenomenon Hydr. Oil Temp. Sensor S/C (Pump controller system)
While engine was running, signal of hydraulic oil temperature sensor rose above 102C.
Response from None in particular. machine monitor Phenomenon occurring on machine Relative information If machine is operated as it is, hydraulic components may be damaged. If hydraulic oil temperature monitor of monitor panel lights up red while engine is running, this failure code is recorded. Input (temperature) from hydraulic oil temperature sensor can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature, 04402: Hydraulic oil temperature sensor voltage) Cause Overheating of hydraulic 1 oil (When system is normal) Standard value in normalcy and references for troubleshooting Hydraulic oil may have been overheated. Remove cause and repair damaged hydraulic parts. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Presumed cause and standard value in normalcy Defective hydraulic oil 2 temperature sensor (Internal defect) P22 (male) Between (1) (2) Between (1) chassis ground Ground fault in wiring 3 harness (Contact with GND circuit) 10 100C Hydraulic oil temperature Resistance 90 3.5 kz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CM02 (female) (12) P22 (female) (1) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective machine monitor CM02 (female) Between (12) (13) Between (12) chassis ground 10 100C Hydraulic oil temperature Resistance 90 3.5 kz Min. 1 Mz
Electric circuit diagram related to hydraulic oil temperature sensor
PC600-8
21
SEN00450-01 Failure code [DHPAMA] F pump P. Sensor Abnormality

Action code Failure content Failure code DHPAMA Failure phenomenon F pump P. Sensor Abnormality (Pump controller system)
40 Troubleshooting
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 machine Relative information The travel speed does not shift automatically (The travel load pressure cannot be detected). a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. Input from the front pump pressure sensor (pressure) can be checked in the monitoring function. (Code No. 01100: Front pump pressure) Cause 1 Sensor power supply system defective Standard value in normalcy and references for troubleshooting If failure code [DA25KP] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. Front pump pressure 2 sensor defective (Internal defect) P25 Between (B) and (A) Between (C) and (A) Power supply Signal Voltage 4.5 5.5 V 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. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Presumed cause and standard value in normalcy Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Wiring harness between CP01 (female) (22), A06, J25, and P25 (female) (B) Wiring harness between CP01 (female) (10), A06, and P25 (female) (A) Wiring harness between CP01 (female) (8) and P25 (female) (C) Grounding fault of wiring harness 4 (Contact with grounding circuit) Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CP01 (female) (8) and P25 (female) (C) and grounding Resistance value Min. 1 Mz
Hot short 5 (Short circuit with 24 V circuit) in wiring harness
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between CP01 (female) (22), A06, J25, and P25 (female) (B) and grounding Between wiring harness between C01 (female) (8) and P25 (female) (C) and grounding Voltage Voltage Max. 1 V Max. 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 6 Pump controller defective CP01 Between (22) and (10) Between (8) and (10) Voltage 4.5 5.5 V 0.5 4.5 V
22
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to front pump pressure sensor
PC600-8
23
SEN00450-01 Failure code [DHPBMA] R pump P. Sensor Abnormality

Action code Failure content Failure code DHPBMA Failure phenomenon R pump P. Sensor Abnormality (Pump controller system)
40 Troubleshooting
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 machine Relative information Transmission gear is not shifted automatically (Travel load pressure cannot be detected). a If 5 V circuit (B) and grounding (GND) circuit (A) of pressure sensor are connected inversely, pressure sensor will be broken. Take extreme care when checking. Input (pressure) from R pump pressure sensor can be checked with monitoring function. (Code: 01101 R pump pressure) Cause 1 Defective sensor power supply system Standard value in normalcy and references for troubleshooting If failure code [DA25KP] is displayed, perform troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and start engine and carry out troubleshooting in each case. Defective R pump pres2 sure sensor (Internal defect) P26 Between (B) and (A) Between (C) and (A) Power supply Signal Voltage 4.5 5.5 V 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. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Presumed cause and standard value in normalcy Disconnection of wiring harness (Disconnection 3 or defective contact with connector) Wiring harness between CP01 (female) (22) A06 J25 P26 (female) (B) Wiring harness between CP01 (female) (10) J08 A06 P26 (female) (A) Wiring harness between CP01 (female) (2) P26 (female) (C) Ground fault in wiring 4 harness (Contact with GND circuit) Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP01 (female) (2) P26 (female) (C) and chassis ground Resistance value Min. 1 Mz
Hot short (Short circuit Wiring harness between CP01 (female) (22) A06 5 with 24V circuit) in wiring J25 P26 (female) (B) harness Wiring harness between CP01 (female) (2) P26 (female) (C) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage Voltage Max. 1 V Max. 1 V
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 Between (22) and (10) Between (2) and (10) Voltage 4.5 5.5 V 0.5 4.5 V
24
PC600-8
40 Troubleshooting
SEN00450-01
Circuit diagram related to R pump pressure sensor
PC600-8
25
SEN00450-01 Failure code [DV20KB] Travel Alarm S/C

Action code Failure content Failure code DV20KB Failure phenomenon Travel Alarm S/C (Pump controller system)
40 Troubleshooting
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 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 machine Relative information The travel alarm does not sound. Operation of the travel alarm (ON or OFF) can be checked in the monitoring function. (Code No. 03701: Controller output 2) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 1 Travel alarm defective (Internal defect) M14 (female) Between (1) and (2) Travel lever Neutral Operated Voltage Max. 1 V 20 30 V
If the above voltage is normal but the travel alarm does not operate, the travel alarm is defective. Grounding fault of wiring harness 2 (Contact with grounding circuit) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CP03 (female) (8) and M14 (female) (1) and grounding Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 3 Pump controller defective CP03 Between (8) and grounding Travel lever Neutral Operated Voltage Max. 1 V 20 30 V
26
PC600-8
40 Troubleshooting
SEN00450-01
Circuit diagram related to travel alarm
PC600-8
27
SEN00450-01 Failure code [DW43KA] Travel Speed Sol. Disc.

Action code Failure content Failure code DW43KA Failure phenomenon Travel Speed Sol. Disc. (Pump controller system)
40 Troubleshooting
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) controller When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine The travel speed does not shift to Hi. (The swash plate angle of the travel motor is not minimized.) 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. (Code No. 02300: Solenoid 1) 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].) Cause Travel speed select 1 solenoid defective (Internal disconnection) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male) Between (2) and (1) Resistance value 20 60 z
Relative information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from CP03 (female) (27) to A05 and V04 (female) (2) Wiring harness between V04 (female) (1) to J23, A05, J08, CP03 (female) (3), (13), (23), J23 and grounding Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 3 with 24V circuit) in wiring Between wiring harness between CP03 (female) (27), harness Voltage Max. 1 V A05, and V04 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CP03 (female) Between (27) and grounding Resistance value 20 60 z
28
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to travel speed select solenoid
PC600-8
29
SEN00450-01 Failure code [DW43KB] Travel Speed Sol. S/C

Action code Failure content Failure code DW43KB Failure phenomenon Travel Speed Sol. S/C (Pump controller system)
40 Troubleshooting
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 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 machine Relative information The travel speed does not turn to Hi. (The swash plate angle of the travel motor is not minimized.) Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF. 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. (Code No. 02300: Solenoid 1) Cause Travel speed select solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male) Between (2) and (1) Between (2) and grounding Resistance value 20 60 z Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CP03 (female) (27), A05, and V04 (female) (2) and grounding Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in high idling during the troubleshooting. 3 Pump controller defective CP03 Between (27) and grounding Travel speed select switch Lo Hi Voltage Max. 1 V 20 30 V
30
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to travel speed select solenoid
PC600-8
31
SEN00450-01 Failure code [DW45KA] Swing Brake Sol. Disc.

Action code Failure content Failure code DW45KA Failure phenomenon Swing Brake Sol. Disc. (Pump controller system)
40 Troubleshooting
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). controller When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine The machine cannot swing (The swing holding brake cannot be released). Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) 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 stops, however). Keep the swing lock switch in the OFF position and the swing holding brake release switch in the RELEASE position during troubleshooting. Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or OFF, refer to the troubleshooting under failure code [DW45KB].) Cause Swing holding brake 1 solenoid defective (Internal disconnection) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male) Between (2) and (1) Resistance value 20 60 z
Assembled-type diode 2 D01 defective (Internal disconnection)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male) Between (7) and (3) Digital tester Diode mode Continuity Continued
Swing lock switch
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S04 (female) Between (3) and (4) Swing lock switch OFF LOCK Resistance value Max. 1 z Min. 1 Mz
3 defective
Presumed cause and standard value in normalcy (Internal disconnection)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 4 (Disconnection or defective contact with connector) Wiring harness between CP03 (female) (37) and D01 (female) (7) Wiring harness between D01 (female) (3), J04, and S04 (male) (3) Wiring harness between S04 (male) (4), V05 (female) (2) Wiring harness between V05 (female) (1), J23, A05, J08 and CP03 (female) (3), (13) and (23) Resistance value Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 5 with 24V circuit) in wiring Between wiring harness between CP03 (female) (37) harness Voltage Max. 1 V and D01 (female) (7) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 6 Pump controller defective CP03 (female) Between (37) and grounding Disconnect D01 and directly connect pins (3) and (7) on the female side. Resistance value 20 60 z
32
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to swing holding brake solenoid
PC600-8
33
SEN00450-01 Failure code [DW45KB] Swing Brake Sol. S/C

Action code Failure content Failure code DW45KB Failure phenomenon Swing Brake Sol. S/C (Pump controller system)
40 Troubleshooting
Abnormal current flowed in the swing holding brake solenoid circuit, when power is supplied to the circuit.
Power to the swing holding brake solenoid circuit is switched OFF. 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 machine Relative information The machine cannot swing (The swing holding brake cannot be released). Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) 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 stops, however). Cause Swing holding brake solenoid defective 1 (Internal short-circuiting or grounding fault) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male) Between (2) and (1) Between (2) and grounding Presumed cause and standard value in normalcy Assembled-type diode 2 D01 defective (Internal short-circuiting) Grounding fault of wiring harness 3 (Contact with grounding circuit) Resistance value 20 60 z Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male) Between (3) and (7) Resistance value (Continuitiy) Min. 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CP03 (female) (37), D01, J04, S04, and V05 (female) (2) and grounding Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. CP03 4 Pump controller defective Between (37) and grounding All levers in neutral Work equipment or swing operated Work equipment control lever Voltage Max. 1 V (5 sec after setting in neutral) 20 30 V
34
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to swing holding brake solenoid
PC600-8
35
SEN00450-01 Failure code [DW48KA] CO Cancel Sol. Disc.

Action code Failure content Failure code DW48KA Failure phenomenon CO Cancel Sol. Disc. (Pump controller system)
40 Troubleshooting
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) controller When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information When the boom is raised and the machine travels, power is low (The pump CO function cannot be cancelled). Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) 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 [DW48KB].) Cause CO cancel 1 solenoid defective (Internal disconnection) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V07 (male) Between (2) and (1) Resistance value 20 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from CP03 (female) (28) to A05 and V07 (female) (2) Wiring harness between V07 (female) (1) to J23, A05, J08, CP03 (female) (3), (13), (23) Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 3 with 24V circuit) in wiring Between wiring harness between CP03 (female) (28), harness Voltage Max. 1 V A05, and V07 (female) (2) and grounding Pump controller defective a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CP03 (female) Between (28) and grounding Resistance value 20 60 z
36
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to CO cancel solenoid
PC600-8
37
SEN00450-01 Failure code [DW48KB] CO Cancel Sol. S/C

Action code Failure content Failure code DW48KB Failure phenomenon CO Cancel Sol. S/C (Pump controller system)
40 Troubleshooting
Abnormal current flew to the CO cancel solenoid circuit, when power was supplied to the circuit.
Power supply to the CO 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 occurring on machine Relative information When the boom is raised and the machine travels, power is low (The pump CO function cannot be cancelled). Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) Cause CO cancel solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V07 (male) Between (2) and (1) Between (2) and grounding Resistance value 20 60 z Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CP03 (female) (28), A05 and V08 (female) (2) and grounding Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 3 Pump controller defective CP03 Between (28) and grounding Swing lock switch OFF ON (Note) Voltage Max. 1 V 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
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to CO cancel solenoid
PC600-8
39
SEN00450-01 Failure code [DW7BKA] Fan Reverse Sol. Disc.

Action code Failure content Failure code DW7BKA Failure phenomenon Fan Reverse Sol. Disc. (Pump controller system)
40 Troubleshooting
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 machine Relative information Fan does not rotate in reverse. Since disconnection of solenoid is detected while output is ON, be sure to turn output ON when checking for reproduction of failure after repair. Cause Defective hydraulic fan 1 reverse solenoid (Internal disconnection) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V17 (male) Between (1) (2) Resistance 20 60 z
Disconnection in wiring harness (Disconnection Wiring harness between CP03 (female) (25) V17 2 in wiring or defective con- (female) (1) tact in connector) Wiring harness between V17 (female) (2) CP03 (female) (3), (13), (23)
a Prepare with starting switch OFF, then turn starting switch ON and carry out Hot short (Short circuit troubleshooting. 3 with 24 V circuit) in wiring Wiring harness between CP03 (female) (25) V17 harness Voltage Max. 1 V (female) (1) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP03 (female) Between (25) chassis ground Resistance 20 60 z
Circuit diagram related to hydraulic fan
40
PC600-8
40 Troubleshooting
SEN00450-01
Failure code [DW7BKB] Fan Reverse Sol. S/C

Action code Failure content Failure code DW7BKB Failure phenomenon Fan Reverse Sol. S/C (Pump controller system)
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 machine Relative information Fan does not rotate in reverse. Operating condition (ON-OFF) of hydraulic fan reverse solenoid can be checked with monitoring function. (Code No. 02300: Solenoid 1) Cause Defective hydraulic fan reverse solenoid (Internal 1 short circuit or ground fault) Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V17 (male) Between (1) (2) Between (2) chassis ground Ground fault in wiring 2 harness (Contact with GND circuit) Resistance 20 60 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP03 (female) (25) V17 (female) (1) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective pump controller CP03 Between (25) chassis ground Working mode Other than L-mode L-mode Voltage Max. 1 V 20 30 V
PC600-8
41
SEN00450-01 Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc.

Action code Failure content Failure code DW4XKA Failure phenomenon Bucket Curl Hi Cancel Sol. Disc. (Pump controller system)
40 Troubleshooting
Any current does not flow to the bucket Curl Hi cancel solenoid circuit, when power was supplied to the circuit.
Response from None in particular (Since any current does not flow, the solenoid does not operate). controller When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information When the bucket and other work equipment are operated simultaneously, the speed of the other work equipment is low (The bucket Curl Hi function is not cancelled). Operation of the bucket Curl Hi cancel solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) Since the controller detects disconnection when the solenoid output is turned ON, be sure to turn the solenoid output ON when checking for reproduction of the failure after repair. (For the method of checking the ON/OFF state of the output, see troubleshooting for failure code [DW4XKB].) Cause Bucket Curl Hi cancel 1 solenoid defective (Internal disconnection) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male) Between (2) and (1) Resistance value 20 60 z
Disconnection of wiring harness (Disconnection 2 or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CP03 (female) (38), A05, and V03 (female) (2) Wiring harness between CP03 (female) (3), J08, and V03 (female) (1) Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 3 with 24 V circuit) in wiring Between wiring harness between CP03 (female) (38), harness Voltage Max. 1 V A05, and V03 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CP03 (female) Between (38) and grounding Resistance value 20 60 z
42
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to bucket curl Hi cancel solenoid
PC600-8
43
SEN00450-01 Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C

Action code Failure content Failure code DW4XKB Failure phenomenon Bucket Curl Hi Cancel Sol. S/C (Pump controller system)
40 Troubleshooting
Abnormal current flowed to the bucket Curl Hi cancel solenoid circuit, when power was supplied to the 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 occurring on machine Relative information When the bucket and other work equipment are operated simultaneously, the speed of the other work equipment is low (The bucket Curl Hi function is not cancelled). Operation of the bucket Curl Hi cancel solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) Cause Bucket Curl Hi cancel solenoid defective 1 (Internal short-circuiting or grounding fault) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male) Between (2) and (1) Between (2) and grounding Grounding fault of wiring 2 harness (Contact with grounding circuit) Resistance value 20 60 z Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. CP03 3 Pump controller defective Between (38) and grounding Work equipment control lever All levers in neutral Bucket Curl + Other work equipment operation Voltage Max. 1 V 20 30 V
44
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to bucket curl Hi cancel solenoid
PC600-8
45
SEN00450-01 Failure code [DWK0KA] 2-stage Relief Sol. Disc.

Action code Failure content Failure code DWK0KA Failure phenomenon 2-stage Relief Sol. Disc. (Pump controller system)
40 Troubleshooting
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) controller When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information The heavy-lift function does not work. Travel power is low (The main relief valve is not set in the HIGH PRESSURE position). Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) 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 [DWK0KB].) Cause 2-stage relief solenoid 1 defective (Internal disconnection) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male) Between (2) and (1) Resistance value 20 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from CP03 (female) (17) to A05 and V08 (female) (2) Wiring harness between V08 (female) (1) to J22, A05, J08, CP03 (female) (3), (13), (23) Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 3 with 24 V circuit) in wiring Between wiring harness between CP03 (female) (17), harness Voltage Max. 1 V A05, and V08 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CP03 (female) Between (17) and grounding Resistance value 20 60 z
46
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to 2-stage relief solenoid
PC600-8
47
SEN00450-01 Failure code [DWK0KB] 2-stage Relief Sol. S/C

Action code Failure content Failure code DWK0KB Failure phenomenon 2-stage Relief Sol. S/C (Pump controller system)
40 Troubleshooting
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 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 machine Relative information Travel power is low (The main relief valve is not set in the HIGH PRESSURE position). Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) Cause 2-stage relief solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male) Between (2) and (1) Between (2) and grounding Resistance value 20 60 z Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 3 Pump controller defective CP03 Between (17) and grounding Travel control lever Neutral Travel operation (Note) Voltage Max. 1 V 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
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to 2-stage relief solenoid
PC600-8
49
SEN00450-01 Failure code [DX16KA] Fan Pump EPC Sol. Disc.

Action code Failure content Failure code DX16KA Failure phenomenon Fan Pump EPC Sol. Disc. (Pump controller system)
40 Troubleshooting
No current flows in hydraulic fan EPC solenoid circuit.
Response from Fan pump is set to maximum swash plate angle and fan may rotate at excessive speed. Accordingly, controller protection mode is selected to lower engine speed. Phenomenon occurring on machine Relative information Fan motor speed cannot be controlled. If fan EPC solenoid system has disconnection or short circuit, fan cannot be reversed. Output (current) to hydraulic fan EPC solenoid can be checked with monitoring function. (Code No. 31623: Hydraulic fan EPC solenoid current) Cause Defective hydraulic fan 1 EPC solenoid (Internal disconnection) Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V13 (male) Between (1) (2) Resistance 7 14 z
Disconnection in wiring harness (Disconnection Wiring harness between CP03 (female) (35) V13 2 in wiring or defective con- (female) (1) tact in connector) Wiring harness between V13 (female) (2) CP03 (female) (3), (13), (23)
Hot short (Short circuit Wiring harness between CP03 (female) (35) V13 3 with 24 V circuit) in wiring (female) (1) and chassis ground harness Wiring harness between V13 (female) (2) CP03 (female) (3), (13), (23)
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage Voltage Max. 1 V Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP03 (female) Between (35) (3), (13), (23) Resistance 7 14 z
50
PC600-8
40 Troubleshooting
SEN00450-01
PC600-8
51
SEN00450-01 Failure code [DX16KB] Fan Pump EPC Sol. S/C

Action code Failure content Failure code DX16KB Failure phenomenon Fan Pump EPC Sol. S/C (Pump controller system)
40 Troubleshooting
Abnormal current flowed in hydraulic fan EPC solenoid circuit.
Response from Fan pump is set to maximum swash plate angle and fan may rotate at excessive speed. Accordingly, controller protection mode is selected to lower engine speed. Phenomenon occurring on machine Relative information Fan motor speed cannot be controlled. If fan EPC solenoid system has disconnection or short circuit, fan cannot be reversed. Output (current) to hydraulic fan EPC solenoid can be checked with monitoring function. (Code No. 31623: Hydraulic fan EPC solenoid current) Cause Defective hydraulic fan EPC solenoid (Internal 1 short circuit or ground fault) Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V13 (male) Between (1) (2) Between (1) chassis ground Ground fault in wiring 2 harness (Contact with GND circuit) Resistance 7 14 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP03 (female) (35) V13 (female) (1) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller CP03 (female) Between (35) (3), (12), (23) Between (35) chassis ground Resistance 7 14 z Min. 1 Mz
52
PC600-8
40 Troubleshooting
SEN00450-01
PC600-8
53
SEN00450-01 Failure code [DXA0KA] TVC Sol. Disc.

Action code E02 Failure content Failure code DXA0KA Failure phenomenon TVC Sol. Disc. (Pump controller system)
40 Troubleshooting
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). controller When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information If the pump load increases, the engine speed lowers extremely and the engine may stall. (The pump absorption torque cannot be controlled.) Output to the TVC solenoid (current) can be checked in the monitoring function. (Code No. 01300: TVC solenoid current) 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. Cause TVC solenoid defective (Internal disconnection) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V11 (male) Between (1) and (2) Resistance value 10 22 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Emergency pump drive 2 switch defective (Internal disconnection) S25 (male) Between (2) and (3) Between (5) and (6) Emergency pump drive switch NORML position EMERGENCY position NORML position EMERGENCY position Resistance value Max. 1 z Min. 1 Mz Max. 1 z Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Wiring harness between CP03 (female) (16) and S25 (female) (3) Wiring harness between S25 (female) (2) and V11 (female) (1) Wiring harness between CP03 (female) (3) and S25 (female) (6) Wiring harness between S25 (female) (5) and V11 (female) (2) Resistance value Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Hot short (Short circuit Between wiring harness between CP03 (female) (16) 4 with 24 V circuit) in wiring and S25 (female) (3) and grounding harness Between wiring harness between S25 (female) (2) and V11 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Voltage Max. 1 V Max. 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CP03 (female) Between (16) and (3) Resistance value 10 22 z
54
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to TVC solenoid
PC600-8
55
SEN00450-01 Failure code [DXA0KB] TVC Sol. S/C

Action code E02 Failure content Failure code DXA0KB Failure phenomenon TVC Sol. S/C (Pump controller system)
40 Troubleshooting
Abnormal current flowed in the TVC solenoid circuit.
Power to the TVC solenoid circuit is switched OFF. 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 machine If the pump load increases, the engine speed lowers extremely and the engine may stall. (The pump absorption torque cannot be controlled.) Output to the TVC solenoid (current) can be checked in the monitoring function. (Code No. 01300: TVC solenoid current) 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 (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. Cause TVC solenoid defective 1 (Internal short-circuiting or grounding fault) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V11 (male) Between (1) and (2) Between (1) and grounding Presumed cause and standard value in normalcy Emergency pump drive switch defective 2 (Internal short-circuiting or grounding fault) Resistance value 10 22 z Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S25 (male) Between (3) and (4) Between (3) and grounding Emergency pump drive switch NORML position Resistance value Min. 1 Mz Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CP03 (female) (16) and S25 (female) (3) and grounding Between wiring harness between S25 (female) (2) and V11 (female) (1) and grounding Resistance value Resistance value Min. 1 Mz Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Pump controller defective CP03 (female) Between (16) and (3) Between (16) and grounding Resistance value 10 22 z Min. 1 Mz
56
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to TVC solenoid
PC600-8
57
SEN00450-01 Failure code [DY20KA] Wiper Working Abnormality

Single wiper specification
Action code Failure content Failure code DY20KA Failure phenomenon Wiper Working Abnormality (Machine monitor system)
40 Troubleshooting
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 machine Relative information The wiper motor does not work. Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 1 Presumed cause and standard value in normalcy Wiper motor defective (Internal disconnection) M05 (female) Windshield wiper blade At upper end of operation range Outside upper end of operation range Resistance value Max. 1 z Min. 1 Mz
Between (6) and (5)
Disconnection of wiring harness 2 (Disconnection or faulty contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CM01 (female) (5) and M05 (male) (6) Wiring harness between M05 (male) (5) and grounding Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Machine monitor defective CM01 Wiper blade At upper end of operation range Outside upper end of operation range Voltage Max. 1 V 20 30 V
Between (5) and grounding
58
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to wiper motor (Single wiper specification.)
PC600-8
59
SEN00450-01 Failure code [DY20MA] Wiper Parking Abnormality

Double wiper specification
Action code Failure content Failure code DY20MA Failure phenomenon Wiper Parking Abnormality (Machine monitor system)
40 Troubleshooting
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 machine Relative information The wiper cannot be retracted completely. It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation range is inputted or not. (Code No.: 04502 Monitor input 3) Cause Upper wiper motor 1 defective (Internal disconnection) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M05 (female) Between (4) and (5) Wiper blade Retraction range Operation range Resistance value Max. 1 z Min. 1 Mz
Lower wiper motor
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M15 (female) Between (4) and (5) Wiper blade Retraction range Operation range Resistance value Max. 1 z Min. 1 Mz
2 defective
(Internal disconnection) Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Wiring harness between CM01 (female) (12) and M05 (male) (4) Wiring harness between M05 (male) (5) and grounding Wiring harness between CM01 (female) (5) and M15 (male) (4) Wiring harness between M15 (male) (5) and grounding Resistance value Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CM01 4 Machine monitor defective Between (12) and grounding CM01 Between (5) and grounding Upper wiper blade Retraction range Operation range Lower wiper blade Retraction range Operation range Voltage Max. 1 V 20 30 V Voltage Max. 1 V 20 30 V
60
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to wiper motor (Double wiper specification.)
PC600-8
61
SEN00450-01
Action code Failure content Failure code DY20MA Failure phenomenon Wiper Parking Abnormality (Machine monitor system)
40 Troubleshooting
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 machine Relative information The wiper cannot be retracted completely. It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation range is inputted or not. (Code No.: 04502 Monitor Input 3) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 1 Presumed cause and standard value in normalcy Wiper motor defective (Internal disconnection) M05 (female) Between (4) and (5) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Wiper blade Retraction range Operation range Resistance value Max. 1 z Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CM01 (female) (12) and M05 (male) (4) Between wiring harness M05 (male) (5) and grounding Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Machine monitor defective CM01 Between (12) and grounding Wiper blade Retraction range Operation range Voltage Max. 1V 20 30 V
62
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to wiper motor (Single wiper specification.)
PC600-8
63
SEN00450-01 Failure code [DY2CKB] Washer Drive S/C

Action code Failure content Failure code DY2CKB Failure phenomenon Washer Drive S/C (Machine monitor system)
40 Troubleshooting
Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was switched ON.
Response from Power supply to the grounding in the window washer motor circuit was switched OFF. Monitor Panel Phenomenon occurring on machine Relative information The window washer stopped moving. Cause Window washer drive 1 motor defective (Internal short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. M06 (male) Between (1) and (2) Resistance value 5 20 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Hot short (Short circuit 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 a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Machine monitor defective CM01 Between (3) and grounding Window washer switch OFF ON Voltage 20 30 V Max. 1 V
64
PC600-8
40 Troubleshooting
SEN00450-01
Electrical circuit diagram related to window washer motor
PC600-8
65
SEN00450-01 Failure code [DY2DKB] Wiper Drive (For) S/C

Action code Failure content Failure code DY2DKB Failure phenomenon Wiper Drive (For) S/C (Machine monitor system)
40 Troubleshooting
Abnormal current flowed in the wiper motor forward rotation circuit, when power is supplied to the circuit.
Response from Power to the wiper motor forward rotation circuit is switched OFF. monitor panel Phenomenon occurring on machine Relative information The wiper stops. Cause Upper wiper motor defective 1 (Internal short-circuiting or grounding fault) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M05 (female) Between (3) and (1) Between (3) and grounding Lower wiper motor defective 2 (Internal short-circuiting or grounding fault) Continuity and resistance value Continued Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M15 (female) Between (3) and (1) Between (3) and grounding Continuity and resistance value Continued Min. 1 Mz
Assembled-type diode 3 D04 defective (Internal short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D04 (male) Between (3) and (7) Between (4) and (8) Resistance value (Continuitiy) Min. 1 Mz (No continuitiy) Min. 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 4 (Contact with grounding circuit) Between wiring harness between CM01 (female) (9) and M05 (male) (3) or between CM01 (female) (9) and D04 (female) (3) and grounding Between wiring harness between CM01 (female) (5), M15 (male) (3) or between CM01 (female) (5) and D04 (female) (4) and grounding Resistance value Resistance value Min. 1 Mz
Min. 1 Mz
Machine monitor defective (Upper wiper motor) 5 Machine monitor defective (Lower wiper motor)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CM01 Between (9) and grounding Upper wiper switch OFF ON Voltage Max. 3 V 20 30 V (Note)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CM01 Between (5) and grounding Lower wiper switch OFF ON Voltage Max. 3 V 20 30 V (Note)
Note:
When the upper wiper and lower wiper are operated simultaneously: Max. 3 V intervals)
20 30 V (at regular
66
PC600-8
40 Troubleshooting
SEN00450-01
Electrical Circuit diagram related to wiper motor (Double wiper specification)
PC600-8
67
SEN00450-01
Action code Failure content Failure code DY2DKB Failure phenomenon Wiper Drive (For) S/C (Machine monitor system)
40 Troubleshooting
Abnormal current flowed in the wiper motor forward rotation circuit, when power is supplied to the circuit.
Response from Power to the wiper motor forward rotation circuit is switched OFF. monitor panel Phenomenon occurring on machine Relative information The wiper stops. Cause Wiper motor defective 1 (Internal short-circuiting or grounding fault) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M05 (female) Between (3) and (1) Between (3) and grounding Grounding fault of wiring harness 2 (Contact with grounding circuit) Continuity and resistance value Continued Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CM01 (female) (9) and M05 (male) (3) and grounding Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Machine monitor defective CM01 Between (9) and grounding Wiper switch OFF ON Voltage Max. 3 V Max. 3 V 20 30 V (at constant cycle)
68
PC600-8
40 Troubleshooting
SEN00450-01
Electric circuit diagram related to wiper motor (Single wiper specification.)
PC600-8
69
SEN00450-01 Failure code [DY2EKB] Wiper Drive (Rev) S/C

Action code Failure content Failure code DY2EKB Failure phenomenon Wiper Drive (Rev) S/C (Machine monitor system)
40 Troubleshooting
Abnormal current flowed in the wiper motor reverse rotation circuit, when power is supplied to the circuit.
Response from Power to the wiper motor reverse rotation circuit is switched OFF. monitor panel Phenomenon occurring on machine Relative information The wiper stops. Cause Wiper motor defective 1 (Internal short-circuiting or grounding fault) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. M05 (female) Between (1) and (3) Between (1) and grounding Grounding fault of wiring harness 2 (Contact with grounding circuit) Continuity and resistance value Continued Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CM01 (female) (10) and M05 (male) (1) and grounding Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Machine monitor defective CM01 Between (10) and grounding Wiper switch OFF ON Voltage Max. 3 V Max. 3 V 20 30 V (at constant cycle)
70
PC600-8
40 Troubleshooting
SEN00450-01
Electric circuit diagram related to wiper motor (Single wiper specification.)
PC600-8
71
SEN00450-01
40 Troubleshooting
72
SEN00451-03
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not rotate) ............................................................................................. 3 E-2 Preheater does not operate........................................................................................................................... 6 E-3 Auto engine warm-up device does not work ................................................................................................. 8 E-4 Auto-decelerator does not operate ................................................................................................................ 9 E-5 All work equipment, swing and travel do not move ..................................................................................... 10 E-6 Power max. function does not operate ........................................................................................................ 12 E-7 Machine push-up function does not operate normally................................................................................. 13 E-8 Any item is not displayed on machine monitor ............................................................................................ 15 E-9 Part of display on machine monitor is missing ............................................................................................ 16 E-10 Machine monitor displays contents irrelevant to the model....................................................................... 16 E-11 Fuel level monitor red lamp lights up while engine is running ................................................................... 17 E-12 Engine coolant temperature gauge does not display correctly.................................................................. 18 E-13 Hydraulic oil temperature gauge does not display correctly ...................................................................... 20 E-14 Fuel gauge does not display correctly ....................................................................................................... 21 E-15 Swing lock monitor does not display correctly........................................................................................... 22 E-16 When monitor switch is operated, nothing is displayed............................................................................. 24 E-17 Wiper and window washer do not work ..................................................................................................... 26 E-18 "Boom Raise" is not correctly displayed in monitoring function................................................................. 34 E-19 "Boom Lower" is not correctly displayed in monitoring function ................................................................ 36 E-20 "Arm IN" is not correctly displayed in monitoring function ......................................................................... 38 E-21 "Arm OUT" is not correctly displayed in monitoring function ..................................................................... 39 E-22 "Bucket CURL" is not correctly displayed in monitoring function............................................................... 40
PC600-8
SEN00451-03
40 Troubleshooting
E-23 "Bucket DUMP" is not correctly displayed in monitoring function .............................................................. 41 E-24 "Swing" is not correctly displayed in monitoring function........................................................................... 42 E-25 "Travel" is not correctly displayed in monitoring function........................................................................... 44 E-26 Air conditioner does not work .................................................................................................................... 46 E-27 Step light does not light up or go off .......................................................................................................... 48 E-28 Electric grease gun does not operate........................................................................................................ 52 E-29 Travel alarm does not sound or does not stop sounding........................................................................... 54 E-30 Horn does not sound ................................................................................................................................. 56 E-31 Bottom dump does not move..................................................................................................................... 58
PC600-8
40 Troubleshooting
SEN00451-03
E-1 Engine does not start (Engine does not rotate)

Failure information Relative information The engine does not start. (Engine does not rotate) The engine starting circuit is equipped with the start lock mechanism of work equipment lock lever type. Cause Battery capacity insufficient Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Battery voltage Min. 24 V 2 Electrolyte specific gravity Min. 1.26
Circuit breakers No. 1 or If a circuit breaker is turned OFF or a fuse is broken, the circuit probably has ground6 or fuse 2, 3, 6 defective ing fault (See cause 9). a Turn the engine starting switch OFF for the preparations, and hold it in the ON position or start the engine during the troubleshooting.
Starting switch defective (Internal disconnection)
M06 (male) Between (1) and (4)
Starting switch OFF ON
Resistance value Min. 1 Mz Max. 1 z
Work equipment lock 4 switch defective (Internal short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S14 (female) Between (1) and (3) Work equipment lock lever FREE LOCK Resistance value Min. 1 Mz Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Starting motor cut-out 5 relay defective (Internal defect) R06 (female) and R07 (female) Between (1) and (2) Between (3) and (5) Between (3) and (6) Resistance value 100 500 z Min. 1 Mz 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 Between B and grounding Starting motor defective 6 (Internal defect) Between ST (1) and grounding Between ST (2) and grounding B (Power supply) S (Start) R (Charge) Voltage 20 30 V 20 30 V Max. 1 V
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. Alternator defective 7 (Internal short-circuiting) a Turn the engine starting switch OFF for the preparations (with only wiring harness R disconnected), and hold it in the ON position during the troubleshooting. Alternator Between terminal R and grounding Voltage Max. 1 V
PC600-8
SEN00451-03
Cause
40 Troubleshooting
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between battery relay terminal B and B16 Wiring harness between B26 and H06 (female) (1) Resistance value Resistance value Resistance value Resistance value Resistance value Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Wiring harness between H06 (female) (4) and R06 (female) (5) Wiring harness between R06 (female) (3) and ST (female) (1) Wiring harness between F01-3 and S14 (male) (1) Wiring harness between S14 (male) (3) and R06 (female) (1)
Wiring harness between R06 (female) (2) and R07 (female) (6) Wiring harness between R07 (female) (3), J04, A07 and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between B26 and H06 (female) (1) and grounding Between wiring harness between H06 (female) (4) and R06 (female) (5) and grounding Grounding fault of wiring harness 9 (Contact with grounding circuit) Between wiring harness between R06 (female) (3) and ST (female) (1) and grounding Between wiring harness between F01-3 and S14 (male) (1) and grounding Between wiring harness between S14 (male) (3) and R06 (female) (1) and grounding Between wiring harness between R06 (female) (2) and R07 (female) (6) and grounding Between wiring harness between R06 (female) (2) and CM02 (female) (14) and grounding Resistance value Resistance value Resistance value Resistance value Resistance value Resistance value Resistance value Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz
Hot short (Short circuit 10 with 24 V circuit) in wiring Between wiring harness between ST (female) (2) and alternator terminal R or between ST (female) (2), J02 harness and D01 (female) (6) or between ST (female) (2) and CM02 (female) (11) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Voltage
Max. 1 V
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram for engine preheating, starting, charging
PC600-8
SEN00451-03 E-2 Preheater does not operate

Failure information Relative information The preheater does not operate.
40 Troubleshooting
(1) When the starting switch is turned to the HEAT position, the preheating monitor does not light up.
The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about 30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds). Input of the preheating signal (ON or OFF) can be checked in the monitoring function. (Code No. 04500: Monitor input 1) Cause Standard value in normalcy and references for troubleshooting If the preheater does not operate (the heater unit is not warmed), carry out troubleshooting (2). a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CM02 (female) (18) and J02 (male) (7) Resistance value Max. 1 z
Starting switch system 1 defective Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations , and hold it in the OFF or HEAT position during troubleshooting. 3 Machine monitor defective CM02 Between (18) and grounding Starting switch OFF HEAT Voltage Max. 1 V 20 30 V
Failure information Relative information
The preheater does not operate.
(2) When the starting switch is turned to the HEAT position, the heater unit is not warmed.
Check that the starting motor rotates normally. (If the starting motor does not rotate, carry out troubleshooting in "Engine does not start".) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF or HEAT position during troubleshooting.
Starting switch defective (Internal disconnection)
H06 (male) Between (1) and (3)
Starting switch OFF HEAT
Resistance value Min. 1 Mz 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. Presumed cause and standard value in normalcy 2 Heater relay defective (Internal disconnection) Heater relay Between coil terminal and grounding Between contact terminals Intake air heater 3 defective (Internal disconnection) Starting switch OFF HEAT Continuity and resistance value Continued Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Intake air heater Between terminals Wiring harness between H06 (female) (3), J02, and heater relay terminal R17 Continuity Continued Resistance value Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Wiring harness between battery relay terminal B and heater relay R15 Wiring harness between heater relay terminal R16 and intake air heater Wiring harness between intake air heater and engine
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram for engine preheating, starting, charging
PC600-8
SEN00451-03 E-3 Auto engine warm-up device does not work

Failure information The auto engine warm-up device does not work.
40 Troubleshooting
The auto engine warm-up device is activated, when the engine coolant temperature is below 30C, and raise the engine rotation up to 1,200 rpm. The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more 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 10C, the turbocharger protection function operates to keep the engine speed below 1,000 rpm for up to 5 seconds after the engine is started. Cause Standard value in normalcy and references for troubleshooting a Turn the starting switch ON for the troubleshooting (monitoring). Monitoring code Item Normal display Compare the monitor Engine coolant temperature indication with the actual (low temperature) engine coolant temperature.
Engine coolant temperature signal fault
04107
If the display on the machine monitor is abnormal, carry out troubleshooting in "E-12 Engine coolant temperature gauge does not display correctly". 2 Engine controller defective If cause 1 is not detected, the engine controller may be defective. (Since trouble is in the engine controller, troubleshooting cannot be carried out.)
PC600-8
40 Troubleshooting
SEN00451-03
E-4 Auto-decelerator does not operate

Failure information The auto-decelerator does not operate. 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. Check the display on the monitor panel while the engine is running. 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". Cause 1 Boom RAISE signal defective Standard value in normalcy and references for troubleshooting Monitoring code 01900 Pressure switch 1 Monitoring code 01900 Pressure switch 1 Monitoring code 3 Arm IN signal defective 01900 Pressure switch 1 Monitoring code 4 Arm OUT signal defective Presumed cause and standard value in normalcy 01900 Pressure switch 1 Monitoring code 01901 Pressure switch 2 Monitoring code 01901 Pressure switch 2 Monitoring code 7 Swing signal defective 01900 Pressure switch 1 Monitoring code 8 Travel signal defective 01900 Pressure switch 1 Monitoring code 9 Service signal defective 01901 Pressure switch 2 Item Boom RAISE Item Boom LOWER Item Arm IN Item Arm OUT Item Bucket CURL Item Bucket DUMP Item Swing Item Right travel Item Service Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF
Boom LOWER signal 2 defective
Bucket CURL signal defective
Bucket DUMP signal 6 defective
10 Pump controller defective 11 Engine controller defective
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.) If causes 1 9 are not detected, the engine controller may be defective. (Since trouble is in the pump controller, troubleshooting cannot be carried out.)
PC600-8
SEN00451-03 E-5 All work equipment, swing and travel do not move
Failure information Relative information All the work equipment, swing and travel do not move. Cause 1 Fuse No. 3 fault
40 Troubleshooting
Standard value in normalcy and references for troubleshooting If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. (See cause 6.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S14 (female) Between (1) and (2) Safety lock lever Free Lock Resistance value Max. 1 z Min. 1 Mz
Safety lock switch 2 defective (Internal disconnection)
PPC lock solenoid defective 3 (Internal disconnection, short-circuiting, or grounding fault) Assembled-type diode 4 D01 defective (Internal short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V01 (male) Between (2) and (1) Between (2) and grounding Resistance value 20 60 z Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male) Between (4) and (8) Resistance value (Continuitiy) Min. 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 5 (Disconnection or defective contact with connector) Wiring harness between F01-3 outlet and S14 (male) (1) Wiring harness from S14 (male) (2) and V01 (female) (2) Wiring harness between V01 (female) (1) and grounding Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 6 (Contact with grounding circuit) Between wiring harness between F01-3 outlet and S14 (male) (1) and grounding Wiring harness from S14 (male) (2) to V01 (female) (2), or between wiring harness between S14 (male) (2) and D01 (female) (4) and grounding Resistance value Resistance value Min. 1 Mz Min. 1 Mz
10
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram for PPC lock solenoid
PC600-8
11
SEN00451-03 E-6 Power max. function does not operate

Failure information Relative information Power max. function does not operate
40 Troubleshooting
If the power max. switch is pressed while the engine is running, the power max. monitor is displayed on the monitor panel. Input condition of the power max. switch (left knob switch) (ON or OFF) can be checked in the monitoring function. (Code No. 02200: Switch input 1) Cause Standard value in normalcy and references for troubleshooting If the fuse is broken, there is a big possibility that grounding fault occurred in the circuit. (See cause 4.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M23 (male) Between (1) and (2) Power max. switch Released Pressed Resistance value Min. 1 Mz Max. 1 z
1 Fuse No. 9 defective
Power max. switch defec2 tive (Internal disconnection) Presumed cause and standard value in normalcy
Disconnection of wiring harness (Disconnection 3 or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between F01-9 outlet and S11 (female) (1) Resistance value Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring 4 harness (Contact with grounding circuit) Between wiring harness between F01-9 outlet and S11 (female) (1) and grounding Between wiring harness between S11 (female) (2) and CP01 (female) (11) and grounding Resistance value Resistance value Min. 1 Mz Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5 Pump controller defective CP01 Between (11) and grounding Power max. switch Released Pressed Voltage Max. 1 V 20 30 V
Electrical circuit diagram related to power max. switch
12
PC600-8
40 Troubleshooting
SEN00451-03
E-7 Machine push-up function does not operate normally

Failure information Relative information Machine push-up function does not operate normally. (1) The machine push-up function does not operate.
When the machine push-up function is set in the high pressure position, the solenoid is turned OFF. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S05 (female) Between (1) and (2) Machine push-up switch Low pressure position High pressure position Resistance value Max. 1 z Min. 1 Mz
Machine push-up switch 1 defective (Internal short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during troubleshooting. Hot short (Short circuit 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 D03 (female) (1) and grounding
Electrical circuit diagram related to machine push-up solenoid
PC600-8
13
SEN00451-03
40 Troubleshooting
Machine push-up function does not operate normally.
(2) The machine push-up function is not turned OFF.
When the machine push-up function is set in the low pressure position, the solenoid is turned ON. Cause Standard value in normalcy and references for troubleshooting If the fuse is broken, the circuit probably has grounding fault (See cause 6). a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S05 (female) Between (1) and (2) Machine push-up switch Low pressure position High pressure position Resistance value Max. 1 z Min. 1 Mz
Machine push-up switch 2 defective (Internal disconnection)
Machine push-up solenoid defective 3 (Internal disconnection, short-circuiting or grounding fault) Assembled-type diode 4 D03 defective (Internal short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V06 (male) Between (2) and (1) Between (2) and grounding Resistance value 20 60 z Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during troubleshooting. D03 (male) Between (1) and (5) Resistance value (Continuitiy) Min. 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 5 (Disconnection or defective contact with connector) Wiring harness between F01-2 outlet and S05 (male) (1) Wiring harness between S05 (male) (2), J01 and V06 (female) (2) Wiring harness between V06 (female) (1) and grounding Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 6 (Contact with grounding circuit) Between wiring harness between F01-2 outlet and S05 (male) (1) or between F01-2 outlet and related circuits and grounding Between wiring harness between S05 (male) (2), J01 and V06 (female) (2) or between S05 (male) (2) and D03 (female) (1) and grounding Resistance value Resistance value Min. 1 Mz
Min. 1 Mz
14
PC600-8
40 Troubleshooting
SEN00451-03
E-8 Any item is not displayed on machine monitor

Failure information Relative information Cause 1 Circuit breaker No. 1 or fuse No. 10 defective Standard value in normalcy and references for troubleshooting If the circuit breaker is turned OFF or the fuse is broken, the circuit probably has grounding fault (See cause 3). a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Wiring harness between CM01 (female) (1), (2) and F01-10 outlet Wiring harness between F01 inlet and B21 Wiring harness between B11 and battery relay terminal M Grounding fault of wiring harness 3 (Contact with grounding circuit) Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z Any item is not displayed on the machine monitor. When the starting switch is turned ON, any item is not displayed on the machine monitor.
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CM01 (female) (1), (2) and F01-10 outlet and grounding Between wiring harness between F01 inlet and B21 and grounding Resistance value Resistance value Min. 1 Mz Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON or OFF position during troubleshooting. Machine monitor 4 defective CM01 (female) Between (1), (2) and grounding Between (6), (7) and grounding Starting switch ON OFF Voltage, Resistance value Voltage: 20 30 V Resistance value: Max. 1 z
Electrical circuit diagram related to machine monitor power supply
PC600-8
15
SEN00451-03 E-9 Part of display on machine monitor is missing

Failure information Relative information Presumed cause and standard value in normalcy Part of display on machine monitor is missing Cause
40 Troubleshooting
Part of the display in the machine monitor is missing during starting switch in ON.
Standard value in normalcy and references for troubleshooting a Turn the starting switch ON during the troubleshooting.
Machine monitor LCD fault
If all the LCD (Liquid Crystal Display) in the machine monitor light up (i.e. the screen becomes totally white) by the following switching operation, then the machine monitor is normal. Switching operation: [ ] + [ A ] (push swiches simultaneously.) If cause 1 is not detected, the machine monitor may be defective. (Since trouble is in the machine monitor, troubleshooting cannot be carried out.)
Machine monitor defective
E-10 Machine monitor displays contents irrelevant to the model

Failure information Relative information Presumed cause and standard value in normalcy The machine monitor displays contents that have nothing to do with the model on which it is installed. Cause Standard value in normalcy and references for troubleshooting a Turn the starting switch in ON during the troubleshooting (monitoring). 1 Model code signal fault (Internal failure) Monitoring code 00200 Item Controller model code Normal display PC600-a
If the display on the monitor panel is normal, troubleshoot failure code [DA2SKQ]. 2 Machine monitor defective If cause 1 is not detected, the machine monitor may be defective. (Since trouble is in the machine monitor, troubleshooting cannot be carried out.)
16
PC600-8
40 Troubleshooting
SEN00451-03
E-11 Fuel level monitor red lamp lights up while engine is running
Failure information Relative information Fuel level monitor red lamp lighted up while the engine was running. If the fuel gauge shows in a red range on the machine monitor, the fuel level monitor lamp lights up red. Cause Fuel level lowered 1 (system in normal condition) Standard value in normalcy and references for troubleshooting Check the fuel level in the fuel tank. If it is low, add fuel. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 2 Fuel level sensor fault (Internal disconnection) P21 (male) Between (1) and grounding Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Fuel level FULL (Upper limit) EMPTY (Lower limit) Resistance value Approx. 12 z 85 110 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Machine monitor defective CM02 (female) Between (2) and grounding Fuel level FULL (Upper limit) EMPTY (Lower limit) Resistance value Approx. 12 z 85 110 z
Electrical circuit diagram related to fuel level sensor
PC600-8
17
SEN00451-03 E-12 Engine coolant temperature gauge does not display correctly
40 Troubleshooting
Failure information
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 range (C). (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 displayed. 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)) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. TWTR (male) Between (A) and (B) Between (A), (B) and grounding Resistance value 3.5 k 90 kz Min. 1 Mz
Engine coolant high temperature sensor defective 1 (Internal disconnection, short-circuiting or grounding fault) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between ENG (female) (15) and TWTR (female) (1) Wiring harness between ENG (female) (38), JM03 and TWTR (female) (2) Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between ENG (female) (15) and TWTR (female) (1) and grounding Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 4 with 24 V circuit) in wiring Between wiring harness between ENG (female) (15) harness Voltage Max. 1 V and TWTR (female) (1) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5 Engine controller defective ENG (female) Between (15) and (38) Between (15), (38) and grounding 6 Machine monitor defective Resistance value 3.5 k 90 kz Min. 1 Mz
If causes 1 5 are not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.)
18
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to engine coolant high temperature sensor
PC600-8
19
SEN00451-03 E-13 Hydraulic oil temperature gauge does not display correctly
40 Troubleshooting
Hydraulic oil temperature rises normally, but the dis Hydraulic oil temperature gauge does not display does not exceed the white range (C). play correctly Hydraulic oil temperature remains stable, but the display rises up the red range (H). Input from the hydraulic oil temperature sensor can be confirmed in the monitor function. (Code No. 04401: Hydraulic oil temperature) Cause Standard value in normalcy and references for troubleshooting
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF Hydraulic oil temperature position during the troubleshooting. sensor defective P22 (male) Hydraulic oil temperature Resistance value 1 (Internal disconnection, short-circuiting or Between (1) and (2) 90 3.5 kz 10 100C grounding fault) Between (1) and grounding Min. 1 Mz Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CM02 (female) (12) and P22 (female) (1) Wiring harness between CM02 (female) (13) and P22 (female) (2) Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 4 with 24 V circuit) in wiring Between wiring harness between CM02 (female) (12) harness Voltage Max. 1 V and P22 (female) (1) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5 Machine monitor defective CM02 (female) Between (12) and (13) Between (12) and grounding 10 100C Hydraulic oil temperature Resistance value 90 3.5 kz Min. 1 Mz
Electrical circuit diagram related to hydraulic oil temperature sensor
20
PC600-8
40 Troubleshooting
SEN00451-03
E-14 Fuel gauge does not display correctly

Failure information Relative information Though fuel was refilled, the display does not exceed the red range (E). Though the remaining fuel level is low, the display does not drop below the green range (F).
Fuel gauge does not display correctly
Input from the fuel level sensor (voltage) can be confirmed in the monitor function. (Code No. 04200: Fuel sensor voltage) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Fuel level FULL (Upper limit) EMPTY (Lower limit) Resistance value Approx. 12 z 85 110 z
Fuel level sensor defective P21 (male) 1 (Internal disconnection or grounding fault) Between (1) and grounding Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 4 with 24 V circuit) in wiring Between wiring harness between CM02 (female) (2) and harness Voltage Max. 1 V P21 (female) (1) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5 Machine monitor defective CM02 (female) Between (2) and grounding Fuel level FULL (Upper limit) EMPTY (Lower limit) Resistance value Approx. 12 z 85 110 z
Electrical circuit diagram related to fuel level sensor
PC600-8
21
SEN00451-03 E-15 Swing lock monitor does not display correctly

40 Troubleshooting
(1) Though the swing lock switch was turned ON, the swing lock monitor does not light up. Swing lock monitor does not display correctly (2) Though the swing lock switch was turned OFF, the swing lock monitor lights up. Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S04 (female) Between (1) and (2) Swing lock switch OFF ON Resistance value Min. 1 Mz Max. 1 z
Swing lock switch defective 1 (Internal disconnection or short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from CM02 (female) (17) to J07 and S04 (male) (1) Wiring harness from S04 (male) (2) to J03 and grounding Resistance value Resistance value Max. 1 z Max. 1 z
Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from CM02 (female) (17) to J07 and S04 (male) (1), or between CM02 (female) (17) to CP02 (female) (38) and grounding Resistance value Min. 1 Mz
Hot short (Short circuit 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 CP02 (female) (38) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Max. 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5 Machine monitor defective CM02 Between (17) and grounding Swing lock switch OFF ON Voltage 20 30 V Max. 1 V
22
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to swing holding brake
PC600-8
23
SEN00451-03 E-16 When monitor switch is operated, nothing is displayed

Failure information Relative information Presumed cause and standard value in normalcy
40 Troubleshooting
When monitor switch is operated, nothing is (1) When mode selector switch is operated, working displayed. mode monitor is not displayed. Cause 1 Machine monitor defective Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
When monitor switch is operated, nothing is (2) When LCD monitor adjustment switch is operated, displayed. mode selection screen is not displayed. Cause 1 Machine monitor defective Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
When monitor switch is operated, nothing is (3) When maintenance switch is operated, item selecdisplayed. tion screen is not displayed. Cause 1 Machine monitor defective Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
When monitor switch is operated, nothing is (4) When auto-deceleration switch is operated, autodisplayed. matic deceleration monitor is not displayed. When the automatic decelerator does not operate either, conduct the troubleshooting for "Auto-decelertor does not operate". Cause 1 Machine monitor defective Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
When monitor switch is operated, nothing is (5) When travel speed selector switch is operated, displayed. travel speed monitor is not displayed.
Cause 1 Machine monitor defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
24
PC600-8
40 Troubleshooting
SEN00451-03
When monitor switch is operated, nothing is (6) When wiper switch is operated, wiper monitor is not displayed. displayed. When the wiper does not operate either, conduct the troubleshooting for "Windshield wiper and window washer do not work". Cause 1 Machine monitor defective Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
PC600-8
25
SEN00451-03 E-17 Wiper and window washer do not work

Failure information Relative information Wiper and window washer do not work Cause Upper wiper motor 1 defective (Internal disconnection) (1) Upper wiper does not operate
40 Troubleshooting
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M05 (female) Between (3) and (1) Continuity and resistance value Continued
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CM01 (female) (9) and M05 (male) (3) Wiring harness between M05 (male) (1) and grounding Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Machine monitor defective CM01 Between (9) and grounding Wiper switch OFF ON Voltage Max. 3 V 20 30 V (Note)
Note:
20 30 V (at regular
26
PC600-8
40 Troubleshooting
SEN00451-03
PC600-8
27
SEN00451-03
Failure information Relative information Wiper and window washer do not work Cause (2) Lower wiper does not operate.
40 Troubleshooting
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S08 (female) Between (1) and (2) Lowe wiper switch OFF ON Resistance value Min. 1 Mz Max. 1 z
Lower wiper switch 1 defective (Internal disconnection)
Lower wiper motor 2 defective (Internal disconnection)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M15 (female) Between (3) and (1) Continuity and resistance value Continued
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Wiring harness between CM02 (female) (15) and S08 (male) (1) Wiring harness between S08 (male) (2), J05 and grounding Wiring harness between CM01 (female) (10), J02 and M15 (male) (3) Wiring harness between M15 (male) (1), J05 and grounding Resistance value Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Machine monitor defective (Lower wiper switch system) 4 Machine monitor defective (Lower wiper motor system)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CM02 Between (15) and grounding Lower wiper switch OFF ON Voltage 20 30 V Max. 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CM01 Between (10) and grounding Lower wiper switch OFF ON Voltage Max. 3 V 20 30 V (Note)
Note:
20 30 V (at regular
28
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to wiper motor (double wiper specification)
PC600-8
29
SEN00451-03
Failure information Relative information Wiper and window washer do not work. Cause Window rear limit switch defective 1 (Internal disconnection or short-circuiting) (3) Wiper does not work.
40 Troubleshooting
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S12 (female) Between (1) and (2) Front window When installed at front When retracted at rear Resistance value Min. 1 Mz Max. 1 z
Wiper motor defective (Internal disconnection)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M05 (female) Between (3) and (1) Continuity and resistance value Continued
Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Grounding fault of wiring harness 4 (Contact with grounding circuit) Machine monitor defective (Window rear limit switch system) 5 Machine monitor defective (Wiper motor system)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CM01 (male) (9) and M05 (female) (3) Wiring harness between CM01 (male) (10) and M05 (female) (1) Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CM02 (female) (15) and S12 (male) (2) Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CM02 Between (15) and grounding Front window When installed at front When retracted at rear Voltage 20 30 V Max. 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CM01 Between (9) and grounding, Between (10) and grounding Wiper switch OFF ON Voltage Max. 3 V Max. 3 V 20 30 V (Constant cycle)
30
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to wiper motor (Single wiper specification)
PC600-8
31
SEN00451-03
40 Troubleshooting
Wiper and window washer do not work. Cause
(4) Window washer does not operate.
Standard value in normalcy and references for troubleshooting If fuse is broken, the circuit probably has grounding fault, etc. (See cause 4.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M06 (male) Between (1) and (2) Between (1) and grounding Resistance value 5 20 z Min. 1 Mz
Washer motor defective 2 (Internal disconnection or grounding fault) Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from F01-4 outlet to J02 and M06 (female) (1) Wiring harness from M06 (female) (2) and CM01 (female) (3) Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from F01-4 outlet to J04 and M06 (female) (1), or F01-4 outlet to D04 (female) (2), and to other relative circuits and grounding Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5 Machine monitor defective CM01 Between (3) and grounding Washer switch OFF ON Voltage 20 30 V Max. 1 V
32
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to window washer motor
PC600-8
33
SEN00451-03 E-18 "Boom Raise" is not correctly displayed in monitoring function

40 Troubleshooting
"Boom Raise" is not correctly displayed in the moni "Boom Raise" is not correctly displayed in monitoring function (special function) on the machine toring function monitor. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. P06 (male) Between (2) and (1) R.H. work equipment control lever NEUTRAL Boom RAISE Resistance value Min. 1 Mz Max. 1 z
Boom Raise PPC pressure switch defective 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CP03 (female) (10) and P06 (female) (2) Wiring harness between P06 (female) (1) and grounding Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CP03 (female) (10) and P06 (female) (2) and grounding Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 4 with 24 V circuit) in wiring Between wiring harness between CP03 (female) (10) harness Voltage Max. 1 V and P06 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective CP03 Between (10) and grounding R.H. work equipment control lever NEUTRAL Boom RAISE Voltage 20 30 V Max. 1 V
Electrical circuit diagram related to boom Raise PPC pressure switch
34
PC600-8
40 Troubleshooting
SEN00451-03
PC600-8
35
SEN00451-03 E-19 "Boom Lower" is not correctly displayed in monitoring function

40 Troubleshooting
"Boom Lower" is not correctly displayed in the moni "Boom Lower" is not correctly displayed in monitoring function (special function) on the machine toring function monitor. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. P02 (male) Between (2) and (1) R.H. work equipment control lever NEUTRAL Boom LOWER Resistance value Min. 1 Mz Max. 1 z
Boom Lower PPC pressure switch defective 1 (Internal disconnection or short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 4 with 24 V circuit) in wiring Between wiring harness between CP03 (female) (20) harness Voltage Max. 1 V and P02 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective CP03 Between (20) and grounding R.H. work equipment control lever NEUTRAL Boom LOWER Voltage 20 30 V Max. 1 V
36
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to boom Lower PPC pressure switch
PC600-8
37
SEN00451-03 E-20 "Arm IN" is not correctly displayed in monitoring function

Failure information Relative information "Arm IN" is not correctly displayed in monitoring function Cause
40 Troubleshooting
"Arm IN" is not correctly displayed in the monitoring function (special function) on the machine monitor.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. P04 (male) Between (2) and (1) L.H. work equipment control lever NEUTRAL Arm IN Resistance value Min. 1 Mz Max. 1 z
Arm IN PPC pressure switch defective 1 (Internal disconnection or short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 4 with 24 V circuit) in wiring Between wiring harness between CP03 (female) (30) harness Voltage Max. 1 V and P04 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective CP03 Between (30) and grounding L.H. work equipment control lever NEUTRAL Arm IN Voltage 20 30 V Max. 1 V
Electrical circuit diagram related to arm IN PPC pressure switch
38
PC600-8
40 Troubleshooting
SEN00451-03
E-21 "Arm OUT" is not correctly displayed in monitoring function

Failure information Relative information "Arm OUT" is not correctly displayed in monitor- "Arm OUT" is not correctly displayed in the monitoring ing function function (special function) on the machine monitor. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. P08 (male) Between (2) and (1) L.H. work equipment control lever NEUTRAL Arm OUT Resistance value Min. 1 Mz Max. 1 z
Arm OUT PPC pressure switch defective 1 (Internal disconnection and short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 4 with 24 V circuit) in wiring Between wiring harness between CP03 (female) (40) harness Voltage Max. 1 V and P08 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective CP03 Between (40) and grounding L.H. work equipment control lever NEUTRAL Arm OUT Voltage 20 30 V Max. 1 V
Electrical circuit diagram related to arm OUT PPC pressure switch
PC600-8
39
SEN00451-03 E-22 "Bucket CURL" is not correctly displayed in monitoring function

Failure information Relative information "Bucket CURL" is not correctly displayed in monitoring function Cause
40 Troubleshooting
"Bucket CURL" is not correctly displayed in the monitoring function (special function) on the machine monitor.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. P01 (male) Between (2) and (1) R.H. work equipment control lever NEUTRAL Bucket CURL Resistance value Min. 1 Mz Max. 1 z
Bucket CURL PPC pressure switch defective 1 (Internal disconnection and short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CP03 (female) (9) and P01 (female) (2) Wiring harness between P01 (female) (1) to J12 and grounding Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 4 with 24 V circuit) in wiring Between wiring harness between CP03 (female) (9) and harness Voltage Max. 1 V P01 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective CP03 Between (9) and grounding R.H. work equipment control lever NEUTRAL Bucket CURL Voltage 20 30 V Max. 1 V
Electrical circuit diagram related to bucket CURL PPC pressure switch
40
PC600-8
40 Troubleshooting
SEN00451-03
E-23 "Bucket DUMP" is not correctly displayed in monitoring function

Failure information Relative information "Bucket DUMP" is not correctly displayed in the mon"Bucket DUMP" is not correctly displayed in moniitoring function (special function) on the machine toring function monitor. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. P05 (male) Between (2) and (1) R.H. work equipment control lever NEUTRAL Bucket DUMP Resistance value Min. 1 Mz Max. 1 z
Bucket DUMP PPC pressure switch defective 1 (Internal disconnection and short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 4 with 24 V circuit) in wiring Between wiring harness between CP03 (female) (19) harness Voltage Max. 1 V and P05 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective CP03 Between (19) and grounding R.H. work equipment control lever NEUTRAL Bucket DUMP Voltage 20 30 V Max. 1 V
Electrical circuit diagram related to bucket DUMP PPC pressure switch
PC600-8
41
SEN00451-03 E-24 "Swing" is not correctly displayed in monitoring function

Failure information Relative information "Swing" is not correctly displayed in monitoring function Cause
40 Troubleshooting
"Swing" is not correctly displayed in the monitoring function (special function) on the machine monitor.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. P03 (male) Between (2) and (1) R.H. work equipment control lever NEUTRAL Swing operated Resistance value Min. 1 Mz Max. 1 z
Swing PPC pressure switch defective 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CP03 (female) (29) and P03 (female) (2) and grounding Resistance value Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 4 with 24 V circuit) in wiring Wiring harness between CP03 (female) (29) and P03 harness Voltage Max. 1 V (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective CP03 Between (29) and grounding R.H. work equipment control lever NEUTRAL Swing operated Voltage 20 30 V Max. 1 V
42
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to swing PPC pressure switch
PC600-8
43
SEN00451-03 E-25 "Travel" is not correctly displayed in monitoring function

40 Troubleshooting
"Travel" is not correctly displayed in the monitor- "Travel" is not correctly displayed in the monitoring ing function. function (special function) of the machine monitor. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. P09 (male) Between (2) and (1) Travel lever Neutral Operated Resistance value Min. 1 Mz Max. 1 z
Travel PPC pressure switch defective 1 (Internal disconnection or short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 4 with 24 V circuit) in wiring Between wiring harness between CP03 (female) (39) harness Voltage Max. 1 V and P09 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 5 Pump controller defective CP03 Between (39) and grounding Travel lever Neutral Operated Voltage 20 30 V Max. 1 V
44
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to travel PPC pressure switch
PC600-8
45
SEN00451-03 E-26 Air conditioner does not work

Failure information Relative information Air conditioner does not work. Cause 1 Fuse No. 11 defective Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
40 Troubleshooting
Standard value in normalcy and references for troubleshooting When fuse is blown, there is a big possibility that grounding fault occurred in the circuit. (See Cause 3.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between F01-11 outlet and M26 (male) (5) Wiring harness between M26 (male) (8) and grounding Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between F01-11 outlet and M26 (male) (5) and grounding Voltage Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Air conditioner unit defective M26 Between (5) and (8) Voltage 20 30 V
If the above voltages are normal and the air conditioner does not operate, the air conditioner unit is defective.
Electrical circuit diagram related to air conditioner
46
PC600-8
40 Troubleshooting
SEN00451-03
PC600-8
47
SEN00451-03 E-27 Step light does not light up or go off

Failure information Relative information Step light does not light up or go off Cause 1 Defective fuse No. 20 2 Defective step light
40 Troubleshooting
(1) When switch is pressed, light does not light up for 1 minute.
Standard value in normalcy and references for troubleshooting If fuse is broken, circuit probably has ground fault (See cause 6). Step light may be defective. Check bulb directly for breakage. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S13 (male) Between (1) (2) Step light switch Released Pressed Resistance Min. 1 Mz Max. 1 z
Defective step light 3 switch (Internal disconnection)
Defective step light relay 4 (Internal defect) Presumed cause and standard value in normalcy
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When step light relay is replaced with another relay, if condition becomes normal, step light relay is defective. R09
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-20 outlet J06 (female) (19) Wiring harness between J06 (female) (20) S13 (female) (2) Wiring harness between J06 (female) (17), (18) R09 (female) (1), (3) Disconnection in wiring harness (Disconnection 5 in wiring or defective contact in connector) Wiring harness between S13 (female) (1) J06 (female) (3) Wiring harness between J06 (female) (2) CP01 (female) (24) Wiring harness between J06 (female) (1) D03 J07 (female) (11), (12) CP03 (female) (14), (24) Wiring harness between R09 (female) (2) CP02 (female) (19) Wiring harness between R09 (female) (5) L06 (female) (1) Wiring harness between L06 (female) (2) chassis ground Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
48
PC600-8
40 Troubleshooting
SEN00451-03
Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-20 outlet J06 S13 (female) (2), or R09 (female) (2), (3) chassis ground Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz
Cause
Ground fault in wiring 6 harness (Contact with GND circuit)
Wiring harness between S13 (female) (1) J06 CP01 (female) (24), or D03 J07 CP03 (female) (14), (24) chassis ground Wiring harness between R09 (female) (5) H02 L06 (female) (1) chassis ground Wiring harness between R09 (female) (2) CP02 (female) (19) chassis ground
Resistance
Resistance Resistance
Defective pump controller (Step light switch input system) 7 Defective pump controller (Step light relay output system)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP01 Between (24) chassis ground Step light switch Released Pressed Voltage Max. 1 V 20 30 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP02 Between (19) chassis ground Step light switch Released Pressed Voltage Max. 1 V 20 30 V (60 seconds)
PC600-8
49
SEN00451-03
40 Troubleshooting
Step light does not light up or go off Cause
(2) While switch is not pressed, light lights up.
Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective step light (Internal short circuit)
S13 (male) Between (1) (2)
Step light switch Released Pressed
Resistance Min. 1 Mz Max. 1 z
Defective step light relay 2 (Internal defect) Presumed cause and standard value in normalcy
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When step light relay is replaced with another relay, if condition becomes normal, step light relay is defective. R09
a Prepare with starting switch OFF, then turn starting switch ON and carry out 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) harness chassis ground Wiring harness between CP02 (female) (19) R09 (female) (2) chassis ground Voltage Max. 1 V
Voltage
Max. 1 V
Defective pump controller (Step light switch input system) 4 Defective pump controller (Step light relay output system)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP01 Between (24) chassis ground Step light switch Released Pressed Voltage Max. 1 V 20 30 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP02 Between (19) chassis ground Step light switch Released Pressed Voltage Max. 1 V 20 30 V (60 seconds)
50
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to step light
PC600-8
51
SEN00451-03 E-28 Electric grease gun does not operate

Failure information Relative information Electric grease gun does not operate. Cause 1 Presumed cause and standard value in normalcy Circuit breaker No. 3 defective
40 Troubleshooting
Standard value in normalcy and references for troubleshooting If the circuit breaker is turned OFF, there is a big possibility that grounding fault occurred in the circuit (See cause 3). a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between B01 (female) (F) and M16 (male) (1) Wiring harness between M16 (male) (2) and grounding Resistance value Resistance value Max. 1 z Max. 1 z
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit) 4 Grease pump defective
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between B01 (female) (F) and M16 (male) (1) and grounding Resistance value Min. 1 Mz
If causes 1 3 are not detected, the grease pump may be defective. (Since trouble is in the grease pump, troubleshooting cannot be carried out.)
Electrical circuit diagram related to electric grease gun
52
PC600-8
40 Troubleshooting
SEN00451-03
PC600-8
53
SEN00451-03 E-29 Travel alarm does not sound or does not stop sounding
Failure information Relative information Travel alarm does not sound or does not stop sounding. Cause
40 Troubleshooting
(1) The alarm does not sound while the machine is traveling. (2) The alarm sounds while the machine is stopped.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. Monitoring code Item Travel Normal display Lever operated: ON Lever in neutral: OFF is
1 Travel signal defective
01900 Pressure switch 1
If the display on the monitor panel is abnormal, carry out troubleshooting in " not displayed normally in monitoring function".
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. M14 (female) Presumed cause and standard value in normalcy Travel alarm defective 2 (Internal defective) Between (1) and (2) Travel lever Neutral Operated Voltage Max. 1 V 20 30 V
If the above voltages are normal and the travel alarm does not sound, the travel alarm is defective. Disconnection of wiring harness 3 (Disconnection or defective contact with connector) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CP03 (female) (8) and M14 (female) (1) Wiring harness between M14 (female) (2) and grounding Resistance value Resistance value Max. 1 z Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Hot short (Short circuit position during the troubleshooting. 4 with 24 V circuit) in wiring Between wiring harness between CP03 (female) (8) and harness Voltage Max. 1 V M14 (female) (1) and grounding a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 5 Pump controller defective CP03 Between (8) and grounding Travel lever Neutral Operated Voltage Max. 1 V 20 30 V
54
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to travel alarm
PC600-8
55
SEN00451-03 E-30 Horn does not sound

Failure information Relative information Cause 1 Defective fuse No. 5 2 Defective horn relay Horn does not sound.
40 Troubleshooting
Standard value in normalcy and references for troubleshooting If fuse is broken, circuit probably has ground fault. (See Cause 6) If the horn sounds after replacing the relay, the relay was defective. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between M07 (1) chassis ground (with horn switch turned ON) Voltage 20 30 V
3 Defective high tone horn
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between M07 (female) (2) chassis ground If above is normal, the horn is defective. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Resistance value Max. 1 z
Between M08 (1) chassis ground (with horn switch turned ON) 4 Defective low tone horn
Voltage
20 30 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between M08 (female) (2) chassis ground If above is normal, the horn is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance value Max. 1 z
Disconnection in wiring harness 5 (Disconnection in wiring or defective contact in connector)
Wiring harness between F01 (5) S10 (female) R08 (female) (3) Wiring harness between S10 (2) R08 M07 (female) (1) Wiring harness between R08 (female) (4) M08 (female) (1)
Resistance value Resistance value Resistance value
Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 6 (Short circuit with GND circuit) Wiring harness between F01 (5) S10 (female) R08 (female) (3) and chassis ground Wiring harness between S10 (female) (2) R08 (female) M07 (female) (1) and chassis ground Wiring harness between R08 (female) (4) M08 (female) (1) and chassis ground Resistance value Resistance value Resistance value Min. 1 Mz Min. 1 Mz Min. 1 Mz
56
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to horn
PC600-8
57
SEN00451-03 E-31 Bottom dump does not move

Failure information Relative information Cause Defective fuse 1 No. 5, No. 9 2 Defective bottom dump open Defective bottom dump close Bottom dump does not move.
40 Troubleshooting
Standard value in normalcy and references for troubleshooting If fuse is broken, circuit probably has ground fault. (See Cause 6) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between S10 (1) (2) Voltage 20 30 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between S11 (1) (3) Voltage 20 30 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective bottom dump close solenoid valve
Between V20 (1) (2)
Voltage
20 30 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between V20 (1) chassis ground Resistance value Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective bottom dump open solenoid valve Between V21 (1) (2) Voltage 20 30 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between V21 (2) chassis ground Resistance value Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective wiring harness Between S10 (2) A11 V21 (1) Between S11 (3) A11 V20 (1) Resistance value Resistance value Max. 1 z Max. 1 z
Bottom dump does not move.
Cause
Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective bottom dump 1 pressure switch
Between P13 (2) A09 CP02 (35)
Resistance value
Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between P13 (2) chassis ground Resistance value Min. 1 Mz
a Solenoid valve and bottom dump pressure switch are connected by hydraulic line.
58
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to bottom dump
PC600-8
59
SEN00451-03
40 Troubleshooting
60
SEN00452-02
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-mode)
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 ............................................................................................................................... 23 H-12 Bottom dump does not move .................................................................................................................... 23 H-13 Hydraulic drift of work equipment is large ................................................................................................. 24 H-14 Time lag of work equipment is large.......................................................................................................... 25 H-15 Power max. function does not operate or stop.......................................................................................... 26 H-16 Machine push-up function does not operate or stop ................................................................................. 26 H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is low.......................... 27
PC600-8
SEN00452-02
40 Troubleshooting
H-18 When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel speed is low............................................................................................................................................................. 27 H-19 When arm and swing are operated simultaneously, swing speed is low................................................... 28 H-20 Machine deviates in one direction ............................................................................................................. 29 H-21 Machine deviates largely at start............................................................................................................... 31 H-22 Travel deviation is large during compound operation................................................................................ 32 H-23 Travel speed or power is low..................................................................................................................... 33 H-24 Machine does not travel (only one track) .................................................................................................. 34 H-25 Travel speed does not change .................................................................................................................. 35 H-26 Upper structure does not swing................................................................................................................. 36 H-27 Swing speed or acceleration is low ........................................................................................................... 37 H-28 Upper structure overruns excessively when it stops swinging .................................................................. 38 H-29 Large shock is made when upper structure stops swinging ...................................................................... 39 H-30 Large abnormal sound is made when upper structure stops swinging ..................................................... 40 H-31 Hydraulic drift of swing is large.................................................................................................................. 41
PC600-8
40 Troubleshooting
SEN00452-02
Before troubleshooting H-mode
PC600-8
SEN00452-02
1. Combination and operation of hydraulic pumps For the work equipment, travel, and swing circuits, 2 tandem pumps (4 pump units) of the No. 1 pump (HPV95+95) and the No. 2 pump (HPV95+95) are used. The oil from the No. 1 front pump and that from the No. 2 front pump merge together and flow in the right side 5-spool valve. The oil from the No. 1 rear pump and that from the No. 2 rear pump merge together and flow in the left side 4-spool valve. The TVC valve installed on the No. 1 rear pump carries out the TVC control of the No. 1 pump and No. 2 pump similarly. The CO, NC valve installed on the No. 1 front pump and the jet sensor installed to the right side 5-spool valve carry out the CO, NC control of the No. 1 front pump and No. 2 front pump similarly. The CO, NC valve installed on the No. 1 rear pump and the jet sensor installed to the left side 4-spool valve carry out the CO, NC control of the No. 1 rear pump and No. 2 rear pump similarly.
40 Troubleshooting
2. Finding cause of trouble that "work equipment speed is low and machine deviates to right" The possible causes of this trouble are as follows: 1) The main relief valve of the right side 5spool valve is defective. 2) The jet sensor of the right side 5-spool valve is defective. 3) The CO, NC valve of the No. 1 front pump is defective. 4) The servo valve of the No. 1 front pump is defective. 5) The No. 1 front pump is defective. 6) The servo valve of the No. 2 front pump is defective. 7) The No. 2 front pump is defective. Whether the main relief valve, jet sensor, and CO, NC valve are good or not can be judged by measuring the relief pressure, differential pressure, and output pressure respectively. Since the oil from the No. 1 front pump and that from the No. 2 front pump merge together 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 equipment speed is low and machine deviates".
PC600-8
40 Troubleshooting
SEN00452-02
4. Judgment matrix for trouble that work equipment speed is low and machine deviates (on the next page) a Carry out diagnosis in order from the top line and judge the factor having the most black points (q) to be the cause of the trouble. 1) To judge the servo valve, remove it and test it or measure the stroke of the servo piston. a Perform the test on the servo piston unit in the specified maintenance shop. 2) If the speed lowers extremely and the pump seems to be abnormal, check the line filter too. 3) If the speed lowers little but cannot be set to the normal level by adjusting each device, check the line filter too. 4) To check the operation of the servo piston, remove the caps from both sides of it and move the servo piston with the hand.
3. Finding cause of trouble that "work equipment speed is low and machine deviates to left" The possible causes of this trouble are as follows: 1) The main relief valve of the left side 4spool valve is defective. 2) The jet sensor of the left side 4-spool valve is defective. 3) The CO, NC valve of the No. 1 rear pump is defective. 4) The servo valve of the No. 1 rear pump is defective. 5) The No. 1 rear pump is defective. 6) The servo valve of the No. 2 rear pump is defective. 7) The No. 2 rear pump is defective. Whether the main relief valve, jet sensor, and CO, NC valve are good or not can be judged by measuring the relief pressure, differential pressure, and output pressure respectively. Since the oil from the No. 1 rear pump and that from the No. 2 rear pump merge together 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 equipment speed is low and machine deviates".
PC600-8
SEN00452-02
40 Troubleshooting
Causes No. 1 pump No. 2 pump Front pump Servo valve defective Pump unit defective Rear pump Servo valve defective Pump unit defective Left Right 4-spool 5-spool valve valve Main relief valve defective Main relief valve defective
Front pump CONC valve defective Servo valve defective
Rear pump CONC valve defective Servo valve defective
Jet sensor defective
Jet sensor defective
Pump unit defective
Pump unit defective
Remedy A: Adjust Remedy X: Repair or replace
Remedy No. Diagnosis 1 2 3 Machine "deviates to right" 4 5 6 7 8 9 10 11 12 13 14 Machine "deviates to left" 15 16 17 18 19 20 21 22 Machine "deviates to right" and work equipment speed and swing speed are low. Machine "deviates to right" and single swing speed is particularly low. Machine "deviates to right" and single swing speed is normal. Travel relief pressure of front pump circuit is low. Machine "deviates to right" (Deviation does not change).
A X
A X
A X
A X
A X
A X
q q q q q q
q q q q
q q q q q
When result of 4 is normal, exchange front and Machine "deviates to left" rear outlet hoses of No. 2 (Deviation changes). pump. Speed of both travel motors is low. When phenomenon of 5 occurs, servo valve of No. 1 front pump is normal. When phenomenon of 6 occurs, servo valve of No. 2 front pump is normal. When phenomenon of 7 occurs, jet sensor differential pressure of right side 5-spool valve is abnormal.
q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
When result of 10 is normal, No. 1 front NC valve output pressure is abnormal. Machine "deviates to left" and work equipment speed is low. Machine "deviates to left" and bucket dump speed is particularly low. Machine "deviates to left" and bucket dump speed is normal. Travel relief pressure of rear pump circuit is low. Machine "deviates to left" (Deviation does not change). Machine "deviates to right" (Deviation changes). Speed of both travel motors is low.
When result of 15 is normal, exchange front and rear outlet hoses of No. 2 pump.
When phenomenon of 16 occurs, servo valve of No. 1 rear pump is normal. When phenomenon of 17 occurs, servo valve of No. 2 rear pump is normal. When phenomenon of 18 occurs, jet sensor differential pressure of left side 4-spool valve is abnormal. When result of 18 is normal, No. 1 front NC valve output pressure is abnormal.
PC600-8
R.H. travel motor X
L.H. travel motor
40 Troubleshooting
SEN00452-02
How to exchange outlet hoses of No. 2 pump and hydraulic circuit diagram after they are exchanged
PC600-8
SEN00452-02 Information in troubleshooting table
40 Troubleshooting
a Tables and related circuit diagrams concerning troubleshooting contains the following information. Please understand the contents sufficiently before carrying out troubleshooting.
Failure Phenomenon Related Information Phenomena on machine Information concerning to failure or troubleshooting. Cause Standard value in normalcy and references for troubleshooting
Causes for presumed failure (The attached No. for filing and reference purpose only. It does not stand for any priority)
<Contents> Standard values for judgement of possible causes. Remarks for judgement
PC600-8
40 Troubleshooting
SEN00452-02
PC600-8
SEN00452-02 H-1 Speed or power of all work equipment, travel, and swing is low
Failure information Speed or power of all work equipment, travel, and swing is low
40 Troubleshooting
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. (If abnormal sound is heard, carry out the related troubleshooting.) 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. Cause Standard value in normalcy and references for troubleshooting a Run the engine at high idle during troubleshooting. Power max. switch and right work equipment control lever Power max. switch OFF + Boom RAISE relief Power max. switch ON + Boom RAISE relief Engine speed Above 1,780 rpm Above 1,730 rpm
1 Engine unit defective
PTO defective internally 2 (Control pump drive system) 3 Control pump defective internally
a Keep the engine stopped for the preparations and troubleshooting. Disconnect the control pump outlet hose and rotate the crankshaft. If oil flows out of the pump outlet, PTO is normal. Control pump may be defective internally. Check inside of pilot filter for metal dust, etc. a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. Control levers Control relief pressure 3.14 All levers in neutral
+0.39 MPa 0 +4 {32 0 kg/cm2}
Wrong adjustment or 4 malfunction of control relief valve
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. 5 Leakage in control system devices Control levers All levers in neutral Control relief pressure 3.14
+0.39 MPa 0 +4 {32 0 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. Wrong adjustment or 6 malfunction of main relief valve Right work equipment control lever Boom RAISE relief (Normal) Main relief pressure 31.87 0.98 MPa {325 10 kg/cm2}
+15 +1.47
If the oil pressure is still abnormal after adjustment, the main relief valve (on the lowpressure set side and high-pressure set side) may be defective. Check the main relief valve directly.
10
PC600-8
40 Troubleshooting
SEN00452-02
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during 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 {Min. 18 kg/cm2} 1.05 0.53 MPa {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. a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
+2.0 +0.20
Cause
Wrong adjustment or malfunction of TVC valve
All levers in neutral
Boom RAISE relief
Malfunction of CO cancel solenoid valve
Swing lock switch ON OFF
Solenoid valve outlet pressure Min. 2.74 MPa {Min. 28 kg/cm2} 0 MPa {0 kg/cm2}
Fig. 1: Control system devices
PC600-8
11
SEN00452-02 H-2 Engine speed lowers remarkably or engine stalls

Failure Phenomenon Related Information Engine speed lowers remarkably or engine stalls Carry out all the troubleshooting in working mode P. Cause
40 Troubleshooting
Standard value in normalcy and references for troubleshooting 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 {Min. 18 kg/cm2} 1.05 0.53 MPa
+2.0 {10.7 5.4 +0.20
Defective adjustment or 1 malfunction of TVC valve
All control levers in neutral Boom relieved in RAISE position
kg/cm2}
If the oil pressure cannot be set normally by adjustment, the TVC valve may have a malfunction. Check the TVC valve directly. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. (Check cause 1 and confirm that the result is normal before troubleshooting.) Defective adjustment or 2 malfunction of CO, NC valve R.H. work equipment control lever Boom relieved in RAISE position CO, NC valve output pressure 1.05 0.53 MPa {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. 3 Defective engine If the results of check of causes 1 and 2 are normal, the engine may be defective. Check the engine
+2.0 +0.20
12
PC600-8
40 Troubleshooting
SEN00452-02
PC600-8
13
SEN00452-02 H-3 All work equipment, travel, and swing systems do not work
Failure information Relative information All work equipment, travel, and swing systems do not work Carry out all the troubleshooting in working mode P. Cause PTO defective internally 1 (Main pump drive system) PTO defective internally 2 (Control pump drive system) 3 Control pump defective internally
40 Troubleshooting
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations and troubleshooting. Disconnect the main pump oil pressure pickup coupler and rotate the crankshaft. If oil flows out of the pump outlet, PTO is normal. a Keep the engine stopped for the preparations and troubleshooting. Disconnect the control pump outlet hose and rotate the crankshaft. If oil flows out of the pump outlet, PTO is normal. Control pump may be defective internally. Check inside of pilot filter for metal dust, etc. a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. Control levers Control relief pressure 3.14 All levers in neutral
+0.39 MPa 0 +4 {32 0 kg/cm2}
Wrong adjustment or 4 malfunction of control relief valve
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. 5 Leakage in control system devices Control levers All levers in neutral Control relief pressure 3.14
+0.39 MPa 0 +4 {32 0 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. 6 Malfunction of PPC lock solenoid valve Work equipment lock lever FREE LOCK Solenoid valve outlet pressure Min. 2.74 MPa {28 kg/cm2} 0 MPa {0 kg/cm2}
14
PC600-8
40 Troubleshooting
SEN00452-02
Fig. 1: Control system devices
PC600-8
15
SEN00452-02 H-4 Abnormal sound is heard from around pump

Failure Phenomenon Related Information Presumed cause and standard value in normalcy Abnormal sound is heard from around pump Cause 1 Low hydraulic oil level 2 Loosened piping clamp 3 4 Clogged hydraulic tank strainer
40 Troubleshooting
Standard value in normalcy and references for troubleshooting Since the hydraulic oil level may be low, check it directly. Since a piping clamp between the hydraulic tank and hydraulic pump may be loosened, check it directly. Since the hydraulic tank strainer may be clogged, check it directly.
Internal defect of hydrauSince 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 while and observe the condition for change.
5 Observation of condition
16
PC600-8
40 Troubleshooting
SEN00452-02
H-5 Auto-decelerator is not reset

Failure information Relative information Presumed cause and standard value in normalcy Auto-decelerator is not reset (1) When machine swings, auto-decelerator is not reset.
The signal pressure of the swing PPC circuit is input through the armswing PPC shuttle valve (swing side) to the swing PPC pressure switch. Carry out all troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Stop the engine for the preparations, and keep it running at high idle during the troubleshooting.
Malfunction of arm, swing 1 PPC shuttle valve (swing side)
L.H. work equipment control lever Neutral Swing left right stroke end
Shuttle valve outlet pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min. 28 kg/cm2}
Auto-decelerator is not reset
(2) When machine travels, auto-decelerator is not reset.
The signal pressure of the travel PPC circuit is input through the travel PPC shuttle valve (in the travel PPC valve) to the travel PPC pressure switch. Carry out all troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Stop the engine for the preparations (measure at the travel PPC pressure switch), and keep it running at high idle during the troubleshooting.
Malfunction of travel PPC 1 valve (internal shuttle valve)
Travel lever All levers in neutral R.H. and L.H. forward-reverse stroke end
PPC valve output pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min. 28 kg/cm2}
PC600-8
17
SEN00452-02 H-6 Boom speed or power is low

Failure information Boom speed or power is low
40 Troubleshooting
(1) Boom speed or power is low in normal mode.
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 abnormal, carry out troubleshooting related to it.) Check that the machine does not deviate during travel. (If the machine deviates, carry out troubleshooting related to travel deviation.) Carry out all the troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Stop the engine for the preparations, and keep it running at high idle during the troubleshooting.
Malfunction of right PPC valve (boom circuit)
R.H. work equipment control lever Boom RAISE, LOWER full stroke
PPC valve output pressure Min. 2.74 MPa {Min. 28 kg/cm2}
2 3
Malfunction of boom control valve (spool)
The spool of the boom control valve (Lo, Hi) may be malfunctioning. Check it directly.
Malfunction of boom con- The main unit of the boom control valve (Lo, Hi) may be malfunctioning. Check it 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.) Malfunction of boom 5 regeneration valve (safety & suction valve) The safety & suction valve of the boom regeneration valve may be malfunctioning. Check it directly. (When checking the safety & suction valve by exchanging it with a valve of another work equipment circuit, stop the hose of the machine push-up solenoid securely. After finishing check, be sure to return the safety & suction valve since its set pressure and structure are different from others.) a Stop the engine for the preparations, and keep it running at high idle during the troubleshooting. R.H. work equipment control lever Boom RAISE relief Leakage from cylinder Max. 20 cc/min
Defective seal of boom cylinder
18
PC600-8
40 Troubleshooting
SEN00452-02
Boom speed or power is low
(2) Boom raise speed or power is low in L-mode.
Check that the other work equipment, travel, and swing are normal. (If any of them is abnormal, carry out troubleshooting related to it.) Check that the machine does not deviate. (If it deviates, carry out troubleshooting related to deviation.) Carry out all the troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
Malfunction of CO cancel solenoid valve
R.H. work equipment control lever Neutral Single boom RAISE operation
Solenoid valve outlet pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. 2 Malfunction of 2-stage relief solenoid valve R.H. work equipment control lever Neutral Single boom RAISE operation Solenoid valve outlet pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Wrong adjustment or 3 malfunction of main relief valve R.H. work equipment control lever Single boom RAISE operation Main relief pressure 37.2 2.0 MPa {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.
+15 +1.5
Failure information
Boom speed or power is low
(3) Boom lower speed or power is low in the machine 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 out troubleshooting related to it.) Check that the machine does not deviate. (If it deviates, carry out troubleshooting related to deviation.) Carry out all the troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
Malfunction of machine push-up solenoid valve
Machine push-up switch OFF ON
Solenoid valve outlet pressure Min. 2.74 MPa {Min. 28 kg/cm2} 0 MPa {0 kg/cm2}
Malfunction of boom 2 regeneration valve (safety & suction valve)
The safety & suction valve of the boom regeneration valve (on the high pressure set side) may malfunction. Check it directly.
PC600-8
19
SEN00452-02 H-7 Arm speed or power is low

Failure Phenomenon Arm speed or power is low Check that the speeds of the other work equipment, travel, and swing are normal. (If they are abnormal, carry out the related troubleshooting.) 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. Cause
40 Troubleshooting
Related Information
Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle.
Malfunction of left PPC valve (arm circuit)
L.H. work equipment control lever Arm IN, OUT full stroke
Malfunction of arm control valve (spool)
Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it directly. The safety-suction valve of the arm control valve (Lo) may malfunction. Check it directly. (After checking the safety-suction valve by exchanging it with a valve of another work equipment circuit, be sure to return it since its set pressure is different from others.) Since the body of the arm control valve (Lo, Hi) may have a malfunction, check it directly. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. L.H. work equipment control lever Relieved in arm CURL position Leakage from cylinder Max. 20 cc/min
Malfunction of arm 3 control valve (safety & suction valve) 4 Defective arm control valve (body) Defective seal of arm cylinder
20
PC600-8
40 Troubleshooting
SEN00452-02
H-8 Bucket speed or power is low

Failure Phenomenon Bucket speed or power is low Check that the speeds of the other work equipment, travel, and swing are normal. (If they are abnormal, carry out the related troubleshooting.) 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. Cause Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. 1 Presumed cause and standard value in normalcy Malfunction of right PPC valve (bucket circuit) R.H. work equipment control lever Bucket CURL, DUMP full stroke 2 Malfunction of bucket control valve (spool) PPC valve output pressure Min. 2.74 MPa {Min. 28 kg/cm2}
Related Information
Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it directly. Since the safety & suction valve of the bucket control valve (Lo, Hi) may have a malfunction, check it directly. (The safety & suction valve may be checked by replacing it with one of another work equipment circuit. After checking, however, be sure to return the safety & suction valve since its set pressure and structure are different from the others.) Since the body of the bucket control valve (Lo, Hi) may have a malfunction, check it directly. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. R.H. work equipment control lever Relieved in bucket CURL position Leakage from cylinder Max. 20 cc/min
Malfunction of bucket 3 control valve (safety & suction valve) Defective bucket control valve (body)
Defective seal of bucket 5 cylinder
PC600-8
21
SEN00452-02 H-9 Boom does not move

Failure Phenomenon Related Information Boom does not move Check that operations of the other work equipment, travel, and swing are normal. (If they are abnormal, carry out the related troubleshooting.) Carry out all the troubleshooting in working mode P. Cause Malfunction of right PPC 1 valve (boom circuit)
40 Troubleshooting
Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. R.H. work equipment control lever Boom RAISE, LOWER full stroke PPC valve output pressure Min. 2.74 MPa {Min. 28 kg/cm2}
Malfunction of boom control valve (spool)
Since the spool of the boom control valve (Lo, Hi) may have a malfunction, check it directly.
H-10 Arm does not move

Failure Phenomenon Related Information Arm does not move Check that operations of the other work equipment, travel, and swing are normal. (If they are abnormal, carry out the related troubleshooting.) Carry out all the troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. 1 Malfunction of left PPC valve (arm circuit) L.H. work equipment control lever Arm IN, OUT full stroke 2 Malfunction of arm control valve (spool) PPC valve output pressure Min. 2.74 MPa {Min. 28 kg/cm2}
Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it directly.
22
PC600-8
40 Troubleshooting
SEN00452-02
H-11 Bucket does not move

Failure Phenomenon Related Information Bucket does not move Check that operations of the other work equipment, travel, and swing are normal. (If they are abnormal, carry out the related troubleshooting.) Carry out all the troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. 1 Malfunction of right PPC valve (bucket circuit) R.H. work equipment control lever Bucket CURL, DUMP full stroke 2 Malfunction of bucket control valve (spool) PPC valve output pressure Min. 2.74 MPa {Min. 28 kg/cm2}
Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it directly.
H-12 Bottom dump does not move

Failure Phenomenon Related Information Bottom dump does not move Check that operations of the other work equipment, travel and swing are normal. (If they are abnormal, carry out the related troubleshooting.) Carry out all the troubleshooting in working mode P. Cause Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. 1 Malfunction of right PPC valve (bucket circuit) R.H. work equipment control lever Bucket DUMP full stroke PPC valve output pressure Min. 2.74 MPa {Min. 28 kg/cm2}
Malfunction of right PPC 2 valve (bottom dump circuit) Malfunction of bucket control valve (spool)
a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. R.H. work equipment control lever Bottom dump OPEN, CLOSE full stroke PPC valve output pressure Min. 2.74 MPa {Min. 28 kg/cm2}
Since the spool of the bucket control valve (Hi) may have a malfunction, check it directly.
PC600-8
23
SEN00452-02 H-13 Hydraulic drift of work equipment is large

Failure Phenomenon Related Information Presumed cause and standard value in normalcy Hydraulic drift of work equipment is large Cause 1 (1) Hydraulic drift of boom is large
40 Troubleshooting
Standard value in normalcy and references for troubleshooting
Malfunction of boom lock Since the poppet of the boom lock valve may have a malfunction, check it directly. valve (poppet)
Malfunction of boom lock 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 3 cylinder a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. R.H. work equipment control lever Relieved in boom RAISE position Leakage from cylinder Max. 20 cc/min
Failure Phenomenon Related Information
Hydraulic drift of work equipment is large Cause
(2) Hydraulic drift of arm is large
Standard value in normalcy and references for troubleshooting Since the spool of the arm control valve (Lo) may have a malfunction, check it directly. Since the safety & suction valve (head side) of the arm control valve (Lo) may have a malfunction, check it directly. (The safety & suction valve may be checked by replacing it with one of another work equipment circuit. After checking, however, be sure to return the safety & suction valve since its set pressure and structure are different from the others.) a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. L.H. work equipment control lever Relieved in arm IN position Leakage from cylinder Max. 20 cc/min
Defective seal of arm control valve (spool)
Malfunction of arm 2 control valve (safety & suction valve)
Defective seal of arm cylinder
Hydraulic drift of work equipment is large Cause
(3) Hydraulic drift of bucket is large
Standard value in normalcy and references for troubleshooting Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it directly. Since the safety & suction valve (bottom side) of the bucket control valve (Lo, Hi) may have a malfunction, check it directly. (The safety & suction valve may be checked by replacing it with one of another work equipment circuit. After checking, however, be sure to return the safety & suction valve since its set pressure and structure are different from the others.) a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. R.H. work equipment control lever Relieved in bucket CURL position Leakage from cylinder Max. 20 cc/min
Defective seal of bucket control valve (spool)
Malfunction of bucket 2 control valve (safety & suction valve)
Defective seal of bucket cylinder
24
PC600-8
40 Troubleshooting
SEN00452-02
H-14 Time lag of work equipment is large

Failure Phenomenon Related Information Time lag of work equipment is large Cause Presumed cause and standard value in normalcy 1 Malfunction of boom regeneration valve Malfunction of boom control valve (suction valve) Standard value in normalcy and references for troubleshooting Since the boom regeneration valve may have a malfunction, check it directly. Since the suction valve (head side) of the boom control valve (Lo) may have a malfunction, check it directly. (When checking by replacing with travel circuit.) (1) Time lag of boom is large
Time lag of work equipment is large Cause
(2) Time lag of arm is large
Standard value in normalcy and references for troubleshooting Since the safety & suction valve (bottom side) of the arm control valve (Lo) may have a malfunction, check it directly. (The safety & suction valve may be checked by replacing it with one of another work equipment circuit. After checking, however, be sure to return the safety & suction valve since its set pressure and structure are different from the others.)
Malfunction of arm control valve (safety & suction valve)
Time lag of work equipment is large Cause
(3) Time lag of bucket is large
Standard value in normalcy and references for troubleshooting
Since the safety & suction valve (bottom side) of the bucket control valve (Lo, Malfunction of bucket Hi) may have a malfunction, check it directly. (The safety & suction valve may control valve (safety be checked by replacing it with one of another work equipment circuit. After & suction valve) checking, however, be sure to return the safety & suction valve since its set pressure and structure are different from the others.)
PC600-8
25
SEN00452-02 H-15 Power max. function does not operate or stop

Failure Phenomenon Related Information Power max. function does not operate or stop Carry out all troubleshooting in working mode P. Cause
40 Troubleshooting
Standard value in normalcy and references for troubleshooting a Stop the engine for the preparations, and keep it running at high idle during the troubleshooting.
Malfunction of 2-stage relief solenoid valve
Power max. switch OFF ON
Malfunction of main relief valve
The main relief valve of the control valve may malfunction. Check it directly.
H-16 Machine push-up function does not operate or stop

Failure Phenomenon Related Information Presumed cause and standard value in normalcy Machine push-up function does not operate or stop Cause 1 Standard value in normalcy and references for troubleshooting Check by (3) in "H-6 Boom speed or power is low".
26
PC600-8
40 Troubleshooting
SEN00452-02
H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is low
Failure Phenomenon Related Information When arm and boom, bucket are operated simultaneously, boom, bucket speed is low Check that all the operations are normal when performed singly. (If any of them is abnormal, carry out troubleshooting related to it.) Carry out all troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Stop the engine for the preparations, and keep it running at high idle during the troubleshooting. Presumed cause and standard value in normalcy 1 Malfunction of boom, bucket PPC shuttle valve R.H. work equipment control lever NEUTRAL Boom or bucket full stroke Shuttle valve outlet pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min. 28 kg/cm2}
Malfunction of control valve The arm throttle valve of the control valve may malfunction. Check it directly. (arm throttle valve)
H-18 When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel speed is low
Failure Phenomenon Related Information When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel speed is low Check that all the operations are normal when performed singly. (If any of them is abnormal, carry out troubleshooting related to it.) Carry out all troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Stop the engine for the preparations, and keep it running at high idle during the troubleshooting. Presumed cause and standard value in normalcy Malfunction of bucket CURL Hi cancel solenoid valve L.H. and R.H. work equipment control levers and travel lever Single operation of bucket CURL Operations other than single operation of bucket CURL Solenoid valve outlet pressure Min. 2.35 MPa {Min. 24 kg/cm2} 0 MPa {0 kg/cm2}
PC600-8
27
SEN00452-02
40 Troubleshooting
H-19 When arm and swing are operated simultaneously, swing speed is low
Failure Phenomenon Related Information When arm and swing are operated simultaneously, swing speed is low Check that both operations are normal when performed singly. (If either of them is abnormal, carry out troubleshooting related to it.) Carry out all troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Stop the engine for the preparations, and keep it running at high idle during the troubleshooting. Presumed cause and standard value in normalcy 1 Malfunction of arm, swing PPC shuttle valve (arm side) L.H. work equipment control lever Neutral Arm IN or OUT full stroke Shuttle valve outlet pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min. 28 kg/cm2}
Malfunction of control The swing priority valve of the control valve may malfunction. Check it valve (swing priority directly. valve)
28
PC600-8
40 Troubleshooting
SEN00452-02
H-20 Machine deviates in one direction

Failure Phenomenon Related Information Machine deviates in one direction (1) Machine deviates in the same direction, regardless of its travel direction
Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.) Carry out all the troubleshooting in working mode A. Cause Standard value in normalcy and references for troubleshooting Carry out troubleshooting by using the judgment matrix in Before troubleshooting Hmode. See Testing and adjusting, Testing and adjusting travel deviation. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle.
1 2 Presumed cause and standard value in normalcy
Troubleshooting with judgment matrix Wrong adjustment of main pump
Malfunction of travel PPC valve
Travel lever FORWARD, REVERSE Full stroke
PPC valve output pressure 2.74 MPa {28 kg/cm2}
4 5
Malfunction of travel control valve (spool) Defective travel control valve (body)
Since the spool of the travel control valve may have a malfunction, check it directly. Since the body of the travel control valve may have a malfunction, check it directly. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle.
Defective seal of center swivel joint
Travel lever Relieved on one side
Leakage from swivel joint Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 2. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. 7 Leakage in travel motor Travel lever Relieved on one side 8 Defective travel motor 9 Internal defect of final drive Since the travel motor may be defective, check it directly. Since the final drive may have a defect in it, check it directly. (The defect can be judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.) Leakage from travel motor Max. 20 l/min
Fig. 2 Defective seals in center swivel joint and travel deviation directions
PC600-8
29
SEN00452-02
40 Troubleshooting
Machine deviates in one direction
(2) Machine deviates in different directions, depending on its travel direction
Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.) Carry out all the troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle.
Travel lever FORWARD, REVERSE full stroke
PPC valve output pressure 2.74 MPa {28 kg/cm2}
Malfunction of travel control valve (spool)
Since the spool of the travel control valve may have a malfunction, check it directly. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle.
Defective seal of center swivel joint
Travel lever Relieved on one side
Leakage from swivel joint Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 2. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. 4 Low set pressure of travel motor safety valve Travel lever Relieved on one side Travel relief pressure 35.3 1.47 MPa {360 15 kg/cm2}
Fig. 2 Defective seals in center swivel joint and travel deviation directions
30
PC600-8
40 Troubleshooting
SEN00452-02
H-21 Machine deviates largely at start

Failure Phenomenon Related Information Machine deviates largely at start (1) Machine deviates only when started with travel lever at full stroke
Check that the machine does not deviate during constant-speed travel. (If the machine deviates even during constant-speed travel, carry out the related troubleshooting.) Carry out all the troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting Since the servo valve of main pumps (No. 1 & No. 2) may have a malfunction, check it directly. (Test the servo valve unit or measure its stroke.) Since the spool of the travel control valve may have a malfunction, check it directly. a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. Travel lever Either side relief Leakage from swivel joint Max. 100 cc/min
1 2
Malfunction of main pump servo-valve Malfunction of travel control valve (spool)
Defective seal of center 3 swivel joint Internal defect of travel motor (body)
Since the travel motor may have a defect in it, check it directly.
Machine deviates largely at start
(2) Machine deviates when started, regardless of travel lever stroke
Check that the machine does not deviate during constant-speed travel. (If the machine deviates even during constant-speed travel, carry out the related troubleshooting.) Carry out all the troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. (Check cause 3 and confirm that the result is normal before troubleshooting.) Travel lever CO, NC valve output pressure Max. 0.55 MPa {Max. 5.5 kg/cm2} Min. 1.7 MPa {Min. 17 kg/cm2}
Defective adjustment or 1 malfunction of CO, NC valve
Neutral Full stroke on one side (Idle travel)
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. 2 Malfunction of main pump servo-valve Since the servo-valve of main pump may have a malfunction, check it directly. (Test the servo-valve unit or measure its stroke.) a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. Travel lever 3 Defective adjustment or malfunction of jet sensor Neutral Full stroke on one side (Idle travel) Differential pressure of jet sensor Min. 1.5 MPa {Min. 15 kg/cm2} Max. 0.2 MPa {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.
PC600-8
31
SEN00452-02 H-22 Travel deviation is large during compound operation

Failure Phenomenon Related Information Travel deviation is large during compound operation Check that the machine does not deviate while any work equipment is not operated. (If the machine deviates, carry out troubleshooting related to travel deviation.) Carry out all the troubleshooting in working mode P. Cause
40 Troubleshooting
Standard value in normalcy and references for troubleshooting a Stop the engine for the preparations, and keep it running at high idle during the troubleshooting.
Malfunction of boom, bucket PPC shuttle valve
R.H. work equipment control lever Neutral Boom or bucket full stroke
Shuttle valve outlet pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. Malfunction of arm, swing 2 PPC shuttle valve (arm side) L.H. work equipment control lever Neutral Arm CURL DUMP full stroke Shuttle valve outlet pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. Malfunction of arm, swing 3 PPC shuttle valve (swing side) Left work equipment control lever Neutral Swing LEFT, RIGHT full stroke Malfunction of control 4 valve (travel shuttle valve) Malfunction of control 5 valve (straight travel valve) Shuttle valve outlet pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min. 28 kg/cm2}
The travel shuttle valve of the control valve may malfunction. Check it directly.
The straight travel valve of the control valve may malfunction. Check it directly.
32
PC600-8
40 Troubleshooting
SEN00452-02
H-23 Travel speed or power is low

Failure Phenomenon Related Information Travel speed or power is low 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. Cause Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. 1 Malfunction of travel PPC valve Travel lever FORWARD, REVERSE full stroke PPC valve output pressure Min. 2.74 MPa {Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. Presumed cause and standard value in normalcy 2 Malfunction of CO cancel solenoid valve Travel lever Neutral Operated Solenoid valve outlet pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. 3 Malfunction of 2-stage relief solenoid valve Travel lever Neutral Operated Solenoid valve outlet pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. Wrong adjustment or 4 malfunction of main relief valve Travel lever Either side relieved Travel relief pressure 35.3 1.47 MPa {360 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.
PC600-8
33
SEN00452-02 H-24 Machine does not travel (only one track)

Failure Phenomenon Related Information Presumed cause and standard value in normalcy Machine does not travel (only one track) Cause 1 2 Malfunction of travel motor (parking brake) Internal defect of travel motor (body) Internal defect of final drive
40 Troubleshooting
(1) Machine does not travel in either direction.
Standard value in normalcy and references for troubleshooting Since the parking brake of the travel motor may have a malfunction, check it directly. Since the travel motor may have a defect in it, check it directly.
Since the final drive may have a defect in it, check it directly. (The defect can be judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.)
Machine does not travel (only one track)
(2) Machine does not travel forward or in reverse
Carry out all the troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle.
Travel levers FORWARD, REVERSE full stroke
2 3
Malfunction of travel control valve (spool) Defective travel control valve (suction valve)
Since the spool of the travel control valve may have a malfunction, check it directly. Since the suction valve of the travel control valve may have a malfunction, check it directly. (The suction valve can be checked by replacing it with normal one.) a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle.
Malfunction of travel motor (safety valve)
Travel levers Relieved on one side (Direction in which machine does not travel)
Travel relief pressure 35.3 1.47 MPa {360 15 kg/cm2}
Malfunction of travel 5 motor (counterbalance valve)
Since the counterbalance valve of the travel motor may have a malfunction, check it directly.
34
PC600-8
40 Troubleshooting
SEN00452-02
H-25 Travel speed does not change

Failure Phenomenon Travel speed does not change Check that the Lo and Hi travel speeds are normal. (If they are abnormal, carry out the related troubleshooting.) The travel speed selection system has the automatic speed changing function. If the oil pressure rises 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). Carry out all the troubleshooting in working mode P. Cause Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idle. Malfunction of travel 1 speed select solenoid valve Travel speed select switch Lo Hi 2 Solenoid valve outlet pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min.28 kg/cm2}
Related Information
Malfunction of travel Since the servo mechanism of the travel motor may have a malfunction, check it motor (servo mechanism) directly.
PC600-8
35
SEN00452-02 H-26 Upper structure does not swing

Failure Phenomenon Related Information Upper structure does not swing
40 Troubleshooting
(1) Upper structure swings in neither direction.
Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out troubleshooting related to it.) When carrying out the following troubleshooting, set the swing lock switch in OFF and the working mode in the P mode. Cause Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
Malfunction of swing 1 holding brake solenoid valve Presumed cause and standard value in normalcy
L.H. work equipment control lever Neutral (after 10 seconds or more) Operated to swing (in either direction)
Malfunction of swing motor (parking brake)
The parking brake of the swing motor may malfunction. Check it directly. a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
Wrong adjustment or 3 malfunction of swing motor (safety valve)
L.H. work equipment control lever Swing relief (in either direction)
Swing relief pressure 29.91 0.98 MPa {305 10 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction. check the safety valve directly. 4 5 Swing motor (motor unit) defective internally Swing machinery defective internally The motor unit of the swing motor may have a defect in it. Check it directly. Swing machinery may have a defect in it. Check it directly. (The swing machinery can be checked by abnormal sound, abnormal heating, metal dust in the drained oil, etc.)
Upper structure does not swing
(2) Upper structure does not swing in only one direction.
Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out troubleshooting related to it.) When carrying out the following troubleshooting, set the swing lock switch in OFF and the working mode in the P mode. Cause Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
Malfunction of left PPC valve (swing circuit)
L.H. work equipment control lever Swing RIGHT, LEFT full stroke
PPC valve output pressure Min. 2.74 MPa {Min.28 kg/cm2}
Malfunction of swing control valve (spool)
The spool of the swing control valve may malfunction. Check it directly. The suction valve of the swing control valve may malfunction. Check it directly. (The suction valves of the right and left swing control valves can be checked by exchanging them with each other and seeing the change of the phenomenon.) The suction valve of the swing motor may malfunction. Check it directly. (The suction valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.) The check valve of the swing motor may malfunction. Check it directly. (The check valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
Malfunction of swing 3 control valve (suction valve) 4 Malfunction of swing motor (suction valve) Malfunction of swing motor (check valve)
36
PC600-8
40 Troubleshooting
SEN00452-02
H-27 Swing speed or acceleration is low

Failure Phenomenon Related Information Swing speed or acceleration is low (1) Swing speed or acceleration is low in both directions.
Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out troubleshooting related to it.) When carrying out the following troubleshooting, set the working mode in the P mode and turn the swing lock switch OFF. Cause Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
1 Leakage in swing motor
Leakage from swing motor Max. 10 l/min
Malfunction of swing 2 motor (parking brake)
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction. check the safety valve directly. 4 Swing motor (motor unit) defective internally Swing machinery defective internally The motor unit of the swing motor may have a defect in it. Check it directly. Swing machinery may have a defect in it. Check it directly. (The swing machinery can be checked by abnormal sound, abnormal heating, metal dust in the drained oil, etc.)
Swing speed or acceleration is low
(2) Swing speed or acceleration is low in only one direction.
Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out troubleshooting related to it.) When carrying out the following troubleshooting, set the working mode in the P mode and turn the swing lock switch OFF. Cause Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
The spool of the swing control valve may malfunction. Check it directly. The suction valve of the swing control valve may malfunction. Check it directly. (The suction valves of the right and left swing control valves can be checked by exchanging them with each other and seeing the change of the phenomenon.) The suction valve of the swing motor may malfunction. Check it directly. (The suction valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.) The check valve of the swing motor may malfunction. Check it directly. (The check valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
Malfunction of swing 3 control valve (suction valve) 4 Malfunction of swing motor (suction valve) Malfunction of swing motor (check valve)
PC600-8
37
SEN00452-02 H-28 Upper structure overruns excessively when it stops swinging

40 Troubleshooting
Upper structure overruns excessively when it (1) Upper structure overruns excessively when it stops stops swinging swinging in both directions. Cause Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction. check the safety valve directly. a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. 2 Leakage in swing motor L.H. work equipment control lever Swing relief (in either direction) Leakage from swing motor Max. 10 l/min
Upper structure overruns excessively when it (2) Upper structure overruns excessively when it stops stops swinging swinging in only one direction.
Cause
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
The spool of the swing control valve may malfunction. Check it directly.
The suction valve of the swing control valve may malfunction. Check it directly. Malfunction of swing con(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.) Malfunction of swing motor (suction valve) Malfunction of swing motor (check valve) The suction valve of the swing motor may malfunction. Check it directly. (The suction valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.) The check valve of the swing motor may malfunction. Check it directly. (The check valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
38
PC600-8
40 Troubleshooting
SEN00452-02
H-29 Large shock is made when upper structure stops swinging

Failure Phenomenon Related Information Large shock is made when upper structure stops swinging (1) Large shock is made when the upper structure stops swinging in both directions.
When carrying out the following troubleshooting, set the working mode in the P mode and turn the swing lock switch OFF. Cause Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
Malfunction of swing 1 holding brake solenoid valve Presumed cause and standard value in normalcy
L.H. work equipment control lever Neutral (After 7 seconds or more) Operated to swing (in either direction)
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction. Check the safety valve directly. 4 Swing motor (motor unit) defective internally Swing machinery defective internally The motor unit of the swing motor may have a defect in it. Check it directly. Swing machinery may have a defect in it. Check it directly. (The swing machinery can be checked by abnormal sound, abnormal heating, metal dust in the drained oil, etc.)
Large shock is made when the upper structure stops swinging.
(2) Large shock is made when the upper structure stops swinging in only one direction.
When carrying out the following troubleshooting, set the working mode in the P mode and turn the swing lock switch OFF. Cause Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
L.H. work equipment control lever Neutral Swing RIGHT, LEFT full stroke
PPC valve output pressure 0 MPa {0 kg/cm2} Min. 2.74 MPa {Min. 28 kg/cm2}
Malfunction of swing control valve (spool) Malfunction of swing motor (suction valve)
The spool of the swing control valve may malfunction. Check it directly. The suction valve of the swing motor may malfunction. Check it directly. (The suction valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
PC600-8
39
SEN00452-02
40 Troubleshooting
H-30 Large abnormal sound is made when upper structure stops swinging
Failure Phenomenon Related Information Large abnormal sound is made when upper structure stops swinging Cause Malfunction of back 1 pressure compensation valve Standard value in normalcy and references for troubleshooting The back pressure compensation valve may malfunction. Check it directly. a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting. Wrong adjustment or 2 malfunction of swing motor (safety valve) L.H. work equipment control lever Swing relief (in either direction) Swing relief pressure 29.91 0.98 MPa {305 10 kg/cm2} (1) Large abnormal sound is made when the upper structure stops swinging in both directions.
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction. Check the safety valve directly. 3 Swing machinery defective internally Swing machinery may have a defect in it. Check it directly. (The swing machinery can be checked by abnormal sound, abnormal heating, metal dust in the drained oil, etc.)
Failure Phenomenon Related Information Presumed cause and standard value in normalcy
Large abnormal sound is made when upper structure stops swinging Cause
(2) Large abnormal sound is made when the upper structure stops swinging in only one direction.
Standard value in normalcy and references for troubleshooting The suction valve of the swing control valve may malfunction. Check it directly. (The suction valves of the right and left swing control valves can be checked by exchanging them with each other and seeing the change of the phenomenon.) The suction valve of the swing motor may malfunction. Check it directly. (The suction valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
Malfunction of swing 1 control valve (suction valve)
Malfunction of swing motor (suction valve)
40
PC600-8
40 Troubleshooting
SEN00452-02
H-31 Hydraulic drift of swing is large

Failure Phenomenon Related Information Presumed cause and standard value in normalcy Hydraulic drift of swing is large (1) While the swing holding brake is applied.
When carrying out the following troubleshooting, set the working mode in the P mode. Cause Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idle during troubleshooting.
Malfunction of swing 1 holding brake solenoid valve
L.H. work equipment control lever Neutral (After 5 seconds or more) Operated to swing (in either direction)
The parking brake of the swing motor may malfunction. Check it directly.
Hydraulic drift of swing is large Cause
(2) While the swing holding brake is released.
Standard value in normalcy and references for troubleshooting The spool of the swing control valve may malfunction. Check it directly.
Malfunction of swing 2 control valve (suction valve) 3 4 5 Malfunction of swing motor (safety valve) Malfunction of swing motor (suction valve) Malfunction of swing motor (check valve)
The suction valve of the swing control valve may malfunction. Check it directly.
The safety valve of the swing motor may malfunction. Check it directly. The suction valve of the swing motor may malfunction. Check it directly. The check valve of the swing motor may malfunction. Check it directly.
PC600-8
41
SEN00452-02
40 Troubleshooting
42
SEN00453-02
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
40 Troubleshooting
Troubleshooting of engine (S-mode)
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
SEN00453-02
40 Troubleshooting
PC600-8
40 Troubleshooting
SEN00453-02
Method of using troubleshooting chart

The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" 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
SEN00453-02
40 Troubleshooting
<Example of troubleshooting> Exhaust gas color is black (incomplete combustion) Let us assume that a trouble of Exhaust gas color is black occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas color slowly became black], [Power slowly became weaker], and [Dust indicator is lighting red].
PC600-8
40 Troubleshooting
SEN00453-02
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in the [Causes] sections. The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is explained according to Step 1 Step 3 shown below.
PC600-8
SEN00453-02 S-1 Starting performance is poor

General causes why starting performance is poor Defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel Coolant in exhaust pipe a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not 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 Operated for long period machine Became worse gradually Starting performance Engine starts easily when warm Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual Engine oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally During operation, charge level monitor indicates abnormal charge Dust indicator is red Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Starting motor cranks engine slowly If air bleeding plug of fuel filter is removed, fuel does not While engine is flow out cranked with starting motor If spill hose from injector is disconnected, little fuel spills When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive Causes
40 Troubleshooting
Questions
Check items
Inspect air cleaner directly q When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows q out (*1) When compression pressure is measured, it is found to be low q q When air is bled from fuel system, air comes out Inspect fuel filter directly Inspect feed pump gauze filter directly Carry out troubleshooting according to No-pressure feed by supply pump (*2) When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change When starting switch is turned to HEAT, intake air heater mount does not become warm Yes Is voltage 20 30 V between alternator terminal R and terminal E with engine at low idle? No When specific gravity of electrolyte and voltage of battery are measured, they are low Remedy
Troubleshooting
For *1 and *2, see the next page.
Clean Replace Correct Replace Clean Correct Clean Clean Replace Replace Replace Replace Replace Replace
Clogged air cleaner element Cracked EGR cooler (Coolant in exhaust pipe) Defective contact of valve, vale seat Worn piston ring, cylinder Clogged air breather hole of fuel tank cap Leaking or clogged fuel piping, entry of air Clogged fuel filter, element Clogged feed pump gauze filter Stuck, seized supply pump plunger Defective injector Defective intake air heater system Defective alternator (regulator section) Defective alternator (generator section) Defective, deteriorated battery
EE Q Q w w
EE Q Q Q Q Q Q w
w w
w w Q Q w
w w w Q w Q w Q Q w w w w Q Q w Q Q Q w
q q q q q
PC600-8
40 Troubleshooting
SEN00453-02
*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, however, it is not a problem.
*2: See failure codes [CA559] and [CA2249] in troubleshooting by failure code (display of codes) (Part 2).
PC600-8
SEN00453-02 S-2 Engine does not start

a) Engine does not turn General causes why engine does not turn Internal parts of engine seized See S-4 Engine stops during operations. Water hammer caused by coolant which entered cylinder Defective electrical system Defective hydraulic pump or PTO
Cracked EGR cooler (Coolant in exhaust pipe)
40 Troubleshooting
Causes
Defective starting motor (safety relay section)
Defective connection of battery terminal
Defective starting motor (motor section)
Confirm recent repair history Questions Degree of use of machine Operated for long period
EEE Q w w w Q Q w w w q q q q q q q
Replace Replace Replace Replace Replace Replace Correct Replace Carry out troubleshooting on H-mode Carry out troubleshooting on E-mode
Condition of horn when Horn does not sound starting switch is turned Horn volume is low ON Battery electrolyte is low Battery terminal is loose When starting switch is turned ON, there is no operating sound from battery relay When starting switch is turned to START, starting pinion does not move out When starting switch is turned to START, starting pinion moves out, but Speed of rotation is low Makes grating noise Soon disengages again Makes rattling noise and does not turn
w Q w w Q
Check items
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1). Inspect flywheel ring gear directly When specific gravity of electrolyte and voltage of battery are measured, they are low There is not voltage (20 30 V) between battery relay terminal M and terminal E Turn starting switch OFF, connect cord, and carry out troubleshooting at ON When terminal B and terminal C of starting switch are connected, engine starts When terminal B and terminal C at safety relay outlet are connected, engine starts Even if terminal B and terminal C at safety relay outlet are connected, engine does not start
Troubleshooting
For *1, see the next page.
Remedy
PC600-8
Defective hydraulic pump or PTO
Defective or deteriorated battery
Defective starting circuit wiring
Broken flywheel ring gear
Defective starting switch
Defective battery relay
40 Troubleshooting
SEN00453-02
PC600-8
SEN00453-02
40 Troubleshooting
b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out
Use of improper fuel Insufficient fuel in tank Clogged air breather hole of fuel tank cap Leaking or clogged fuel piping, entry of air Clogged fuel filter element
Causes
Wrong connection of supply pump PCV Defective operation of overflow valve (Does not close) Defective operation of flow damper Defective fuel injector
Fuel is not being supplied Supply of fuel is extremely small Improper selection of fuel (particularly in winter)
EEE w Q w w w w w w Q w w Q Q Q w w w Q Q Q Q Q q q q q q q q q q q
Replace Add Correct Correct Replace Clean Replace Replace Replace Replace Remedy Correct Replace Replace Replace
Clogged feed pump gauze filter Seized, abnormally worn feed pump Broken supply pump shaft, key Stuck, seized supply pump plunger Defective supply pump PCV
Exhaust smoke suddenly stopped coming out (when starting again) Replacement of filters has not been carried out according to Operation and Maintenance Manual When fuel tank is inspected, it is found to be empty Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained When fuel filter is removed, there is not fuel in it
EE Q
Q Q
Check items
Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy If air bleeding plug of fuel filter is removed, fuel does not flow While engine is cranked with start- out ing motor If spill hose from injector is disconnected, little fuel spills When air is bled from fuel system, air comes out Inspect fuel filter directly
w Q w w w w Q
Troubleshooting
Inspect feed pump gauze filter directly Inspect feed pump directly Carry out troubleshooting according to No-pressure feed by supply pump (*1) Carry out troubleshooting according to Abnormality in PCV1 (*2) or Abnormality in PCV2 (*3) Inspect overflow valve directly Engine can be started in reduced cylinder mode
*1: Failure code [CA559] and failure code [CA2249] *2: Failure code [CA271] and failure code [CA272] *3: Failure code [CA273] and failure code [CA274]
10
PC600-8
40 Troubleshooting
SEN00453-02
c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel
Causes Clogged air cleaner element Worn dynamic valve system (Valve, rocker lever, etc.) Worn piston ring, cylinder liner Use of improper fuel Clogged air breather hole of fuel tank cap Leaking or clogged fuel system, entry of air Clogged fuel filter, strainer Clogged feed pump gauze filter Stuck, seized supply pump plunger Clogged injector, defective spray Defective, deteriorated battery Defective coolant temperature sensor, wiring harness Defective intake air heater system
Confirm recent repair history Degree of use of machine Operated for long period Questions Suddenly failed to start Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual Engine oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally Dust indicator is red Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained When fuel filter is removed, there is not fuel in it Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Starting motor cranks engine slowly Check items When engine is cranked, abnormal sound is generated around cylinder head While engine is cranked with starting motor, If air bleeding plug of fuel filter is removed, fuel does not flow out If spill hose from injector is disconnected, little fuel spills
E w w w
EE
E w QQ
ww
w w Q ww w w wQQ w w Q ww w w q q q q q q q q q q q
Clean Replace Replace Replace Clean Correct Clean Clean Replace Clean Replace Replace Replace
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Inspect air cleaner directly Inspect dynamic valve system directly When compression pressure is measured, it is found to be low When air is bled from fuel system, air comes out Inspect fuel filter, strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to No-pressure feed by supply pump (*1) When injector unit is tested, spray condition is bad When specific gravity of electrolyte and voltage of battery are measured, they are low Coolant temperature gauge does not indicate normally (if coolant temperature gauge is installed) When starting switch is turned to HEAT, intake air heater mount does not become warm Remedy
*1: Failure code [CA559] and failure code [CA2249]
Troubleshooting
PC600-8
11
SEN00453-02 S-3 Engine does not pick up smoothly

General causes why engine does not pick up smoothly Insufficient intake of air Insufficient supply of fuel Defective condition of fuel spray
Defective contact of valve and valve seat Seized turbocharger, interference of turbocharger
40 Troubleshooting
Causes
Defective operation of flow damper (Large leakage from injector)
Stuck, seized supply pump plunger
EGR valve is stuck open (There is much EGR gas and intake of air is insufficient)l
EEE Q w w
E Q Q
EE w w w w w Q w
Engine pick-up suddenly became worse Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual Oil must be added more frequently Dust indicator is red Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
w w w w w w w Q Q Q w w Q w w Q Q w q q q q q q q q q q q
Replace Replace Adjust Replace Replace Clean Replace Replace Correct Correct Clean Clean Clean
Check items
Color of exhaust gas
Blue under light load Black
When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, interference sound is generated around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) Blow-by gas is excessive Inspect air cleaner directly Carry out troubleshooting according to Abnormality in EGR valve servo (*1) When compression pressure is measured, it is found to be low
w w Q w
Troubleshooting
Inspect valve clearance directly When turbocharger is rotated by hand, it is found to be heavy When air is bled from fuel system, air comes out Inspect fuel filter, strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to No-pressure feed by supply pump (*2) When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Remedy
*1: Failure code [CA1228] and failure code [CA1625] *2: Failure code [CA559] and failure code [CA2249]
12
PC600-8
Clogged injector, defective spray
Clogged feed pump gauze filter
Worn piston ring, cylinder liner
Clogged air cleaner element
Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
Clogged air breather hole of fuel tank cap
Improper selection of fuel
Leaking or clogged fuel piping, entry of air
Clogged fuel filter, strainer
Improper valve clearance
Stuck EGR valve
w w
40 Troubleshooting
SEN00453-02
S-4 Engine stops during operations

General causes why engine stops during operations Seized parts inside engine Insufficient supply of fuel There is overheating Defective hydraulic pump or PTO Causes
Broken dynamic valve system (valve, rocker arm, etc.) Broken, seized piston, connecting rod Broken, seized crankshaft bearing Broken, seized gear train Insufficient fuel in tank Clogged air breather hole of fuel tank cap Leaking, clogged fuel piping Clogged fuel filter, strainer Clogged feed pump gauze filter Broken, seized feed pump Broken supply pump shaft, key Stuck, seized supply pump plunger
Confirm recent repair history Degree of use of machine Operated for long period Abnormal noise was heard and engine stopped suddenly w w w w Questions Condition when engine stopped Engine overheated and stopped Engine stopped slowly There was hunting and engine stopped Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual Fuel level monitor indicates low level When fuel tank is inspected, it is found to be empty Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Rust and water are found when fuel tank is drained Check items Metal particles are found when oil is drained Does not turn at all When engine is cranked Turns in opposite direction by hand Moves by amount of gear backlash Supply pump shaft does not turn Engine turns, but stops when load is applied to machine Inspect dynamic valve system directly Inspect piston, connecting rod directly Troubleshooting Inspect crankshaft bearing directly Inspect gear train directly Inspect fuel filter, strainer directly Inspect feed pump gauze filter directly Inspect feed pump directly Carry out troubleshooting according to No-pressure feed by supply pump (*1) Remedy *1: Failure code [CA559] and failure code [CA2249]
EE Q w Q w w w Q Q Q Q Q Q Q Q Q w w w w w w w Q Q w w Q Q w Q
w w w w w w
w w
Carry out troubleshooting on H-mode
q q q q q q q q q
Replace Replace Replace Replace Add Clean Correct Clean Clean Replace Replace Replace
Defective hydraulic pump or PTO
PC600-8
13
SEN00453-02 S-5 Engine does not rotate smoothly

General causes why engine does not rotate smoothly Air in fuel system Defective speed sensor (Error at degree that it is not indicated) Defective EGR valve
Leaking or clogged fuel piping, entry of air Clogged air breather hole of fuel tank cap Causes
40 Troubleshooting
Defective operation of flow damper (Large leakage from injector)
Defective Ne speed sensor, wiring harness
Confirm recent repair history Degree of use of machine Operated for long period Questions Occurs at a certain speed range Condition of hunting Occurs at low idle Occurs even when speed is raised Occurs on slopes Replacement of filters has not been carried out according to Operation and Maintenance Manual When fuel tank is inspected, it is found to be empty Check items Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Carry out troubleshooting according to Abnormality in EGR valve servo (*1) Carry out troubleshooting according to Abnormality in bypass valve servo (*2) Troubleshooting When air is bled from fuel system, air comes out Inspect feed pump gauze filter directly Inspect fuel filter, strainer directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Carry out troubleshooting according to Abnormality in engine Ne speed sensor (*3) Carry out troubleshooting according to Abnormality in engine Bkup speed sensor (*4) Replace Replace Replace Replace Replace Replace Correct Correct Correct Clean Remedy
EE Q Q Q w Q Q
EE Q Q Q Q Q Q Q Q Q w Q w w w w Q Q w w Q Q Q Q Q Q
q q q q q q q q q
Correct
*1: Failure code [CA1228] and failure code [CA1625] *2: Failure code [CA1628] and failure code [CA1629] *3: Failure code [CA689] *4: Failure code [CA778]
14
Add
Defective G speed sensor, wiring harness
Defective bypass valve

Defective operation of bypass valve
Clogged injector, defective spray (dirt in injector)
Defective operation of EGR valve
Low setting of low idle speed
Insufficient fuel in tank
PC600-8
40 Troubleshooting
SEN00453-02
S-6 Engine lacks output (or lacks power)

General causes why engine lacks output Insufficient intake of air
Seized turbocharger, interference of turbocharger Clogged injector, defective spray (dirt in injector)
Causes
Defective installation of charge pressure sensor (air leakage)
Clogged air cleaner element
Leaking, clogged fuel piping
Confirm recent repair history Degree of use of machine Questions Power was lost Operated for long period Suddenly Gradually
E Q Q w
E Q
E Q
There is overheating See S-14 Coolant temperature becomes too high (Overheating)
E E Q Q Q Q Q Q Q Q Q
Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual Engine oil must be added more frequently Dust indicator is red Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping Output becomes insufficient after short stop of operation Color of exhaust gas Black Blue under light load
Q Q Q w w w w w w w w w w Q w w Q w w q q q q q q q q q q q q q q q
Replace Replace Replace Replace Replace Replace Replace Replace Replace Correct Correct Correct Adjust Clean Clean Clean
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Check items When engine is cranked, interference sound is generated around turbocharger When engine is cranked, abnormal sound is generated around cylinder head High idle speed is too high High idle speed under no load is normal, but speed suddenly drops when load is applied Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive Inspect air cleaner directly Inspect air intake piping directly When boost pressure is measured, it is found to be low When compression pressure is measured, it is found to be low Troubleshooting Inspect valve clearance directly Inspect fuel filter, strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to No-pressure feed by supply pump (*1) When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Inspect charge pressure sensor mount directly Carry out troubleshooting according to Abnormality in charge pressure sensor (*2) Carry out troubleshooting according to Abnormality in fuel temperature sensor (*3) Remedy
Q Q Q Q Q Q
Improper selection of fuel

Air leakage from air intake piping
Defective drive of injector (signal, solenoid)
Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Defective spray condition of fuel
Defective fuel temperature sensor, wiring harness
Defective charge pressure sensor, wiring harness
Insufficient supply of fuel
PC600-8
15
SEN00453-02 S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black Insufficient intake of air Excessive injection of fuel Defective condition of fuel injection Improper selection of fuel
Clogged air cleaner element Seized turbocharger, interference of turbocharger Leakage of air between turbocharger and cylinder head
40 Troubleshooting
Causes
Defective coolant temperature sensor, wiring harness
EGR valve is stuck open (There is much EGR gas and intake of air is insufficient)
Confirm recent repair history Degree of use of machine Operated for long period Suddenly became black Questions Color of exhaust gas Gradually became black Blue under light load Non-specified fuel is being used Oil must be added more frequently Power was lost Dust indicator is red Muffler is crushed Air leaks between turbocharger and cylinder head, clamp is loosened Engine is operated in low-temperature mode at normal temperature When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Check items When engine is cranked, interference sound is generated around turbocharger When engine is cranked, abnormal sound is generated around cylinder head Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal Engine does not pick up smoothly and combustion is irregular Blow-by gas is excessive If spill hose from injector is disconnected, abnormally much fuel spills Inspect air cleaner directly When turbocharger is rotated by hand, it is found to be heavy Carry out troubleshooting according to Abnormality in EGR valve servo (*1) Troubleshooting When compression pressure is measured, it is found to be low Inspect valve clearance directly When muffler is removed, exhaust sound improves Carry out troubleshooting according to No-pressure feed by supply pump (*2) When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Inspect fuel spill piping (on cylinder head side) directly Carry out troubleshooting according to Abnormality in coolant temperature sensor (*3) Suddenly Gradually
E w
Stuck EGR valve
E E w Q Q
E Q Q Q Q
w Q Q w w Q w w w Q Q Q Q w w w Q Q Q Q Q w Q Q Q w w q q q q q q q q q q Replace Replace Replace Replace Replace Replace Replace Replace Replace Correct Correct Adjust Adjust Adjust Clean q q Q Q w Q Q Q Q Q Q
Remedy
16
Improper fuel injection pressure
Improper fuel injection timing
There is overheating See S-14 Coolant temperature becomes too high (Overheating)
Clogged fuel spill piping (on cylinder head side)
Defective contact of valve and valve seat
Crushed, clogged muffler
Abnormally worn injector
Clogged, seized injector
PC600-8
40 Troubleshooting
SEN00453-02
S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive Abnormal consumption of oil Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) External leakage of oil Wear of parts in lubrication system Causes Dust sucked in from intake system Worn, damaged valve (stem, guide, seal) Worn seal at turbocharger end Turbocharger Worn seal at blower end Oil leakage from EGR valve stem Clogged breather, breather hose Broken piston ring Worn piston ring, cylinder liner Worn, damaged rear oil seal Broken oil cooler Oil leakage from oil cooler Oil leakage from oil filter Oil leakage from oil piping Oil leakage from oil drain plug Oil leakage from oil pan, cylinder head, etc. EEEE w Q w Q Q w E Q Q w w w w w w Q w w w Q Q Q w w w w w Correct Correct Replace Replace Replace Clean Replace Replace Correct Replace Replace Correct Correct Correct Correct
Confirm recent repair history Degree of use of Operated for long period machine Oil consumption suddenly increased Oil must be added more frequently Oil becomes contaminated quickly Outside of engine is dirty with oil There are loose piping clamps in intake system Inside of turbocharger intake outlet pipe is dirty with oil Inside of turbocharger exhaust outlet pipe is dirty with oil There is oil in coolant Oil level in damper chamber of machine is high Exhaust smoke is blue under light load Excessive Amount of blow-by gas None
Check items Troubleshooting
Questions
When intake manifold is removed, dust is found inside q When intake manifold is removed, inside is found to be dirty abnorq mally 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 When compression pressure is measured, it is found to be low q 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 Remedy
PC600-8
17
SEN00453-02 S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly Entry of exhaust gas into oil due to internal wear Clogging of lubrication passage Use of improper fuel Use of improper oil Operation under excessive load Causes
40 Troubleshooting
Check items
Confirm recent repair history Degree of use of Operated for long period machine Non-specified fuel is being used Engine oil must be added more frequently Even when engine oil temperature rises, oil filter clogging monitor indicates clogging Metal particles are found when oil is drained Inside of exhaust pipe is dirty with oil Engine oil temperature rises quickly Color of exhaust gas Blue under light load color Black Excessive Amount of blow-by gas None Excessive play of turbocharger shaft When EGR valve is removed, exhaust port is found to be dirty with oil When compression pressure is measured, it is found to be low Inspect breather and breather hose directly Inspect oil cooler directly Inspect oil filter directly Spring of oil filter safety valve is hitched or broken Inspect turbocharger lubrication drain tube directly Remedy
Questions
Troubleshooting
q q q q q
18
Replace Replace Replace Replace Clean Clean Replace Replace Clean PC600-8
See S-7
Defective turbocharger turbine side seal Worn EGR valve guide Worn valve, valve guide Worn piston ring, cylinder liner Clogged breather, breather hose Clogged oil cooler Clogged oil filter Defective oil filter safety valve Clogged turbocharger lubrication drain tube Exhaust smoke is bad E E E E Q Q w w Q Q w w w w Q Q w w q q q q Q w Q
40 Troubleshooting
SEN00453-02
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive Leakage of fuel Defective condition of fuel injection (fuel pressure, injection timing) Excessive injection of fuel Causes Fuel leakage inside head cover Fuel leakage from fuel filter, piping, etc. Defective feed pump oil seal Defective supply pump plunger Defective common rail pressure Defective spray by injector Defective operation of injector Improper fuel injection timing Defective coolant temperature sensor, wiring harness q q q q q q q Remedy Correct Correct Replace Replace Correct Replace Replace Correct Correct
Confirm recent repair history Degree of use of 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, temperaw ture of some cylinders is low Low idle speed is high Q Torque converter stall speed or pump relief speed is high Q Q Q Q Q Exhaust smoke Black color White Q Remove and inspect head cover directly q Inspect feed pump oil seal directly Carry out troubleshooting according to No-pressure feed by supply pump (*2) When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change If spill hose from injector is disconnected, much fuel spills Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) Confirm with monitoring function on machine monitor
*1: Failure code [CA559] and failure code [CA2249] *2: Failure code [CA144] and failure code [CA145]
Troubleshooting
Check items
Questions
PC600-8
19
SEN00453-02 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
General causes why oil is in coolant Internal leakage in lubrication system Internal leakage in cooling systeml Causes Damaged cylinder liner O-ring, holes caused by pitting
40 Troubleshooting
Insufficient protrusion of cylinder liner w q Replace
Broken cylinder head, head gasket
Internal cracks in cylinder block
Confirm recent repair history Degree of use of machine Operated for long period Suddenly increased Oil level Gradually increased Hard water is being used as coolant Oil level has risen and oil is milky There are excessive air bubbles in radiator, coolant spurts back Pressure-tightness test of cylinder head shows there is leakage
Questions
E Q Q Q Q Q Q w q q q
Troubleshooting
Check items
Inspect cylinder block, liner directly Inspect cylinder liner directly Pressure-tightness test of oil cooler shows there is leakage Replace
Replace
Replace
Remedy
20
Replace
Broken oil cooler core, O-ring E Q Q w q
PC600-8
40 Troubleshooting
SEN00453-02
S-12 Oil pressure drops

General causes why oil pressure drops Leakage, clogging, wear in lubrication system Defective oil pressure control Selection of oil by the temperature etc. specified in the "Operation and Maintenance Manual" is not observed. Deterioration of oil due to overheatingl Causes Worn journal of bearing Lack of oil in oil pan Coolant, fuel in oil Clogged strainer in oil pan Clogged, broken pipe in oil pan Defective oil pump Defective oil pump relief valve Clogged oil filter Leaking, crushed, clogged hydraulic piping Defective EGR oil pump Leaking EGR hydraulic piping Defective oil pressure sensor, wiring harness Defective oil level sensor, wiring harness w q q q See S-13 q q q q q q Q Q Replace Add Clean Clean Replace Adjust Replace Correct Replace Replace Replace Replace
Check items Troubleshooting
Confirm recent repair history Degree of use of Operated for long period E E E machine Oil pressure monitor indicates low oil pressure 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 Indicates pressure drop at low, high idle Q w w w Q Q Q Oil pressure monitor Indicates pressure drop on slopes w Sometimes indicates pressure drop w Q Q Oil level monitor indicates oil level drop w w Oil level in oil pan is low w External hydraulic piping is leaking, crushed w w 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
Questions
Metal particles are found in oil filter q Inspect oil pan strainer, pipe directly Oil pump rotation is heavy, there is play in oil pump Valve and spring of oil pump relief valve are fatigued, damaged Inspect oil filter directly Relief valve of EGR oil pump is damaged, oil leaks from it Inspect EGR hydraulic piping directly Carry out troubleshooting according to Abnormality in oil pressure sensor (*1) If oil level sensor is replaced, oil pressure monitor indicates normally Remedy
*1: Failure code [CA135] and failure code [CA141]
PC600-8
21
SEN00453-02 S-13 Oil level rises (Entry of coolant or fuel)

General causes why oil level rises Coolant in oil (milky) Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for S-11 Oil is in coolant Causes
40 Troubleshooting
Confirm recent repair history 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 numw Q ber of bubbles appear, or coolant spurts back 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) When compression pressure is measured, it is found to be low q 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 Remedy Replace Replace Correct Replace Replace Correct Replace Replace Correct Replace PC600-8
22
Troubleshooting
Check items
Questions
Cracked EGR cooler (Entry of coolant) Broken cylinder head, head gasket Fuel leakage inside head cover Cracks inside cylinder block Damaged cylinder liner O-ring, holes caused by pitting Worn, damaged rear oil seal Broken oil cooler core, O-ring Clogged water pump drain hole (breather hole), defective seal Defective thermostat seat Defects in supply pump
40 Troubleshooting
SEN00453-02
PC600-8
23
SEN00453-02 S-14 Coolant temperature becomes too high (overheating)

General causes why coolant temperature becomes too high Lack of cooling air (deformation, damage of fan)
External leakage of coolant from EGR cooler Damaged cylinder liner O-ring, hole caused by pitting Causes
40 Troubleshooting
Drop in heat dissipation efficiency Problem in coolant circulation system
Defective radiator cap (pressure valve)
Defective coolant temperature gauge
Broken cylinder head, head gasket
Confirm recent repair history Questions Degree of use of machine Condition of overheating Operated for long period Sudden overheated Always tends to overheat Q Q w Q w w w w w w w q q q q q q q q q q q q
Check, replace
E E E Q Q w
E E Q w w w w w
Coolant temperature Rises quickly gauge Does not go down from red range Radiator coolant level monitor indicates drop of coolant level Engine oil level has risen, oil is milky Fan belt tension is low When fan pulley is turned, it has play Milky oil is floating on coolant
Check items
There are excessive air bubbles in radiator, coolant spurts back When light bulb is held behind radiator core, no light passes through Radiator shroud, inside of underguard are clogged with dirt or mud Coolant is leaking because of cracks in hose or loose clamps Coolant flows out from radiator overflow hose Fan belt whines under sudden acceleration Inspect EGR cooler for coolant leakage When compression pressure is measured, it is found to be low Inspect cylinder liner directly Inspect oil cooler directly
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large When operation of thermostat is carried out, it does not open at cracking temperature Temperature difference between upper and lower tanks of radiator is slight Inspect radiator core directly When operation of radiator cap is carried out, its cracking pressure is low When coolant temperature is measured, it is fount to be normal Inspect fan rotation Inspect fan pump oil pressure
Replace
Replace
Replace
Replace
Replace
Replace
Replace
24
Replace
Correct
Correct
Remedy
Add
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
PC600-8
40 Troubleshooting
SEN00453-02
S-15 Abnormal noise is made

General causes why abnormal noise is made
Defective inside of muffler (dividing board out of position) Leakage of air between turbocharger and cylinder head Causes Deformed cooling fan, loose fan belt, interference of fan belt
Abnormality due to defective parts Abnormal combustion Air sucked in from intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a The engine is operated in the low-temperature mode while it is not warmed up sufficiently. Accordingly, the engine sound becomes a little larger. This does not indicate abnormality, however. 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.
Broken dynamic valve system (valve, rocker lever)
Interference of turbocharger, seized turbocharger
Confirm recent repair history Questions Degree of use of machine Condition of abnormal noise Operated for long period Gradually occurred Sudden occurred
E Q Q Q Q w w w w w w w w Q w Q w Q Q w q q q q q q q q q q q q q
Replace Replace Replace Replace Replace Replace Replace Replace Replace Correct Correct Correct Remedy Correct
Q Q Q w
Non-specified fuel is being used Oil must be added more frequently Metal particles are found when oil filter is drained Air leaks between turbocharger and cylinder head When engine is cranked, interference sound is generated around turbocharger When engine is cranked, abnormal sound is generated around EGR gas piping When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, beat noise is generated around muffler When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas Blue under light load Black
Check items
Engine does not pick up smoothly and combustion is irregular Abnormal noise is loud when engine is accelerated Blow-by gas is excessive When turbocharger is rotated by hand, it is fount to be heavy Inspect EGR gas piping directly Inspect dynamic valve system directly Troubleshooting When muffler is removed, abnormal noise disappears Inspect valve clearance directly When compression pressure is measured, it is found to be low Inspect gear train directly Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Abnormal noise is heard only when engine is started Confirm with monitoring function on machine monitor
w Q Q
Improper fuel injection timing (abnormality in coolant temperature sensor)
Excessive wear of piston ring, cylinder liner
Removed, seized gear train bushing
Cracked, leaking EGR gas piping
Improper gear train backlash
Clogged, seized injector
Dirt caught in injector
PC600-8
25
SEN00453-02 S-16 Vibration is excessive

General causes why vibration is excessive Defective parts (abnormal wear, breakage) Misalignment between engine and chassis Abnormal combustion a If abnormal noise is made and vibration is excessive, carry out troubleshooting for S-15 Abnormal noise is made, too.. Causes Stuck dynamic valve system (valve, rocker lever) Worn main bearing, connecting rod bearing Improper gear train backlash Worn camshaft bushing Improper injection timing Loose engine mounting bolts, broken cushions Broken output shaft, parts in damper on PTO E Q Q Q w w Q Q w q q q q q q q Remedy Replace Replace Replace Replace Adjust Replace Q Q w w Q Q E Q Q Q Q Q
40 Troubleshooting
Check items
Confirm recent repair history Degree of use of Operated for long period machine Suddenly increased Condition of vibration Gradually increased Non-specified fuel is being used Metal particles are found when oil filter is drained Metal particles are found when oil pan is drained Oil pressure is low at low idle Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Inspect dynamic valve system directly Inspect main bearing and connecting rod bearing directly Inspect gear train directly Inspect camshaft bushing directly Confirm with monitoring function on machine monitor Inspect engine mounting bolts and cushions directly Inspect output shaft or inside of damper directly
26
Troubleshooting
Questions
PC600-8
40 Troubleshooting
SEN00453-02
PC600-8
27
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40 Troubleshooting
28
SEN01062-04
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8 PC600LC-8
Machine model
PC600-8 PC600LC-8
Serial number
50 Disassembly and assembly1

General information on disassembly and assembly
How to read this manual ................................................................................................................................. 2 Coating materials list....................................................................................................................................... 4 Special tools list .............................................................................................................................................. 7 Sketches of special tools .............................................................................................................................. 13
PC600-8
SEN01062-04
50 Disassembly and assembly
How to read this manual

1. Removal and installation of assemblies Special tools q Special tools which are necessary for r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e described as A1, X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used q : Special tools that will be useful if available and are substitutable with tools available on the market 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of Sketches of special tools. q Part No. of special tools starting with : 79 Tmeans that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
(Rev. 2009.1) 1
Removal q In Removal section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for removal are described as [1], [2] etc. and their part numbers, part names and quantities are not described. q Various symbols used in Removal section are explained and listed below.
k : Precautions related to work safety a : Guidance or precautions for the work [*1] : This mark shows that instructions or precautions for parts installation work are given in Installation section. 6 : Amount of oil or coolant to be drained 4:
Weight of part or component
* *** ****
Installation q Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which corresponds to the mark in Removal section. q Common tools that are necessary for installation are described as [1], [2] etc. and their part numbers, part names and quantities are not described. q Marks shown in the Installation section stand for the following.
k
: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque
5
: Amount of oil or coolant to be replenished
Sketches of special tools q Various special tools are illustrated for the local manufacture.
PC600-8
SEN01062-04
2.
Disassembly and assembly of assemblies Special tools q Special tools which are necessary for disassembly and assembly of parts are described as A1, X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used. q : Special tools that will be useful if available and are substitutable with tools available on the market. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of Sketches of special tools. q Part No. of special tools starting with : 79 Tmeans that they are not available from Komatsu Ltd. (i.e. tools to be made locally). Disassembly q In Disassembly section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for disassembly are described as [1], [2] etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in Disassembly section are as follows. a : Precautions related to work safety : Guidance or precautions for the work 6 : Amount of oil or coolant drained
k
Assembly q In Assembly section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be replenished are described. q Common tools that are necessary for assembly are described as [1], [2] etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in Assembly section are as follows.
k
* *** ****
: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque
5
: Amount of oil or coolant to be replenished
Sketches of special tools Various special tools are illustrated for the local manufacture.
PC600-8
SEN01062-04
Coating materials list
(Rev. 2009.02) 1
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual.
Category Komatsu code LT-1A Part number 790-129-9030 Q'ty 150 g Container Tube Main features and applications Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g (2 pcs.)
Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloPolyethylene ride), rubber, metal, and non-metal parts container which require immediate and strong adhesion. Polyethylene Features: Resistance to heat and chemicals. container Used to fix and seal bolts and plugs. Can Used to stick and seal metal, glass, and plastics.
LT-2
09940-00030
50 g
LT-3 Adhesive
790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener) 790-129-9040 790-129-9120 250 g 75 g
LT-4 Holtz MH 705 ThreeBond 1735
Polyethylene Used to seal plugs. container Tube Heat-resistant seal used to repair engines. Quick-setting adhesive. Polyethylene Setting time: Within 5 sec. to 3 min. container Used mainly to stick metals, rubbers, plastics, and woods. Quick-setting adhesive. Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container Used mainly to stick rubbers, plastics, and metals. Features: Resistance to heat and chemicals. Polyethylene Used for fitted portions used at high temperacontainer tures. Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container Used to seal tapered plugs, elbows, and nipples of hydraulic piping. Features: Silicon-based heat and cold-resistant sealant. Used to seal flange surfaces and threaded portions. Used to seal oil pan, final drive case, etc. Features: Silicon-based quick-setting sealant. Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc. Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. Used to seal transfer case, etc. Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. Can be coated with paint.
790-129-9140
50 g
Aron-alpha 201
790-129-9130
2g
Loctite 648-50
79A-129-9110
50 cc
LG-5
790-129-9080
1 kg
LG-6 Gasket sealant
790-129-9160
200 g
Tube
LG-7
790-129-9170
1 kg
Tube
LG-8 ThreeBond 1207B
419-15-18131
100 g
Tube
LG-9 ThreeBond 1206D
790-129-9310
200 g
Tube
PC600-8
SEN01062-04
CateKomatsu code gory LG-10 ThreeBond 1206E LG-11 ThreeBond 1121 ThreeBond 1211 LM-P Molybdenum disulfide lubricant
Part number
Q'ty
Container
Main features and applications Used as lubricant/sealant when the radiator hoses are inserted. Can be coated with paint. Feature: Can be used together with gaskets. Used for covers of the transmission case and steering case etc. Gasket sealant used to repair engine. Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. Used to lubricate linkages, bearings, etc. Spray type Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from scuffing each other. Applicable for the propeller shaft splines, needle bearings, pins and bolts of various links, etc. Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Gasket sealant
790-129-9320
200 g
Tube
790-129-9330
200 g
Tube
790-129-9090
100 g
Tube
09940-00040
200 g
Tube
09995-00250
190 g
Can
Seizure prevention compound
LC-G NEVER-SEEZ
Can
SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI SYGA-160CNLI *: For cold district SYG0-400LI-A (*) SYG0-160CNLI (*)
Various
Various
Feature: Lithium grease with extreme pressure lubrication performance. General purpose type.
SYG2-400M Molybdenum disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM
Used for parts under heavy load. Caution: 400 g x 10 Bellows-type Do not apply grease to rolling bearings like 400 g x 20 container swing circle bearings, etc. and spline. The grease should be applied to work equipment 16 kg Can pins at their assembly only, not applied for greasing afterwards. 400 g 16 kg Bellows-type container Can Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*) Hyper White Grease G2-T, G0-T (*) SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*) G2-S ThreeBond 1855
Grease
400 g 16 kg
Bellows-type Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microorganisms, animals, and plants. Can Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. Used for oil seals of the transmission, etc. Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. Used for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.
200 g
Tube
G2-U-S ENS grease
427-12-11871
2 kg
Can
PC600-8
SEN01062-04
CateKomatsu code gory SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER Primer SUNSTAR PAINT PRIMER 435-95 SUNSTAR GLASS PRIMER 435-41 SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SEAL 580 SUPER S or W Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381
Part number
Q'ty
Container Glass container
Main features and applications Used as primer for cab side. (Using limit: 4 months after date of manufacture) Used as primer for glass side. (Using limit: 4 months after date of manufacture) Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture) Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture) S is used for high-temperature season and W for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture) Used as adhesive for glass. (Using limit: 6 months after date of manufacture) Used as adhesive for glass. (Using limit: 6 months after date of manufacture) Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture) Used to seal front window. (Using limit: 6 months after date of manufacture) Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)
20 ml 417-926-3910 20 ml
22M-54-27230
20 ml
Glass container
22M-54-27240
150 ml
Can
22M-54-27250
20 ml
Glass container
417-926-3910
320 ml
Polyethylene container
Adhesive
20Y-54-39850
310 ml
22M-54-27210
320 ml
Ecocart (Special container) Polyethylene container Polyethylene container
417-926-3920
320 ml
Caulking material
20Y-54-55130
333 ml
22M-54-27220
333 ml
Cartridge
Adhesive for cab glass
Polyethylene container
Adhesive for cab glass
Glass container
PC600-8
SEN01062-04
Special tools list

a a a
Tools with part number 79 Tmeans that they are not available from Komatsu Ltd. (i.e. tools to be made locally). Necessity: t ............ Special tools that cannot be substituted and should always be used q ............ Special tools that will be useful if available and are substitutable with tools available on the market New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively. R ............ Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank ..... Tools already available for other models. They can be used without any modification. Tools marked with Q in the sketch column are presented in the sketches of the special tools (See Sketches of special tools).
* *** ****
New/remodel
Necessity
Component
Symbol
Part No.
Part Name
Sketch Q Q
Qty
Nature of work, remarks
Removal and installation of fuel supply pump assembly Removal and installation of cylinder head assembly, engine rear seal
795-630-5500 1 01010-81090 01643-31032 2 3 4 A 5 790-331-1110 795-931-1100 795T-521-1111 01050-31655 01050-31635 795T-521-1150 01050-31635 795T-421-1270 6 01050-31645 01643-31645 795T-421-1240 7 01050-31645 01643-31645 795T-421-1250 8 01050-31645 01643-31645
Standard puller Bolt Washer Wrench Seal puller Push tool Bolt Bolt Push tool Bolt Push tool Bolt Washer Push tool Bolt Washer Push tool Bolt Washer Push tool Wrench Unit repair stand Unit repair stand Bracket Plate Plate
t t t q t t t t t t t t t t t t t t t t t q q q q q
1 2 2 1 1 1 4 4 1 4 1 4 8 1 4 4 1 4 8 1 1 1 1 1 1 1 Disassembly, assembly of final drive N Q Press fitting of engine front seal (Sleeve type) N Q N N N Q N N N N Q Press fitting of bearing Tightening of ring gear bolt AC100V AC110V, 220V Press fitting of engine rear seal N Q (Sleeve type) Press fitting of engine rear seal (Standard type) N Q Tightening of cylinder head bolt, flywheel bolt Pulling out of oil seal Press fitting of engine front seal (Standard type, sleeve type) Pulling out of drive gear
Removal and installation of engine front seal, rear seal
Disassembly, assembly of swing machinery assembly
1 F 2
796T-626-1110 790-331-1110 790-501-5000
Disassembly, assembly of final drive assembly
1 J 2 3
790-501-5200 790-901-4110 796T-627-1510 796T-627-1520
PC600-8
SEN01062-04
New/remodel
Necessity
Component
Symbol
Part No.
Part Name
Sketch Q
Qty
790-431-1031 791-730-1130 790-101-2360 01643-32060 01580-12016 4 796-627-1420 790-201-2790 790-201-2690 790-101-2102 Disassembly, assembly of final drive assembly 790-101-1102 J 5 796-627-1020 790-101-2510 791-830-1320 790-101-2570 01643-31645 6 01580-11613 796-627-1410 796T-627-1330 790-101-2102 790-101-1102 7 Disassembly, assembly of idler assembly Disassembly, assembly of track roller assembly Disassembly, assembly of carrier roller 1 2 3 L 4 5 6 790-331-1110 791-575-1520 791-601-1000 790-701-3600 791-560-1520 791-601-1000 790-701-3600 791-651-1510 791-601-1000 790-701-3600 791-685-8502 791-635-3160 Disassembly, assembly of recoil spring assembly 1 790-101-1600 790-101-1102 2 M Removal and installation of track shoe assembly 790-201-1500 796-632-1200 790-101-4300 3 790-101-4200 790-101-1102 4 790-331-1100
Block Bolt Plate Washer Nut Adapter Spacer Plate Puller (294 kN {30 ton}) Pump Installer Block Rod Washer Washer Nut Adapter Push tool Puller Pump Wrench Installer Adapter Installer Adapter Installer Adapter Compressor Extension Cylinder (686 kN {70 ton}) Pump Push tool Remover, installer Cylinder
(1,471 kN {150 ton})
t t t t t t t t t t t t t t t t t q t t t t q t q t q t t t t t t t t t t
1 2 2 2 2 2 1 1 1 1 1 1 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Installation of push tool Disassembly, assembly of recoil spring Tightening angle of cover bolt Installation of floating seal Filling with oil, check sealing AC110 220 V, AC220 240 V Installation of floating seal Filling with oil, check sealing AC110 220 V, AC220 240 V Installation of floating seal Filling with oil, check sealing AC110 220 V, AC220 240 V Press fitting of bearing Press fitting of floating seal Removal of travel motor
Oil pump assembly q
Oil pump assembly q
Oil pump assembly q
Puller (294 kN {30 ton}) Pump Wrench
PC600-8
SEN01062-04
New/remodel
Necessity
Sketch
Qty
Component
Symbol
Part No.
Part Name
791-680-9580 1 791-680-9590 01010-52760 01010-51440 790-101-1102 2 790-101-4300 791-685-9510 791-685-9520 791-685-9530 791-685-9550 791-685-9560 3 791-680-9570 01010-51030 04530-12030 790-101-1102 790-101-4300 4 Disassembly, assembly of 1 link at field N 791-685-9540 791-685-9550 791-685-9510 791-685-9520 791-685-9530 791-685-9550 791-685-9560 791-126-0150 791-680-5520 5 791-126-0140 791-680-9570 01010-51030 04530-12030 791-685-9620 790-101-1102 790-101-4300 790-101-1102 6 790-101-4200 791-680-5542 791-632-1110 791-680-5580
Adapter Guide Bolt Bolt Pump Cylinder Frame Frame Rod Nut Bolt Adapter Bolt Eyebolt Pump Cylinder Rod Nut Frame Frame Rod Nut Bolt Adapter Guide Pusher Adapter Bolt Eyebolt Extension Pump Cylinder Pump Puller Adapter Adapter Guide
t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t
1 1 2 2 1 1 1 1 1 3 4 1 1 1 1 1 1 3 1 1 1 3 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 294 kN {30 ton} 1,471 kN {150 ton} Removal, press fitting of master pin and regular pin 1,471 kN {150 ton} 1,471 kN {150 ton}
7 8
PC600-8
SEN01062-04
New/remodel
Necessity
Component
Symbol
Part No.
Part Name
Sketch
Qty
791-685-9510 791-685-9520 791-685-9530 791-685-9540 791-685-9550 791-685-9560 9 791-126-0150 01010-51030 791-685-9620 791-680-5542 791-680-5560 790-101-1102 790-101-4300 791-685-9510 791-685-9520 791-685-9530 791-685-9540 791-685-9550 791-685-9560 Disassembly, assembly of 1 link at field 791-126-0150 10 01010-51030 791-685-9620 791-680-5560 791-632-1110 791-680-9630 790-101-1102 790-101-4300 11 791-680-1520 791-685-9510 791-685-9520 791-685-9530 791-685-9540 791-685-9550 791-685-9560 12 791-126-0150 791-680-5560 791-680-9570 01010-51030 791-680-1520 790-101-1102 790-101-4300
Frame Frame Rod Rod Nut Bolt Adapter Bolt Extension Adapter Guide Pump Cylinder Frame Frame Rod Rod Nut Bolt Adapter Bolt Extension Guide Adapter Adapter Pump Cylinder Guide Frame Frame Rod Rod Nut Bolt Adapter Guide Adapter Bolt Guide Pump Cylinder
t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t
1 1 1 1 3 4 1 1 1 1 1 1 1 1 1 1 1 3 4 1 1 1 1 1 1 1 1 1 1 1 1 1 3 4 1 1 1 1 1 1 1 1,471 kN {150 ton} 1,471 kN {150 ton} Removal, press fitting of master pin and regular pin 1,471 kN {150 ton}
10
PC600-8
SEN01062-04
New/remodel
Necessity
Component
Symbol
Part No.
Part Name
Sketch Q Q
Qty
790-101-1102 13 Disassembly, assembly of 1 link at field 790-101-4200 791-680-9501 N 790-101-1102 14 790-101-4200 790-101-4300 Removal, installation of engine, PTO, hydraulic pumps, etc S 796-660-2010 790-101-2501 790-101-2510 790-101-2520 Disassembly, assembly of center swivel joint assembly 791-112-1180 1 T 790-101-2540 790-101-2630 790-101-2570 790-101-2560 790-101-2660 Disassembly and assembly of travel PPC valve assembly 2 3 4 1 2 3 796T-416-1040 796T-416-1050 796T-416-1020 790-502-1003 790-720-1000 796-720-1670 07281-01279 790-201-1702 790-101-5021 Disassembly, assembly of hydraulic cylinder assembly 4 U 01010-50816 790-201-1871 790-445-4210 790-201-1881 790-201-1500 790-101-5021 5 01010-50816 790-201-1680 790-201-1970 790-201-1690 6 790-102-4300 790-102-4310
Pump Puller Remover, installer Pump Puller Cylinder Oil stopper Push-puller Block Screw Nut Washer Leg Plate Nut Adapter Push tool Push tool Push tool Cylinder repair stand Expander Ring Clamp Push tool kit Grip Bolt Push tool Push tool Push tool Push tool kit Grip Bolt Plate Plate Plate Wrench Pin
t t t t t t q t t t t t t t t t t t t q q q q t
1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 Boom Bucket Arm Press fitting of cylinder head bushing Q Press fitting of bushing Disassembly, assembly of hydraulic cylinder Expansion of piston ring Installation of piston ring Disconnection of rotor and shaft 294 kN {30 ton} Removal, press fitting of master pin and regular pin 294 kN {30 ton} 1,471 kN {150 ton} Stopping hydraulic oil
1 1 1 1 1 1 Press fitting of dust seal Bucket Arm Removal, installation of piston
t t
1 2
PC600-8
11
SEN01062-04
New/remodel
Necessity
Sketch
Qty
Component
Symbol
Part No.
Part Name
796T-670-1210 796T-670-1220 791-775-1130 796-670-1130 Removal of boom, arm assembly V 1 796-870-1110 01643-33080 01803-13034 790-101-4000 790-101-1102 Operators cab glass Y 1 2 793-498-1210 20Y-54-13180
Sleeve Sleeve Plate Screw Adapter Washer Nut Puller (490 kN {50 ton}) Pump Adapter
t t t t t t t t t t
1 1 1 1 1 1 1 1 1 2 2
Q Boom foot pin Q Boom top pin
Removal of pin
Lifter (Suction cup) t
Installation of operators cab glass
12
PC600-8
SEN01062-04
Sketches of special tools

Note:
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A4. Push tool
A5. Push tool
PC600-8
13
SEN01062-04
A6. Push tool
A7. Push tool
14
PC600-8
SEN01062-04
A8. Push tool
F1. Push tool
PC600-8
15
SEN01062-04
J2. Plate
J3. Plate
16
PC600-8
SEN01062-04
J6. Push tool
8
36
2 100
(3 49 )
150
CDP00509
HEAT TREATMENT PART NAME PUSH TOOL
MATERIAL STKM13A QTY 1
796T-627-1330
T2 Push tool
PC600-8
17
SEN01062-04
T3 Push tool
T4. Push tool
18
PC600-8
SEN01062-04
V1. Sleeve
V1. Sleeve
PC600-8
19
SEN01062-04
20
SEN01063-02
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8 PC600LC-8
Machine model
PC600-8 PC600LC-8
Serial number

Engine and cooling system, Part 1
Removal and installation of fuel supply pump assembly ................................................................................ 2 Removal and installation of cylinder head assembly ...................................................................................... 8 Removal and installation of fuel injector assembly ....................................................................................... 24 Removal and installation of engine front seal ............................................................................................... 27 Removal and installation of engine rear seal ................................................................................................ 31
PC600-8
SEN01063-02
Removal and installation of fuel supply pump assembly 1

Special tools
Necessity Symbol Part number 795-630-5500 A 1 01010-81090 01643-31032 Part name Standard puller Bolt Washer Sketch Qty N/R
4. 5.
Disconnect hose clamps (4). a Disconnect the clamp of hose (H), too. Remove frame (5).
t 1 t 2 t 2
Removal
k k
Lower the work equipment to the ground and stop the engine. Disconnect the cable from the negative () terminal of the battery. Remove the counterweight assembly. For details, see Removal and installation of counterweight assembly. Remove the fan, fan motor and shroud assembly (1). For details, see Removal and installation of fan motor assembly.
6.
1.
Disconnect connector M34 (6) from air conditioner compressor (7). Loosen locknut (8) and disconnect air conditioner compressor (7). [*1] a Do not disconnect air conditioner hoses. Remove air conditioner compressor belt (9). Disconnect clamp (10). Remove bracket (11).
2.
7. 8. 9.
10. Remove blow-by hose (12).
3.
Remove covers (2) and (3).
PC600-8
SEN01063-02
11. Remove the undercover of part (A).
18. Disconnect wiring harness clamp (19). 19. Disconnect connectors PCV1 (21), PCV2 (20), and G (22).
12. Disconnect fuel hose (13). 13. Disconnect filter (14).
[*2] 20. Disconnect lubrication tube (23). [*6] [*7]
14. Remove fuel tube (15). 15. Remove oil gauge (16). 16. Remove fuel tube (17).
[*3] 21. Disconnect fuel hose (24). [*4] 22. Remove lubrication tube and fuel tube assembly (25). a (25-1): Lubrication tube, (25-2): Fuel tube [*8] 23. Remove fuel tube assembly (26). 24. Remove bracket (27). 25. Remove clamps (28). 26. Disconnect clamp (29). 27. Remove bracket (30). 28. Remove 4 covers (31). a Remove 2 covers each from the fuel supply pump side and common rail side. [*9]
17. Remove lubrication tube (18).
[*5]
PC600-8
SEN01063-02
29. Remove high-pressure pipe assembly (32).
32. Check that bolt hole (H) is set to the tap hole of the fuel supply pump drive gear. a If the bolt hole is not set accurately, bar the engine one more turn (The bolt hole is set when the key is on the upper side). 33. Remove nut (34). [*10] a The washer and nut are set as one unit. Take care not to drop the nut. 34. Install tool A1. 35. Tighten bolt (B) to pull out the gear. a Keep tool A1 installed until the gear is installed again.
30. Remove cover (33). 31. By barring the engine with bolt (BB), set stamp (A) of the damper to pointer (P). a At this time, the stamp of 25 TOP is almost at the top.
PC600-8
SEN01063-02
36. Disconnect bracket (35). 37. Remove fuel supply pump (36).
Installation
k
k k
The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. Never bend a high-pressure pipe for the convenience sake. Before installing a high-pressure pipe, confirm the following points. If any abnormality was found, replace it with another healthy one. Otherwise, leakage of fuel can result. q Check that the taper seal portion of the connection ((a) portion: areas 2 mm inside the tip) is free from visually recognizable striations (b) or patchy dents (c). q Check that nails are not caught by steps in portion (d) (2 mm inside the tip) (this portion is free from deformation).
1.
While setting key (K) of fuel supply pump (36) to key way (G) of the gear, install fuel supply pump (36). 2 Mounting bolt: Adhesive (LT-2)
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2.
Tighten all of supply pump (36), bracket (35), and high-pressure pipes (32) temporarily with the fingers. Tighten high-pressure pipes (32) permanently. 3 Sleeve nut: 39.2 58.8 Nm {4 6 kgm} (Common rail side) 39.2 49 Nm {4 5 kgm} (Supply pump side) Tighten supply pump (36) permanently.
Carry out the following installation in the reverse order to removal.
3.
[*1] Adjust the air conditioner compressor belt tension. For details, see Testing and adjusting, Testing and adjusting air conditioner compressor belt tension. [*2]
3
Sleeve nut of fuel hose (13): 43 47 Nm {4.4 4.8 kgm} Joint bolt of fuel tube (15): 14.8 19.6 Nm {1.5 2.0 kgm} (Supply pump side) 24.5 34.3 Nm {2.5 3.5 kgm} (Filter side) Sleeve nut of fuel tube (17): 43 47 Nm {4.4 4.8 kgm}
4. 5.
[*3] Tighten bracket (35) permanently.
[*4]
6.
Install cover (31). a Direct the slit on the fuel supply pump side toward the cylinder block and direct that on the common rail side down. Install bracket (27). Tighten the brackets and upper and lower clamps of high-pressure pipe clamps (28), (29), and (30) temporarily with the fingers and then tighten them permanently in order. 3 Clamping bolt: 9.8 1 Nm {1.0 0.1 kgm} [*5]
7. 8.
Joint bolt of lubrication tube (18): 9.8 12.7 Nm {1.0 1.3 kgm} Lubrication tube (23): 43 47 Nm {4.4 4.8 kgm} Joint bolt of fuel hose (24): 14.8 19.6 Nm {1.5 2.0 kgm}
[*6]
[*7]
PC600-8
SEN01063-02
[*8]
3 3 3
Clamp of fuel tube and lubrication tube assembly (25): 9.8 1 Nm {1.0 0.1 kgm} Joint bolt of lubrication tube (25-1): 7.9 12.7 Nm {0.8 1.3 kgm} Joint bolt of fuel tube (25-2): 14.8 19.6 Nm {1.5 2.0 kgm} (Supply pump side) 17.7 22.6 Nm {1.8 2.3 kgm} (Common rail side) Joint bolt of fuel tube (26): 14.8 19.6 Nm {1.5 2.0 kgm} (Supply pump side) 43 47 Nm {4.4 4.8 kgm} (Sleeve nut side)
[*9]
[*10]
Mounting nut of fuel supply pump drive gear: 176 196 Nm {18 20 kgm}
Check that the fuel injector wiring harness is at least 10 mm apart from the high-pressure pipe. Bleed air from the fuel system. For details, see Testing and adjusting, Bleeding air from fuel system.
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Removal and installation of cylinder head assembly

Special tools
Necessity Symbol Part number 790-331-1110 Part name Wrench (Angle)
5.
Remove radiator undercover (4).
A2
q 1
Removal
k k
Lower the work equipment to the ground and stop the engine. Disconnect the cable from the negative () terminal of the battery. Remove the counterweight assembly. For details, see Removal and installation of counterweight assembly. Sling engine hood (1) temporarily. Remove pin (2). Fix bolt (B) to hole (A) of bar (3) and erect engine hood (1) upright.
Sketch
Qty
N/R
6.
Drain the coolant.

6
1.
Coolant: 58 l
7.
Remove undercover (A).
2. 3. 4.
8.
Remove 3 covers (5).
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SEN01063-02
9.
Disconnect filter bracket (6). a Disconnect the fuel hose clamp (HC).
12. Remove covers (9) and (10).
10. Disconnect reservoir tank hoses (7).
13. Disconnect clamps (11) and (12). a Disconnect the clamp of hose (H), too. 14. Remove stay (13).
11. Lift off frame (8). 15. Remove cover (14).
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16. Remove air hose, tube and bracket assembly (15). [*1] a Make a mark on the tube at the end of each hose to indicate the insertion position of the hose. (See the figure below.) 17. Loosen air hose clamps (16). 18. Remove cover (17). [*2]
20. Disconnect fuel hose (19). 21. Remove filter assembly (20). 22. Remove fuel tube (21). 23. Remove oil level gauge (22). 24. Remove fuel tube assembly (23).
[*3]
[*4]
[*5]
25. Disconnect wiring harness (24). 26. Remove cover (25).
19. Lift off muffler (18). a Remove the hose clamp from the bottom.
10
PC600-8
50 Disassembly and assembly a
SEN01063-02
Disconnect the following parts from around cover (25).
32. Disconnect oil tubes (26). 33. Remove oil filter (27).
27. Disconnect connector SBP (71). 28. Disconnect connectors BP (72), EGR (73), and SEGR (74). 29. Disconnect clamp (75). 30. Disconnect wiring harnesses (76). 31. Disconnect connector PEVA (77). a Connector PEVA is abolished after engine serial number 530885.
34. Disconnect oil filler clamp (28). 35. Remove bracket (29). 36. Remove cover (30).
Exhaust side 37. Remove covers (78) (80).
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38. Remove cover (81). 39. Remove brackets (82). 40. Disconnect clamps (83) and (84). 41. Remove brackets (85) (87). 42. Disconnect bypass tube (88). [*7]
44. Remove brackets (34). 45. Disconnect lubrication tube (35). [*8] a Disconnect lubrication tube (35) from the clamp and cylinder block side and take it out after removing the exhaust manifold.
46. Remove the tube (36-1) between EGR cooler from part (B). [*9] 43. Remove brackets (33). 47. Remove bracket (36). 48. Remove lubrication tube (37). 49. Disconnect the turbocharger from plate (38).
12
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50. Sling the turbocharger, exhaust manifold and connector assembly (39) temporarily and remove the exhaust manifold mounting bolts. [*10] 51. Disconnect hose (H). 52. Lift off the turbocharger, exhaust manifold and connector assembly (39).
4
59. Lift off pump and diffuser assembly (46). a Take care of exposed bleeding tube (C).
Turbocharger, exhaust manifold and connector assembly: 70 kg
60. Disconnect wiring harness (47). 61. Remove fuel return tube (48). 62. Remove fuel return tube (49). [*13] [*13]
63. Disconnect connector TIM (50), TFUEL (51). 64. Disconnect connector PIM (52) by the following method. [*14] 1) Rotate housing (H1) in the direction of the arrow. 2) Pull housing (H1) in the direction of the arrow. 65. Disconnect high-pressure pipe clamps (53). 56. Remove corrosion resistor assembly (43). [*12] 57. Remove blow-by tube and hose assembly (44). 58. Remove bracket assembly (45). a White portion (W) is sealing tape applied to cover the hole.
53. Disconnect heater terminal (40). 54. Loosen clamps (41). 55. Disconnect air intake connector (42). [*11]
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SEN01063-02
69. Lubrication tubes (59) and (60). 70. Remove bypass valve (61).
[*16] [*16]
71. Disconnect lubrication tubes (62) and (63). [*17] 72. Remove EGR valve (64). [*18]
73. Remove tube (89) first and then remove air housing assembly (58). a Tube (89) is abolished after serial number 530885.
66. Disconnect wiring harness (54). 67. Remove bracket (55). 68. Disconnect lubrication tube (56). [*15]
74. Disconnect clamps (65) and (66).
14
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SEN01063-02
75. Disconnect high-pressure pipe clamps (67) and (68). a There are clamps on the right side, too. 76. Sling air intake manifold assembly (69) and remove the mounting bolts.
80. Remove clamp (95). 81. Remove cover (96). 82. Remove bracket (97).
83. Remove 12 covers (98). 77. Lift off air intake manifold assembly (69).
4
Air intake manifold assembly: 40 kg
84. Remove clamps (99) and (100). 85. Remove 6 high-pressure pipes (101). 86. Disconnect connector (102). a Disconnect connector (102) according to the following procedure; Insert flat-head screwdriver [3] in shoulder (a). While pressing stopper (b), move the screwdriver in direction (X), and connector (c) is disconnected. (d): Fuel injector wiring side
78. Disconnect air bent tube (93). 79. Remove air bent tube (94). [*19]
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87. Disconnect wiring harness (103). 88. Remove spill tube (104). 89. Remove cylinder head cover (105).
93. Remove push rod (109).
94. Remove capture nut (111) from fuel injector (110) and disconnect the wiring harness. 95. Disconnect clamp (112).
90. By barring the engine with bolt (BB), set stamp of 16 TOP of the damper to pointer (P).
96. Remove holder mounting bolt (113). 97. Insert small L-bar [2] under connector (CN) of fuel injector (110) and pry off fuel injector (110) slowly. a Never hold and pull out the solenoid valve on the top of fuel injector (110) with pliers, etc.
91. Loosen locknut (106) and then loosen adjustment screw (107) fully. 92. Remove rocker arm shaft assembly (108).
16
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98. Loosen locknut (114) and adjustment screw (115). 99. Remove crosshead assembly (116). 100.Remove mounting bolts (117) and auxiliary bolt.
Installation
a Before installing the cylinder head, check the following items. 1) Measure stem length (e) of every bolt. 2) Make sure that stem length (e) of every bolt is as follows. q Short bolt: Less than 170.8 mm q Long bolt: Less than 205.8 mm 3) If a mounting bolt is longer than the above using limit or it has been tightened 5 times (there are 5 punch marks on it), do not reuse it but replace it.
101.Remove cylinder head assembly (118).

4
Cylinder head assembly: 25 kg
102.Remove cylinder head gasket (119). 4) 5) 1. 2. Check that the cylinder head mounting face and inside of the cylinder are free from foreign matter. When fitting the gasket, check that the grommets are fitted correctly.
Set cylinder head gasket (119). Install cylinder head (118).
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17
SEN01063-02 a
Tighten cylinder head mounting bolts (1) (6) and auxiliary bolt (7) in the following order. a A special socket is required to tighten the head bolts. 2 Mounting bolt: Molybdenum disulfide lubricant (LM-P) 3 Mounting bolts ((1) (6) in the following figure): a Tighten in the order of (1) (6). 1st time: 137 157 Nm {14 16 kgm} 2nd time: 284 294 Nm {29.0 30.0 kgm} 3rd time: 1] When using tool A2 Retighten each bolt by 90 +30 in the +0 order of (1) (6).
2]
When not using tool A2 Make marks (a) and (b) on the bolts and cylinder head, then retighten each bolt by 90 +30 in the order of (1) +0 (6). a After tightening bolts (1) (6), tighten auxiliary bolt (7). 3 Auxiliary bolt (7) 66.6 7.4 Nm {6.8 0.8 kgm}
3.
Crosshead Install crosshead (116). a Adjust the crosshead according to the following procedure. 1] Loosen locknut (114) and return adjustment screw (115). 2] Holding the top of the crosshead lightly, tighten adjustment screw (115). 3] After adjustment screw (115) touches the valve stem, tighten it further by 20. 4] Tighten locknut (114) at this position. 3 Locknut: 58.7 5.9 Nm {6.0 0.6 kgm}
18
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SEN01063-02
4.
Fuel injector a Check that the inside of the injector sleeve is free from dirt. 1] Install gasket (120) and O-rings (121) to fuel injector (110). 2 O-ring: Engine oil (EO30-DH) 2] Install holder (122) in fuel injector (110), then insert the injector connector in the high-pressure pipe insertion hole. 3] Fit ball washer (123) to bolt (113) and tighten holder (122) temporarily. 2 Ball washer: Engine oil (EO30-DH) a Tighten holder (122) permanently after installing the wiring harness and connector and tightening the high-pressure pipe temporarily.
5.
Push rod Install push rods (109). a Check that the point of push rod is in the cam follower socket area.
6.
Install connector (102). a Install the connector before installing the high-pressure pipe.
4]
5]
Install wiring harness terminal right and left (111) to fuel injector (110) with the nuts. 3 Terminal nut: 1.8 2.2 Nm {0.18 0.22 kgm} Install spring clamp (124) and wiring harness holder clamp (112). a Slack off the wiring harness and press it against the injector.
7.
k k
High-pressure pipe The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. Never bend a high-pressure pipe for the convenience sake. Before installing a high-pressure pipe, confirm the following points. If any abnormality was found, replace it with another healthy one. Otherwise, leakage of fuel can result. q Check that the taper seal portion of the connection ((a) portion: areas 2 mm inside the tip) is free from visually recognizable striations (b) or patchy dents (c). q Check that nails are not caught by steps in portion (d) (2 mm inside the tip) (this portion is free from deformation).
PC600-8
19
SEN01063-02
1)
2)
3)
4)
Put sleeve nut (126) of high-pressure pipe (101) in the fuel high-pressure pipe insertion part and tighten it temporarily. a Check that the O-rings are fitted to both of the injector and sleeve nut. Rotate sleeve nut (127) by 2 turns with the fingers on the threads of the injector, and then tighten sleeve nut (127) with a spanner (do not tighten it permanently at this time). a If sleeve nut (127) does not catch the threads of the injector, press its end with another small spanner etc. and rotate its hexagonal part with the spanner. a After tightening sleeve nut (127), check that the O-ring is not projected from the end of the sleeve nut (127). Tighten mounting bolts (113) of holder (122) permanently. 3 Holder mounting bolt: 58.8 73.5 Nm {6.0 7.5 kgm} Tighten sleeve nut (127) of high-pressure pipes (101). a Tighten the common rail side, too. a Control the tightening torque with torque wrench [1] of spanner type. 3 Sleeve nut: 39.2 49 Nm {4 5 kgm}
8.
Install rocker arm and shaft assembly (108). a Before tightening the mounting bolt, check that the ball of adjustment screw (107) is fitted to the socket of the push rod (109) securely. 3 Mounting bolt: 93 103 Nm {9.5 10.5 kgm} a Adjust the valve clearance. For details, see Adjusting valve clearance in Testing and adjusting. 3 Locknut (106): 53 64.7 Nm {5.4 6.6 kgm} a After tightening the locknut, check the valve clearance again.
20
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SEN01063-02
9.
Install cylinder head cover (105). 3 Cylinder head cover mounting bolt: 29.4 34.3 Nm {3.0 3.5 kgm}
10. Install covers (98) to the sleeve nut of highpressure pipes (101). a Direct the slit as follows. Cylinder head side: Direct the slit down. Common rail side: Direct the slit toward the cylinder block. 11. Install fuel spill tube (104). 3 Fuel spill tube joint bolt: 9.8 12.7 Nm {1.0 1.3 kgm} 12. Install wiring harness (103). 13. Install upper and lower clamps (126) and (99) of the high-pressure pipe temporarily. At this time, tighten the stay and upper and lower clamps with the fingers. a Tighten the clamps permanently after installing the air intake manifold.
15. Install the air intake manifold. a Before installing the air intake manifold, insert 3 bolts (B). a Tighten the mounting bolts of air intake manifold assembly in the order of [1] [24] shown below. 3 Air intake manifold assembly mounting bolt: 59 74 Nm {6 7.5 kgm}
14. Insert lubrication tube (129) of turbocharger (TC). a The lubrication tube cannot be inserted after the air intake manifold is installed.
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21
SEN01063-02
16. High-pressure pipe clamp 1) Tighten high-pressure pipe clamps (126) above the air intake manifold (described above) and stay (127) permanently. a Bend the rubber in advance. 3 Clamping bolt: 9.8 1 Nm {1 0.1 kgm} 2) Tighten stays (128) of clamps (99) under the air intake manifold (described above) temporarily. 3) Install high-pressure pipe clamp (100) and bracket (96) temporarily with the fingers. 4) Install high-pressure pipe clamp (95) and bracket (97) temporarily. 5) Tighten high-pressure pipe clamps (100) and (95) permanently first. 3 Clamping bolt: 9.8 1 Nm {1 0.1 kgm} 6) Tighten brackets (96) and (97) permanently. 7) Tighten high-pressure pipe clamps (99) permanently. 3 Clamping bolt: 9.8 1 Nm {1 0.1 kgm} 8) Tighten stays (128) permanently.
[*1]
Air hose clamp (Right and left): 8.8 0.5 Nm {0.9 0.05 kgm}
[*2] MIKALOR clamp a Use a new MIKALOR clamp. 1) Set the hose to the original position. (Insertion depth of air hose: 80 mm) 2) Set bridge (BR) under the clamp bolt and adjust its overlap (b) with bridge (BR) and band to at least 5 mm. 3) Tightening of the clamp. 2 Threads of clamp bolt (BC): Lubricating oil (THREEBOND PANDO 18B) a Do not use an impact wrench. q When reusing the hose. Install the clamp to the clamp mark made on the hose. 3 Clamp bolt: Min. 6 Nm {0.6 kgm} q When using a new hose. Tighten until dimension (a) is 5 8 mm.
[*3]
Tightening torque for fuel hose (19): 43 47 Nm {4.4 4.8 kgm}
[*4]
Tightening torque for fuel tube (21): 43 47 Nm {4.4 4.8 kgm} (Upper side) 14.8 19.6 Nm {1.5 2.0 kgm} (Lower side) Tightening torque for fuel tube assembly (23): 24.5 34.3 Nm {2.5 3.5 kgm} (Filter side) 14.8 19.6 Nm {1.5 2.0 kgm} (Lower side) Mounting bolt of bypass tube (88): 44.1 53.9 Nm {4.5 5.5 kgm}
[*5]
[*7]
22
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SEN01063-02
[*8]
Joint bolt of turbocharger lubrication tube (35): 24.5 34.3 Nm {2.5 3.5 kgm}
[*9]
[*14] 1) Set the connector groove in position and insert to the end. 2) Rotate housing (H1) in the direction of the arrow until it clicks.
Mounting bolt of EGR cooler tube: 44.1 53.9 Nm {4.5 5.5 kgm}
[*10] Exhaust manifold, turbocharger and connector assembly 1) Apply heat-resistant sealant to the fitting parts of the exhaust manifold (between ports No. 2 and No. 3 and between ports No. 4 and No. 5). 2 Fitting parts: Heat-resistant sealant (HOLTS MH705) 2) Fit the gasket and sling and install exhaust manifold (1). 3) Tighten the mounting bolts in the following order. a Tighten the 3 bolts of (1) (3) shown below temporarily in the numeric order and then tighten other bolts (4) (24) temporarily in the numeric order. Then, tighten all bolts (1) (24) to the specified torque in the numeric order. 2 Mounting bolt: Seizure prevention compound (LC-G) (NEVER-SEEZ (Bostik, Inc.) or equivalent) 3 Mounting bolt: 59 74 Nm {6 7.5 kgm}
[*15]
Joint bolt of lubrication tube (56): 34.3 44.1 Nm {3.5 4.5 kgm}
[*16] [*18] 3 Joint bolts of lubrication tubes (60) and (63): 24.5 34.3 Nm {2.5 3.5 kgm} 3 Mounting bolts of EGR valve (64) and bypass valve (61): 59 74 Nm {6 7.5 kgm} [*19]
3
Joint bolt of air vent tube (94): 9.8 12.7 Nm {1.0 1.3 kgm}
Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again.
5
Coolant: 58 l
Bleed air from the fuel system. For details, see Testing and adjusting, Bleeding air from fuel system. Before starting the engine, check that the wiring harnesses are at least 10 mm apart from the high-pressure pipe.
[*11] See MIKALOR clamp [*2]. [*12]

3
Corrosion resistor joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm} Fuel return tube joint bolts (48) and (49): 9.8 12.7 Nm {1.0 1.3 kgm}
[*13]
PC600-8
23
SEN01063-02
Removal and installation of fuel injector assembly 1

Removal
1. Remove the counterweight assembly. For details, see Removal and installation of counterweight assembly. (The counterweight must be removed to bar the engine.) Remove the air intake manifold assembly (1). For details, see Removal and installation of cylinder head assembly.
5. 6.
Remove covers (4). a Remove the common rail side, too. Remove the clamp and high-pressure pipes (5). Disconnect connector (6) of the injector wiring. a Insert flat-head screwdriver [3] in shoulder (a). While pressing stopper (b), move the screwdriver in direction (X), and connector (c) is disconnected. (d): Fuel injector wiring side Remove cylinder head covers (7).
7.
2.
8.
3. 4.
Remove clamp (2). Remove brackets (3).
9.
By barring the engine with bolt (BB), set stamp 16TOP of the damper to pointer (P).
24
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SEN01063-02
10. Remove the mounting bolts and rocker arm assembly (8). a Loosen locknut (9), and then loosen adjustment screw (10) by 2 3 turns so that an excessive force will not be applied to the push rod when the rocker arm assembly is installed.
12. Remove holder mounting bolt (19) of fuel injector assembly (11) and then remove fuel injector assembly (11). a Insert small L-shaped bar [2] under the connection of the fuel injector and pry off the injector slowly. a Do not grip the solenoid valve on the fuel injector with pliers etc. to remove.
11. Disconnect the injector wiring harness according to the following procedure. 1) Remove 2 nuts (12) of the upper solenoid valve of fuel injector (11). 2) Pull out spring clamp (13). 3) Disconnect clamp (14). a Remove the injector wiring harness according to the following procedure. 1] Remove 1 mounting bolt (hexagon socket head bolt) (17) of holder (16) of connector (having an O-ring) (15). 2] Remove holder (16) and push in connector (15) to remove. [*1]
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SEN01063-02
Installation
1. Referring to installation step 4 and after in Removal and installation of cylinder head assembly, install the removed parts up to the air intake manifold. Carry out the following installation in the reverse order to removal. When installing the parts, observe the precautions described in Removal and installation of cylinder head assembly. Procedure for installing fuel injector wiring harness assembly a It is difficult to install the connector having the O-ring from inside. 1) Remove O-ring (23) and take wiring harness connector (22) out of the connector insertion opening. 2) Fit O-ring (23) and apply engine oil (SAE30) to its outside. 3) Install connector holder (24) and push it in. 4) Fix connector holder (24) with mounting bolt (17).
[*1]
26
PC600-8
SEN01063-02
Removal and installation of engine front seal

Special tools
Necessity Symbol Part number 3 795-931-1100 4 01050-31655 01050-31635 5 01050-31635 Part name Seal puller Bolt Bolt Bolt
3)
1
a a a
t 1 t 1 N Q t 3 t 3 t 1 N Q t 3
Insert the top end of tool A3 into the drilled hole, and remove the front seal by the impact of slide hammer (SH). (Apply the slide hammer evenly not to tilt the front seal.) Remove the metal powders completely. When the sleeve is attached, cut sleeve (6) using a gad and hammer to remove it. Take care not to damage crankshaft (5).
795T-521-1111 Push tool A
795T-521-1150 Push tool
Removal
1. Remove the fan and fan shroud assembly. For details, see "Removal and installation of fan motor assembly". Remove inside 6 mounting bolts (1) and pulley and damper assembly (2). a Since there are stamps on damper (2), make a match mark (M) on it and the front cover.
2.
3.
Remove front seal (3) from housing (4) according to the following procedure. a Take care in the removal not to damage front seal (3) installation position on housing (4) and the seal contact face on crankshaft (5). a Before removing, slightly drive the front seal in once to free it from fixation. a When front seal (3) is fixed too hard to the housing (4), carry out the following procedure. 1) Drill through a hole of approx. 3 mm dia. on front seal (3). 2) Replace the tip of tool A3 with the drill type one.
Sketch
Qty
N/R
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27
SEN01063-02
Installation
a Check the seal by checking the wear of the shaft and replace it with the "standard seal" or "sleeved seal". If the shaft is worn to the degree of luster (If wear which you feel with your finger is less than 10 mm) and does not have any flaw, install "standard seal A". In other cases, install "sleeved seal B". (7): Plastic inside cylinder which is also used as installation guide. (6): Sleeve. Do not remove installation guide (7) from front seal (3) before installing the front seal. Handle front seal (3) and sleeve (6) as an assembly and never separate them from each other. Sleeved seal
a a a a
Standard spare seal
2)
1.
Procedure for installing standard seal a Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing. a When installing the seal, do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. a Never remove inside plastic cylinder (7) of the replacement seal before installing the seal. 1) Set large inside diameter side (b) of plastic inside cylinder (7) to the end of crankshaft (5). a Take care not to mistake the direction of the plastic inside cylinder.
3)
Push the metal ring of front seal (3) evenly as if you are passing over the large inside diameter side of plastic inside cylinder (7). a Hit the metal ring of front seal with plastic hammer evenly. a Do not hit it strongly. After pushing in the seal, remove plastic inside cylinder (7). a When removing the inside cylinder, take care not to damage the seal lip.
28
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4)
Using tool A4, tighten the 3 bolts evenly to press fit seal (3) until the end of tool A4 reaches the end of crankshaft (5). a Tighten tool A4 first until the 55-mm bolts stop and then replace the 55mm bolts with the 35-mm bolts and tighten them. a Seal driving distance (a) from crankshaft: 9.1 10.1 mm a When press fitting the seal, take care not to damage the lip of the seal with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery.
2)
Set the sleeve of the front seal to the end of crankshaft (5) and tighten the 3 bolts evenly to press fit sleeve and front seal assembly (9) until the end of tool A5 reaches the end of crankshaft (5). a Tighten tool A5 (for press fitting the sleeved seal) until the 35-mm bolt stops.
3) 4) 2. Procedure for installing sleeved seal a When installing the front seal, do not apply oil or grease to the shaft, inside cylinder surface of sleeve (6) and seal lip. 1) Set sleeve (6) and front seal (3) assembly to tool A5 (for fitting the sleeved seal). 2 Sleeve (6) inside cylinder surface: Gasket sealant (LG-7)
Remove tool A5 (for press fitting the sleeved seal) and install tool A4 (for press fitting the seal). Tighten the 35-mm bolts of tool A4 evenly to press fit seal and sleeve assembly (9) until the end of tool A4 reaches the end of crankshaft (5). a Seal driving distance (a) from crankshaft: 9.1 10.1 mm a When press fitting the seal, take care not to damage the lip of the seal with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery.
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29
SEN01063-02
3.
While setting match mark (M), install pulley and damper assembly (2) and tighten the mounting bolt (1). 3 Mounting bolt: 245 308.7 Nm {25 31.5 kgm}
30
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Removal and installation of engine rear seal

Special tools
Necessity Symbol Part number 3 795-931-1100 6 01050-31645 01643-31645 A 7 01050-31645 01643-31645 8 01050-31645 01643-31645 Part name Seal puller Bolt Washer Bolt Washer Bolt Washer
5.
t 1 t 1 t 4 t 8 t 1 t 4 t 4 t 1 t 4 t 8 Q Q Q
795T-421-1270 Push tool
795T-421-1240 Push tool
795T-421-1250 Push tool
Sketch
Qty
N/R
Remove rear seal (2) according to the following procedure. a Measure the distance from the end of the housing. 1) Before pulling out rear seal (2), drive in it a little to separate it from the flywheel housing (FWH).
2)
Removal
1. Remove the PTO assembly and hub assembly. For details, see "Removal and installation of PTO assembly". Remove 1 mounting bolt of flywheel (1) and install guide bolt. Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (1) temporarily and remove the 8 mounting bolts. Move flywheel (1) toward this side and lift it off. k Since the socket part of the flywheel is shallow, it may fall suddenly. Take care not to catch your fingers in the flywheel.
4
3)
2. 3.
If the seal is sleeved, cut and remove sleeve (5) with a chisel and a hammer. a When cutting, take care extremely not to damage crankshaft (4). Hitch the end of tool A3 to the metal ring of rear seal (2) and pull out the seal with impacts of slide hammer (SH). a Do not use a drill etc. since chips may enter the engine. a If chips were made, remove all of them. Tool A3
4.
Flywheel: 65 kg
PC600-8
31
SEN01063-02 a
Left: Standard seal, Right: Sleeved seal
Installation
a Check the Teflon seal (Laydown lip seal) by checking the wear of the crankshaft and replace it with the "standard seal" or "sleeved seal". If the shaft is worn to the degree of luster (If wear which you feel with your finger is less than 10 mm) and does not have any flaw, install standard seal (A). In other cases, install sleeved seal (B). a (3): Plastic inside cylinder which is also used as installation guide. a (5): Sleeve. a Do not remove installation guide (3) from rear seal (2) before installing the rear seal. a Handle rear seal (2) and sleeve (5) as an assembly and never separate them from each other. spare seal
q Sleeved
q Standard
seal
a a a
Clean, degrease, and dry the seal surface on the flywheel housing side. Clean, degrease, and dry the seal lip surface (periphery of the crankshaft). Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing.
32
PC600-8
SEN01063-02
1.
Procedure for installing standard seal a When installing rear seal (2), do not apply oil or grease to the shaft and seal lip. 1) Set large inside diameter side (b) of plastic inside cylinder (3) of rear seal (2) to the end of crankshaft (4). a Take care not to mistake the direction of the plastic inside cylinder.
4)
Tighten the 3 bolts evenly to press fit rear seal (2) until the end of tool A6 (for press fitting the seal) reaches the end of crankshaft (4). a Tighten tool A6 (for press fitting the seal) first until it reaches the bolt (45 mm) and then tighten the bolt (25 mm). a When press fitting the seal, take care not to damage the lip on the PTO side with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery.
2) 3)
Hold the metal ring of rear oil seal (2) with both hands and push it in evenly. After pushing in the seal, remove plastic inside cylinder (3). a When removing the inside cylinder, take care not to damage the seal lip.
2.
Procedure for installing sleeved seal a When installing the rear seal, do not apply oil or grease to the shaft and sleeve inside cylinder surface (C). 1) Set sleeve and rear seal assembly (6) to tool A7 (for press fitting the sleeved seal). 2 Sleeve inside cylinder surface (C): Gasket sealant (LG-7)
PC600-8
33
SEN01063-02
2)
Set sleeve of the rear seal to the end of crankshaft (4) and tighten the 4 bolts of tool A7 evenly to press fit sleeve and rear seal assembly (6). a Tighten tool A7 (for press fitting the sleeved seal) with 1 washer inserted in each bolt until the bolts reach the end.
3.
Flywheel Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (1), install it to the crankshaft, and tighten the bolts. a If there are 5 punch marks on a bolt, do not use that bolt but replace it. 2 Threads and seat of bolt: Engine oil (EO30-DH)
4
Flywheel: 65 kg
3) 4)
Remove tool A7 (for press fitting the sleeved seal) and install tool A8 (for press fitting the seal). Tighten the 4 bolts evenly to press fit sleeve and rear seal assembly (6) until the end of tool A8 (for press fitting the seal) reaches the end of crankshaft (4). a Tighten the bolt of tool A8 (for press fitting the seal) without washer until it reaches, and then tighten the bolt using 2 washers (for each bolt). a After press fitting the seal, remove the red sealant layer from its periphery. a Seal driving depth (b) from the end of crankshaft: 13.2 0.2 mm
Tighten the mounting bolts according to the following procedure. 3 Flywheel mounting bolts 1st time: 118 4.9 Nm {12 0.5 kgm} 2nd time: 1) When using tool A2 (See the tools list) Retighten each bolt by 90 +30 in +0 the order of [1] [8]. 2) When not using tool A2 Make marks (f) on each bolt and flywheel with paint, then retighten each bolt by 90 +30 in the order +0 of [1] [8].
34
PC600-8
SEN01063-02
After tightening, make 1 punch mark (g) on each bolt head to indicate the number of tightening time.
After installing the flywheel, measure the facial runout and radial runout with tool [1]. a Radial runout: Max. 0.30 mm a Facial runout: Max. 0.30 mm
PC600-8
35
SEN01063-02
36
SEN01064-02
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8 PC600LC-8
Machine model
PC600-8 PC600LC-8
Serial number

Engine and cooling system, Part 2
Removal and installation of engine, PTO and hydraulic pump assembly ....................................................... 2 Removal and installation of radiator assembly ............................................................................................... 9 Removal and installation of hydraulic oil cooler assembly .............................................................................11 Removal and installation of aftercooler assembly......................................................................................... 13 Removal and installation of fan motor assembly .......................................................................................... 15 Removal and installation of fuel tank assembly ............................................................................................ 19
PC600-8
SEN01064-02
Removal and installation of engine, PTO and hydraulic pump assembly 1

Special tools
Necessity Symbol Part number 796-660-2010 Part name Oil stopper Sketch Qty N/R
3.
Set engine hood (1) vertically as shown below. 1) Sling engine hood (1) temporarily. 2) Remove pin (2) and stay (3). 3) Fix hole (A) of stay (3) with bolt (B). a Take care of the direction of stay (3).
q 1
Removal
k k
Lower the work equipment to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Disconnect the cable from the negative () terminal of the battery. Install oil stopper plugs to the disconnected tubes and hoses. Before disconnecting each hose, mark it with a tag etc. to indicate its position. Remove the hydraulic tank strainer and stop the oil with tool S. a When not using tool S, remove the drain plug and drain the oil.
6
a a 1.
Hydraulic tank: 360 l 4. Remove undercover (4).
2.
Remove the counterweight assembly. For details, see Removal and installation of counterweight assembly.
5.
Drain the coolant.

6
Coolant: 58 l
PC600-8
SEN01064-02
6.
Remove 3 covers (5).
9.
Lift off frame (8).
7.
Remove filter bracket (6). a Disconnect the fuel hose clamp (HC).
10. Remove covers (9) and (10).
8.
Disconnect reservoir tank hoses (7).
11. Disconnect clamps (11) and (12). a Disconnect the clamp of hose (H), too. 12. Remove stay (13).
PC600-8
SEN01064-02
13. Remove handrail (14). 14. Disconnect hoses (15) from reservoir tank (RT). 15. Disconnect connector P24 from under reservoir tank (RT). 16. Remove cover (16).
19. Remove stay (20). 20. Disconnect air hose (21). [*1] a Make a mark on the tube to show the position of the hose end. 21. Remove air tube and bracket assembly (22). [*2] 22. Disconnect bracket (23). 23. Remove air tube (24). 24. Disconnect radiator hose (25). 25. Disconnect heater hoses (26) and (27). [*3] [*4]
17. Remove cover assembly (17). a Lift off the cover and frame together. 18. Remove covers (18) and (19).
PC600-8
SEN01064-02
33. Disconnect heater terminal (36). 26. Disconnect dust indicator hose (28). 34. Disconnect hose (37). 27. Remove air cleaner bands (29) and air cleaner (30). [*5] 28. Lift off frame, stay and bracket assembly (31). 35. Disconnect connector M34 (38). 36. Loosen locknut (39) and disconnect air conditioner compressor (40). [*8] a Do not disconnect the air conditioner hose. 37. Remove the air conditioner compressor belt. 38. Disconnect cover (41). 39. Disconnect fuel hose (42). 40. Disconnect wiring harness (43). [*9] [*7]
29. Disconnect hose (32). 30. Disconnect reservoir tank hoses (33). 31. Remove radiator hose (34). 32. Disconnect hose clamp (35). [*6]
41. Remove undercovers (44) and (45).
PC600-8
SEN01064-02
48. Disconnect 2 hoses (57) from pump No. 1. 49. Disconnect hoses (58) (61). 50. Disconnect wiring harness (62). 51. Disconnect hoses (63) and (64) from the PTO oil cooler. 52. Disconnect suction connector (65) from pump No. 1. a Do not disconnect suction hose (SH1) from suction connector (65). 42. Disconnect lubrication hose (46) from above the PTO. 43. Disconnect clamps (47) and (48). 44. Disconnect connector (49). 53. Disconnect hose (66) from under the PTO.
45. Remove 2 hoses (50) from pump No. 2. 46. Disconnect hose (51). 47. Disconnect hoses (52) (56) from gear pump (G.P.).
54. Disconnect clamps (67). 55. Disconnect hose (68) from the gear pump. 56. Disconnect suction connector (70) from the gear pump. a Do not disconnect suction hose (SH1) from suction connector (70).
PC600-8
SEN01064-02
57. Disconnect suction connector (71) from pump No. 2.
63. Disconnect starting motor terminal (84). 64. Disconnect clamp (85). 65. Disconnect ground wire (86). 66. Remove mounting bolts (87). [*11]
58. Disconnect fuel return hose (72). 59. Remove controller cover (73).
[*10]
60. Disconnect connector P44 (74), ground wire T09 (75), and connector E22 (76).
67. Lift off engine, PTO and pump assembly (88).

4
Engine, PTO and pump assembly: 2,700 kg
61. Disconnect connectors CE03 (77) and CE02 (78). 62. Disconnect clamps (79). a Use 2 M30 eyebolts (EB).
PC600-8
SEN01064-02
Installation
q
Carry out installation in the reverse order to removal.
[*8] Adjust the air conditioner compressor belt tension. For details, see Testing and adjusting, Testing and adjusting air conditioner compressor belt tension. [*9]
3
[*1], [*2] 3 Air hose clamps (right and left): 8.3 9.3 Nm {0.85 0.95 kgm} [*3], [*7] MIKALOR clamp a Use a new MIKALOR clamp. 1) Set the hose to the original position. (Insertion depth of air hose: 80 mm) 2) Set bridge (BR) under the clamp bolt and adjust its overlap (b) with bridge (BR) and band to at least 5 mm. 3) Tightening of the clamp. 2 Threads of clamp bolt (BC): Lubricating oil (THREEBOND PANDO 18B) a Do not use an impact wrench. q When reusing the hose. Install the clamp to the clamp mark made on the hose. 3 Clamp bolt: Min. 6 Nm {0.6 kgm} q When using a new hose. Tighten until dimension (a) is 5 8 mm.
Tightening torque for fuel hose (41): 43 47 Nm {4.4 4.8 kgm} Joint bolt of fuel return hose (72): 19.6 29.4 Nm {2.0 3.0 kgm} Engine mounting bolt: Adhesive (LT-2) Engine mounting bolt: 824 1,030 Nm {84 105 kgm}
[*10]
[*11]
2 3
Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again.
5
Coolant: 58 l
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
5
Hydraulic oil: 360 l
[*4]
Radiator hose clamp: 8.3 9.3 Nm {0.85 0.95 kgm} Air cleaner band: 17.6 21.6 Nm {1.8 2.2 kgm} Radiator hose clamp: 8.3 9.3 Nm {0.85 0.95 kgm}
[*5]
[*6]
PC600-8
SEN01064-02
Removal and installation of radiator assembly

Removal
k k
4.
Remove undercover (4).
a a 1. 2. 3.
Lower the work equipment to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Disconnect the cable from the negative () terminal of the battery. Install oil stopper plugs to the disconnected tubes and hoses. Before disconnecting each hose, mark it with a tag etc. to indicate its position. Sling engine hood (1) temporarily. Remove pin (2). Fix bolt (B) to hole (A) of bar (3) and set engine hood (1) vertically. a Take care of the direction of bar (3).
5.
Drain the coolant.

6
Coolant: 58 l
6. 7. 8. 9.
Disconnect reservoir tank hoses (5). Disconnect radiator hose (6). Disconnect clamp (7). Disconnect radiator hose (8). [*1] [*2]
10. Disconnect radiator hose (9).
PC600-8
SEN01064-02
11. Disconnect 2 fan hoses (11). (These hoses must be disconnected to remove radiator hose (13).) a Prepare an oil receiver. a Fit a plug. q Adapter size: #06 --- 2 pieces
17. Lift off radiator assembly (18) and (19).

4
Radiator assembly: 25 kg (One side)
Installation
q
12. Disconnect radiator hose (12). 13. Remove radiator hose (13). 14. Remove covers (14) (16).
[*3] [*4]
[*1] [*4] 3 Radiator hose clamp: 8.3 9.3 Nm {0.85 0.95 kgm}
q
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again.
5
Coolant: 58 l
15. Remove cover (17). 16. Remove covers (C) (E).
10
PC600-8
SEN01064-02
Removal and installation of hydraulic oil cooler assembly

Removal
k k
8.
Remove lower mounting bolts (6).
Lower the work equipment to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Sling engine hood (1) temporarily and lift it off. [*1] Open right and left covers (2). Remove plate (3). 9. Disconnect tube (7) from the top of the hydraulic oil cooler.
1. 2. 3.
10. Remove net (8). 11. Sling hydraulic oil cooler assembly (10) temporarily with (A). 12. Remove cover (9). 13. Lift off hydraulic oil cooler assembly (10).
4
Hydraulic oil cooler assembly: 40 kg
a 4. Remove undercover (4).
AC: Air conditioner condenser, FC: Fuel cooler
5.
Drain the hydraulic oil tank.

6
Hydraulic oil tank: 360 l
6.
Loosen drain plug (DP) and drain the hydraulic oil cooler. a Loosen the upper tube of the hydraulic oil tank to let the air in. Disconnect tube (5) from the bottom of the hydraulic oil cooler. a Prepare an oil receiver.
7.
PC600-8
11
SEN01064-02
Installation
q
[*1] Precautions for installing engine hood 1. Secure clearance (FC) of at least 10 mm between the engine hood and oil cooler frame. 2. The engine hood must not interfere with stopper (S). 3. Adjust the positions of hinge (H), bracket (B), catcher (C), and U-bolt (UB).
5
Hydraulic oil tank: 360 l (Refill capacity)
12
PC600-8
SEN01064-02
Removal and installation of aftercooler assembly

Removal
k
4.
1
5. 6.
Disconnect aftercooler hose (4). [*2] a Make a mark on the tube to show the position of the hose end. Disconnect oil cooler hoses (5) and (6). Disconnect aftercooler hose (7). [*2] a Make a mark on the tube to show the position of the hose end. Sling aftercooler assembly (8) temporarily and remove 6 mounting bolts (9) from the back side. Lift off aftercooler assembly (8).
4
Lower the work equipment to the ground and stop the engine. Remove engine hood (1). Remove right cover (2). Remove plate (3). [*1]
1. 2. 3.
7.
8.
Aftercooler assembly (8): 40 kg
PC600-8
13
SEN01064-02
Installation
q
[*1] Precautions for installing engine hood 1. Secure clearance (FC) of at least 10 mm between the engine hood and oil cooler frame. 2. The engine hood must not interfere with stopper (S). 3. Adjust the positions of hinge (H), bracket (B), catcher (C), and U-bolt (UB).
[*2] MIKALOR clamp a Use new MIKALOR clamps. 1) Set each hose to the original position. (Insertion depth of air hose: 80 mm) 2) Set bridge (BR) under the clamp bolt and adjust its overlap (b) with bridge (BR) and band to at least 5 mm. 3) Tightening of the clamp. 2 Threads of clamp bolt (BC): Lubricating oil (THREEBOND PANDO 18B) a Do not use an impact wrench. q When reusing the hose. Install the clamp to the clamp mark made on the hose. 3 Clamp bolt: Min. 6 Nm {0.6 kgm} q When using a new hose. Tighten until dimension (a) is 5 8 mm.
14
PC600-8
SEN01064-02
Removal and installation of fan motor assembly 1

Removal
k k
4.
Remove undercover (4).
a a 1. 2. 3.
Lower the work equipment to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Disconnect the cable from the negative () terminal of the battery. Install oil stopper plugs to the disconnected tubes and hoses. Before disconnecting each hose, mark it with a tag etc. to indicate its position. Sling engine hood (1) temporarily. Remove pin (2). Fix bolt (B) to hole (A) of bar (3) and set engine hood (1) vertically.
5.
Drain the coolant.

6
Coolant: 58 l
6. 7.
Remove the counterweight. For details, see Removal of counterweight assembly. Remove 3 covers (5).
8.
Disconnect filter bracket (6). a Disconnect the hose clamp (HC).
PC600-8
15
SEN01064-02
9.
Disconnect reservoir tank hoses (7).
15. Disconnect plates (13) and (14).
10. Lift off frame assembly (8).
16. Disconnect 3 fan motor hoses (15) from the bottom of the fan motor. a Before disconnecting each hose, mark it with a tag etc. to indicate its position. a Prepare an oil receiver. a Fit a plug. q Adapter size: #06 --- 2 pieces #04 --- 2 pieces a Remove the clip, too.
11. Disconnect hose (9). 12. Disconnect 2 reservoir tank hoses (10). 13. Disconnect radiator hose (11). [*1]
17. Disconnect connector A16 (16). 18. Remove cover (17). 19. Remove 3 covers (18).
14. Disconnect radiator hose (12).
[*1]
16
PC600-8
SEN01064-02
20. Remove cover (19). 21. Remove front and rear covers (20). 22. Remove cover (19-1) from the bottom of cover (19). 23. Sling fan and fan motor shroud assembly (21) temporarily with (H). 24. Remove 5 mounting bolts (22) from the right and left of fan and fan motor shroud assembly (21) respectively.
25. Lift off fan and fan motor shroud assembly (21).
4
Fan and fan motor shroud assembly: 100 kg
26. Remove lock plate (23).
[*2]
27. Remove nut (24). [*3] a When removing the nut, insert a bar etc. in part (C) to fix the fan assembly. 28. Using puller [1], remove fan assembly (25). [*4] a When removing the fan assembly, do not hit the motor shaft with a hammer etc.
PC600-8
17
SEN01064-02 a
Puller fixing tap (T) (4 M10 1.5 20) made on boss (BS) can be used.
Installation
q
Carry out installation in the reverse order to removal. Radiator hose clamp: 8.3 9.3 Nm {0.85 0.95 kgm}
[*1]
[*2] When setting the bolt holes of the lock plate, do not rotate the lock plate in the loosening direction. (If bolt hole does not match, turn the lock plate clockwise to match the hole.) [*3] 29. Disconnect connector V16 (26). 30. Remove cover (27). 31. Disconnect tubes (28), (29), and (30). a Disconnect the clamps, too. 32. Remove fan motor assembly (31). a
3
Fan mounting nut: 833 882 Nm {85 90 kgm}
After installing the nut, measure dimension (d). (d): 1.2 3.0 mm
[*4]
q q
Degrease both hole and shaft. Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again.
5
Coolant: 58 l
18
PC600-8
SEN01064-02
Removal and installation of fuel tank assembly 1

Removal
k k
4.
Disconnect fuel supply hose (3) and return hoses (4).
Lower the work equipment to the ground and stop the engine. Disconnect the cable from the negative () terminal of the battery. Open the drain valve to drain the fuel.
6
1.
Fuel tank: 880 l (When full)
2.
Remove handrail (1) and cover assembly (2).

4
Cover assembly: 80 kg
3.
Disconnect wiring connector P06 (6) from the fuel tank.
5. 6.
Remove fuel tank mounting bolt. Lift off fuel tank assembly (5).
4
[*1]
Fuel tank assembly: 500 kg
Installation
q

3
[*1]
Fuel tank mounting bolt: 319 608 Nm {32.5 62 kgm}
PC600-8
19
SEN01064-02
20
SEN01065-02
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8 PC600LC-8
Machine model
PC600-8 PC600LC-8
Serial number

Power train
Removal and installation of PTO assembly .................................................................................................... 2 Disassembly and assembly of PTO assembly ................................................................................................ 4 Removal and installation of swing motor and swing machinery assembly ..................................................... 7 Disassembly and assembly of swing machinery assembly ............................................................................ 8 Removal and installation of swing circle assembly ....................................................................................... 15 Disassembly and assembly of final drive assembly...................................................................................... 16
PC600-8
SEN01065-02
Removal and installation of PTO assembly 1

Removal
k k
3.
Remove partition cover (1) between the engine and pump.
a a
Lower the work equipment to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Disconnect the cable from the negative () terminal of the battery. Install oil stopper plugs to the disconnected tubes and hoses. Before disconnecting each hose, mark it with a tag etc. to indicate its position. Remove the counterweight assembly. For details, see "Removal and installation of counterweight assembly". Lift off each hydraulic pump assembly. For details, see "Removal and installation of hydraulic pump assembly".
4 4 4
1.
4.
Drain the PTO lubricating oil.

6
Lubricating oil: 6 l
2.
5. 6.
Disconnect clamp (2). Disconnect lubrication hose (3). a Disconnect lower lubrication hose, too.
Pump No. 1 assembly (No. 1): 170 kg Pump No. 2 assembly (No. 2): 160 kg Cooling fan pump (Control, PTO lubrication and fan pump) assembly (G.P.): 90 kg
7.
Using 2 M30 eyebolts, lift off PTO assembly (6). [*1]

4
PTO assembly: 210 kg
PC600-8
SEN01065-02
8. Remove shaft (7). [*2] Note: Do not remove coupling unit (8) from hub assembly (9). When coupling (8) needs to be replaced, replace it together with hub assembly (9).
Installation
q
[*1]
PTO mounting bolt: 98 123 Nm {10 12.5 kgm}
[*2]
Hub assembly mounting bolt: 98 123 Nm {10 12.5 kgm}
Refilling with oil (PTO case) Tighten the drain plug and add oil through the oil filler to the specified level.
5
PTO case: 7.2 l (EO30-DH)
FWH: Flywheel housing
PC600-8
SEN01065-02
Disassembly and assembly of PTO assembly

Disassembly
1. Remove all lubrication tubes (20).
4.
Bearing 1) Using puller [1], remove bearings (7) from gears (2) and (3).
2) 3) 2. Case Remove the mounting bolts and then remove case (1) with a forcing screw. a Check the quantity and thickness of the inserted shims. Gear assemblies Remove gear assemblies (2), (3), and (4). a Using a puller, remove each gear assembly. a When removing gears (2) and (3), remove nipples (5) and (6) first and then use the puller.
Remove snap ring (8). Using puller [1], remove bearings (9) and (10) from gear (4).
3.
4) 5)
Remove snap ring (11) from case (1). Remove outer race (12).
PC600-8
SEN01065-02
5.
Oil seal Remove oil seal (13) from case (14).
2.
Bearing 1) Press fit outer race (12) to case (1). 2) Install snap ring (11). 2 Pin: Grease (G2-LI)
Assembly
a Clean all the parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. Oil seal Press fit oil seal (13) to case (14). 2 Press fitting surface of oil seal: Adhesive (LG-6) a Do not stick adhesive to the oil seal lip and shaft. a Add grease (G2-LI) to about 40 60%. 3) 4) Press fit bearings (9) and (10) to gear (4). Install snap ring (8).
1.
5)
Press fit bearings (7) to gears (2) and (3).
PC600-8
SEN01065-02
3.
Gears 1) Install nipples (5) and (6) to case (14). 3 Nipple: 2.9 5.9 Nm {0.3 0.6 kgm} 2) Install gears (4), (3), and (2). a Check that the gears rotate smoothly and then apply red lead and check the tooth contact. 2 Rolling surface of bearing: Grease (G2-LI) Case Install case (1). 2 Mating face of case: Gasket sealant (LG-11) 3 Mounting bolt: 98 123 Nm {10 12.5 kgm}
4.
PC600-8
SEN01065-02
Removal and installation of swing motor and swing machinery assembly 1

Removal
k k
Lower the work equipment to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Remove step (1). Disconnect 4 hoses (2) between the control valve and swing motor. a Install tags and oil stopper plugs to all the disconnected hoses. Disconnect 2 suction hoses (3). [*1] Disconnect 2 swing holding brake hoses (4). Disconnect 3 drain hoses (5). Remove hose bracket (6). Disconnect drain plug assembly (8) from the chassis at the rear of swing motor and swing machinery assembly (7). Remove mounting bolts (9) and lift off swing motor and swing machinery assembly (7). [*1]
4 q q 3
1. 2.
Installation
q
3. 4. 5. 6. 7.
Swing motor and swing machinery assembly mounting bolt: 824 1,030 Nm {84 105 kg}
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Bleeding air Bleed air from the swing motor. For details, see Testing and adjusting, "Bleeding air from each part".
8.
Swing motor and swing machinery assembly: 440 kg (1 piece)
PC600-8
SEN01065-02
Disassembly and assembly of swing machinery assembly

Special tools
Necessity Symbol Part number Part name
3)
Remove No. 1 carrier assembly (4).
1 796T-626-1110 Push tool 2 790-331-1110 Wrench
t 1 t 1
Disassembly
1. Draining oil Loosen drain plug and drain oil from swing machinery.
6
Sketch
Qty
N/R
4.
Swing machinery case: 12.8 13.1 l
2.
Cover Remove mounting bolts, then lift off cover (1).
Disassembly of No. 1 carrier assembly 1) Push pin (5) in shaft (6), and knock out shaft (6) from carrier (7). a After removing the shaft, remove pin (5). 2) Remove thrust washer (8), gear (9), bearing (10), and thrust washer (11).
5 8
10
9
3. No. 1 carrier assembly. 1) Remove thrust washer (2). 2) Remove No. 1 sun gear (3).
11
6
CEP00208
5.
Ring gear Lift off ring gear (12).
PC600-8
SEN01065-02
6.
No. 1 sun gear 1) Remove thrust washer (13). 2) Remove button (36) and spacer (14). 3) Remove No. 1 sun gear (15).
8.
Disassembly of No. 2 carrier assembly 1) Push in pin (18), and knock out shaft (19) from carrier (17). a After removing the shaft, remove pin (18). 2) Remove thrust washer (20), gear (21), bearing (22), and thrust washer (23).
19 20 21 23
4) Remove thrust washer (16).
22
17
18
9.
CEP00213
Pinion shaft assembly 1) Remove bolt (24), then remove holder (25). 2) Remove gear (26).
24 26 25
7.
No. 2 carrier assembly Lift off No. 2 carrier assembly (17).
CEP00214
3)
Turn over case and pinion assembly, then remove mounting bolts (28) of cover assembly (27).
27
28
CEP00215
PC600-8
SEN01065-02
4)
Turn over case and pinion assembly (29), and set on press stand, then using push tool [1], remove pinion shaft assembly (30) with press. a Set a wooden block under the press, and be careful not to damage the pinion shaft assembly when removing it.
Assembly
a Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Bearing Using push tool [3], press fit bearing (31) to case (35).
1.
10. Disassembly of pinion shaft assembly 1) Using push tool [2], remove cover assembly (27) and bearing (31) from shaft (32). 2) Remove oil seal (33) from cover (27).
2.
Cover assembly 1) Using push tool [4], press fit oil seal (33) to cover (27). 2 Outside circumference of oil seal: Gasket sealant (LG-6) a Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when press fitting.
11. Bearing Using push tool, remove bearing (34) from case (35).
35
34
CEP00220
10
PC600-8
SEN01065-02
2)
Fit cover assembly (27) to case (35), and tighten mounting bolts (28). a Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when press fitting. a Take care that gasket sealant will not be projected into the oil pass. 2 Cover mounting surface: Gasket sealant (LG-6) 3 Mounting bolt: 66.2 7.4 Nm {6.75 0.75 kgm} 2 Oil seal lip: Supply grease (G2-LI) by about 40 60%.
2)
Bearing Using tool F1, press fit bearing (34). a Press the bearing inner race and outer race at the same time when press fitting. Do not press only the inner race when press fitting. a After press fitting the bearing, check that the case rotates smoothly.
3)
3.
Case assembly 1) Set case assembly (35) to shaft (32), then using push tool [5], press fit bearing inner race portion. a When setting the case assembly to the shaft, be extremely careful not to damage the oil seal.
Gear, holder Assemble gear (26), then fit holder (25) and tighten bolt (24). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 179 196 Nm {16 20 kgm}
24 26 25
CEP00214
PC600-8
11
SEN01065-02
4.
Assembly of No. 2 carrier assembly a There are the remains of caulking after fitting the pin at the end of side hole (h) of the carrier. Remove the swelled part inside the hole in advance. 1) Install bearing (22), upper and lower thrust washers (23) and (20) to gear (21), then install gear assembly to carrier (17).
5.
No. 2 carrier assembly 1) Assemble thrust washer (16).
22 20 21 23
17
2)
h
2)
CEP00226
Raise No. 2 carrier assembly (17) and install. a Align the position so that the tip of the gear shaft enters at 4 places, then install.
3)
Align with position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (19). a When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. Insert pin (18). a After inserting the pin, caulk the pin portion of the carrier. a After assembling the carrier assembly, check that gear (21) rotates smoothly. 6. No. 2 sun gear 1) Install No. 2 sun gear (15) to No. 2 carrier. 2) Install spacer (14) and button (36). 3) Install thrust washer (13).
21
19
18
CEP00227
12
PC600-8
SEN01065-02
7.
Ring gear Raise ring gear (12) and install.
2)
3) a
Align position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (6). a When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. Insert pin (5). a After inserting the pin, caulk the pin portion of the carrier. After assembling the carrier assembly, check that gear (9) rotates smoothly.
5
a Apply the gasket sealant around the hole (a) for checking oil, but do not apply around the other holes. 2 Fitting faces of ring gear and case: Gasket sealant (LG-6)
6
CEP00229
9.
No. 1 carrier assembly Install No. 1 carrier assembly (4).
8.
Assembly of No. 1 carrier assembly a There are the remains of the caulking when the pin is inserted at the end face of hole (h) at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. 1) Install bearing (10), upper and lower thrust washers (8) and (11) to gear (9), then install gear assembly to carrier (7).
h 8
10
11
CEP00228
PC600-8
13
SEN01065-02
10. No. 1 sun gear 1) Assemble No. 1 sun gear (3) to carrier assembly. 2) Install thrust washer (2).
11. Cover Using tool F2, install cover (1). a When coating gasket sealant, follow the precautions in item 7. 2 Cover mounting surface: Gasket sealant (LG-6) 3 Mounting bolt: First time: 98 Nm {10 kgm} Second time: Tighten by 80 90. (Make marks on each bolt and the cover with paint, then tighten the bolt by 80 90.)
12. Refilling with oil Tighten drain plug and add engine oil through oil filler.
5
Swing machinery case: 12.8 l (low level) 13.1 l (high level)
14
PC600-8
SEN01065-02
Removal and installation of swing circle assembly 1

Removal
1. Remove the revolving frame assembly. For details, see "Removal of revolving frame assembly". Remove grease tube from swing circle.
Installation
q
[*1]
2 3
Mounting bolt: Thread tightener (LT-2) Mounting bolt: 1,180 1,470 Nm {120 150 kgm}
2. 3.
[*2] Remove mounting bolts (1). [*1] a a a
Swing circle mounting surface Gasket sealant (LG-6) Amount of grease (G2-LI) in oil bath: Approx. 31 l Coat inside teeth with grease (G2-LI). Install the inner ring soft zone position (Smark), directing it to the right side of the machine.
4.
Using eyebolts and nut [1], lift off swing circle assembly (2). [*2]
4
Swing circle assembly: 1,150 kg
5.
Remove seal assembly (3).
PC600-8
15
SEN01065-02
Disassembly and assembly of final drive assembly

Special tools
Necessity Symbol Part number 790-501-5000 1 790-501-5200 790-901-4110 Part name Unit repair stand Unit repair stand Bracket
Disassembly
1.
Draining oil Set drain plug (1) at bottom and remove it to drain oil from final drive case.
6
q 1 q 1 q 1 q 1 q 1 t 1 t 2 t 2 t 2 t 2 t 2 t 1 t 1 t 1 t 1 t 1 t 1 t 2 t 2 t 2 t 2 t 2 q 1 t 1 t 1 t 1 Q Q Q
2 796T-627-1510 Plate 3 796T-627-1520 Plate 970-431-1031 791-730-1130 790-101-2360 01643-32060 01580-12016 4 796-627-1420 790-201-2790 790-201-2690 J 790-101-2102 790-101-1102 5 796-627-1020 790-101-2510 791-830-1320 790-101-2570 01643-31645 6 01580-11613 796-627-1410 790-101-2102 790-101-1102 7 790-331-1110 Block Bolt Plate Washer Nut Adapter Spacer Plate Puller (294 N {30 ton}) Pump Installer Block Rod Washer Washer Nut Adapter Puller Pump Wrench
Sketch
Final drive case: 10.5 l (Each side)
Qty
N/R
2.
Cover 1) Using tools J1 and J2, support final drive assembly. a Install by using the sprocket mounting bolt holes on the hub.
796T-627-1330 Push tool
2)
Using eyebolts [1], lift off cover (2).
16
PC600-8
SEN01065-02
3.
Spacer Remove spacer (3). No. 1 sun gear shaft Remove No. 1 sun gear shaft (4).
3]
Remove 2 thrust washers (9), planetary gear (10), and bearing (11).
4.
6.
No. 1 ring gear Using eyebolts [2], lift off No. 1 ring gear (12).
5.
No. 1 carrier assembly 1) Lift off No. 1 carrier assembly (5).
7.
No. 2 ring gear Using eyebolt [3], lift off No. 2 ring gear (13).
2)
Disassemble No. 1 carrier assembly as follows. 1] Push pin (6) in shaft (7). 2] Remove shaft (7) from carrier (8).
PC600-8
17
SEN01065-02
8.
Thrust washer Remove thrust washer (14). No. 2 sun gear Remove No. 2 sun gear (15).
2)
9.
Disassemble No. 2 carrier assembly as follows. 1] Push pin (18) in shaft. 2] Remove shaft (19) from carrier (20).
3] 10. Thrust washer Remove thrust washer (16).
Remove 2 thrust washers (21), planetary gear (22), and bearing (23).
11. No. 2 carrier assembly 1) Lift off No. 2 carrier assembly (17).
12. Retainer 1) Sling the final drive assembly and remove it temporarily. 2) Remove tool J2 and install tool J3, then install final drive assembly to tool J3. a Install tool J3 to the surface of the travel motor case.
18
PC600-8
SEN01065-02
3)
Remove 22 mounting bolts (24) and 14 mounting bolts (25), then remove retainer (26).
3)
Disassemble hub assembly as follows. 1] Remove floating seal cover assembly (30) from hub (31).
4)
Remove spacer (27).
2]
Remove bearings (32) and (33) from hub.
13. Hub assembly 1) Using tool J4, remove hub assembly (28) from travel motor assembly (29). 2) Using eyebolts [4], lift off hub assembly (28).
14. Floating seal 1) Remove floating seal (34) from cover (35).
PC600-8
19
SEN01065-02
2)
Remove floating seal (36) from travel motor (37).
3.
Assembly
a Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Travel motor assembly Install travel motor assembly to tools J1 and J3. Floating seal 1) Using tool J5, install floating seal (36) to travel motor (37). a Remove all oil and grease from the O-ring and O-ring contact surface, and dry the parts before installing the floating seal. a After installing the floating seal, check that the angle of the floating seal is within 1 mm.
Hub assembly 1) Assemble the hub assembly as follows. 1] Using push tool [5], press fit bearing (32) to hub (31). a Similarly, press fit bearing (33). a Press fit the bearing until it fits to the hub.
1.
2.
2]
Install floating seal cover assembly (30) to hub (31). 2 Cover fitting face: Gasket sealant (LG-6) 3 Mounting bolt: 98 123 Nm {10 12.5 kgm}
2)
Using tool J5, install floating seal (34) to cover (35). a Observe the precautions for installation in 1) above.
20
PC600-8
SEN01065-02
2) 3)
4)
Using eyebolts, sling and install hub assembly (28) to travel motor assembly. Using tool J6, press fit the inner race of bearing (32). a Before press fitting, rotate the hub assembly by two three turns on the travel motor. Under the condition of 3) above, measure distance (a) between the inner race of the bearing and retainer fitting face with depth gauge or caliper [6]. a Press fitting force: 22 25 kN {2.2 2.6 ton} a Calculate the thickness of spacer (27) by the following formula. Thickness of spacer = Distance (a) (0.10 to 0.15) a Distance (a) (Standard): 3.5 mm a Thickness of spacer (Standard): (t) = 3.4 mm a Thicknesses of spacer: t = 3.25, t = 3.3, t = 3.35, t = 3.4, t = 3.45, t = 3.5, t = 3.55
2)
Install retainer (26) and tighten 22 mounting bolts (24) and 14 mounting bolts (25). 2 Mounting bolts (24), (25): Thread tightener (LT-2) 3 Mounting bolts (24), (25): 853 931 Nm {87 95 kgm}
5.
Measurement of tangential force Using push-pull scale [7], measure tangential force of hub in its rotating direction on motor case. a Measure the tangential force at the sprocket mounting hole on the hub. a Tangential force: 620 N {63 kg} max. a Measure the maximum tangential force when the hub starts rotating.
4.
Retainer 1) Install spacer (27) selected by step 2) 4) above.
PC600-8
21
SEN01065-02
6.
No. 2 carrier assembly 1) Sling the final drive assembly and move it temporarily. 2) Remove tool J3 from tool J1 and install it to tool J2, then install final drive assembly to tool J2. a Install by using the sprocket mounting bolt holes on the hub.
3)
Assemble No. 2 carrier assembly as follows. a There is caulking left at the pin fitting pa r t o f t h e c a r r i e r. R e m o v e t h e swelled part inside the hole in advance. 1] Install bearing (23) and 2 thrust washers (21) to planetary gear (22), then install them to carrier (20). 2] Tap shaft (19) to install it to carrier (20). a When installing shaft (19), rotate planetary gear (22), and take care not to damage the thrust washers. 3] Insert pin (18).
When inserting the pin, assemble so that the 3 notched parts (portion a) on the circumference on the pin do not overlap the thin metal part (portion b) of the carrier. (Basically, the inside of the chassis (direction A ) is the thin metal side). However, with the actual part, the thin metal may be on the opposite side, so check the part and make sure when assembling that the protruding parts of the pin is not at the same place as the thin metal. a After inserting the pin, caulk the pin portion of the carrier. After assembling the carrier assembly, check that planetary gear (22) rotates smoothly.
22
PC600-8
SEN01065-02
4)
Sling and install No. 2 carrier assembly (17).
10. No. 2 ring gear 1) Install O-ring to hub. 2) Using eyebolts [3], sling and install No. 2 ring gear (13). a Do not apply gasket sealant to the fitting faces of the hub and No. 2 ring gear. a Degrease the fitting faces of the hub and No. 2 ring gear.
7.
Thrust washer Install thrust washer (16).
Install the ring gear with the identification cut (b) up.
8.
No. 2 sun gear Install No. 2 sun gear (15). Thrust washer Install thrust washer (14).
9.
11. No. 1 ring gear Using eyebolts [2], sling and install No. 1 ring gear (12). 2 Fitting faces of No. 1 ring gear and No. 2 ring gear: Gasket sealant (LG-6)
PC600-8
23
SEN01065-02 a
12. No. 1 carrier assembly 1) Assemble No. 1 carrier assembly as follows. a Caulking remains at the pin fitting part of the carrier. Remove the swelled part inside the hole in advance. 1] Install bearing (11) and 2 thrust washers (9) to planetary gear (10), then install them to carrier (8). 2] Tap shaft (7) to install it to carrier (8). a When installing shaft (7), rotate planetary gear (10), and take care not to damage the thrust washers.
After assembling the carrier assembly, check that planetary gear (10) rotates smoothly.
3]
Insert pin (6). a When inserting the pin, assemble so that the 3 notched parts (portion c) on the circumference on the pin do not overlap the thin metal part (portion d) of the carrier. (Basically, the inside of the chassis (direction B ) is the thin metal side). However, with the actual part, the thin metal may be on the opposite side, so check the part and make sure when assembling that the protruding parts of the pin is not at the same place as the thin metal. a After inserting the pin, caulk the pin portion of the carrier.
2)
Sling and install No. 1 carrier assembly (5).
24
PC600-8
SEN01065-02
13. No. 1 sun gear shaft Install No. 1 sun gear shaft (4). 14. Spacer Install spacer (3).
Refilling with oil 1) Tighten drain plug (1) and remove oil filler plug (38). 3 Drain plug: 59 78 Nm {6 8 kgm} 2) Set cover with "TOP" position up, and supply oil up to bottom of oil filler. Final drive case (Each side): 10.5 l (EO30-DH) Tighten oil filler plug (38). 3 Oil filler plug: 59 78 Nm {6 8 kgm} a After installing the final drive assembly to the machine, check the oil level again by the above method.
5
3)
15. Cover 1) Using eyebolts [1], sling and install cover (2). 2 Fitting face of cover: Gasket sealant (LG-6)
2)
Tighten the cover mounting bolts in the following order. 3 Cover mounting bolt: 1st time: 98 Nm {10 kgm} 2nd time: Tighten by 150. (Make marks on each bolt and the cover with paint, then tighten the bolt by 144 155 with tool J7.)
PC600-8
25
SEN01065-02
26
SEN01066-03
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8 PC600LC-8
Machine model
PC600-8 PC600LC-8
Serial number

Removal and installation of track shoe assembly ........................................................................................... 2 Disassembly and assembly of 1 link in field.................................................................................................... 4 Removal and installation of idler, recoil spring assembly................................................................................ 8 Disassembly and assembly of idler assembly ................................................................................................ 9 Disassembly and assembly of recoil spring assembly.................................................................................. 12 Removal and installation of track roller assembly ......................................................................................... 14 Disassembly and assembly of track roller assembly .................................................................................... 15 Removal and installation of carrier roller assembly ...................................................................................... 18 Disassembly and assembly of carrier roller assembly .................................................................................. 19 Removal and installation of revolving frame assembly ................................................................................. 22 Removal and installation of counterweight assembly ................................................................................... 24 Removal and installation of counterweight remover assembly ..................................................................... 25
PC600-8
SEN01066-03
Removal and installation of track shoe assembly 1

Special tools
Necessity Symbol Part number 796-632-1200 790-101-4300 M 3 790-101-4200 790-101-1102 4 790-331-1100 Part name Sketch Qty N/R
3.
Using tool M, pull out master pin.
Remover, installer t 1 Cylinder (1,471 kN {150 ton}) Puller (294 kN {30 ton}) Pump Wrench t 1 t 1 t 1 t 1
4.
Removal
1. Positioning master pin a Move the master pin so that it is midway between the idler and the carrier roller. The track shoe is opened to the rear, so be sure that there is enough space. [*1] Loosen track shoe tension. k Never loosen lubricator (1) more than one turn. a If the track tension is not relieved even when the lubricator is loosened, move the machine backwards and forwards. 5.
Fit block or hydraulic jack [1] (10 ton) under shoe at idler end, then remove guide pin [2]. [*2]
2.
Raise tip of track shoe with crane, and move machine slowly to rear to open track shoe assembly (3).
PC600-8
SEN01066-03
Installation
q
[*1] a Adjust the track shoe tension. For details, see Testing and adjusting, Adjusting track shoe tension. 3 Lubricator: 73.5 14.7 Nm {7.5 1.5 kgm} [*2] a Assemble spacer (4) and washer (5) to the link, connect to bottom link, then install guide pin.
PC600-8
SEN01066-03
Necessity
Symbol
Part number 791-685-9560
Part name Bolt Adapter Bolt Extension Adapter Guide Pump Cylinder (*1) Frame Frame Rod Rod Nut Bolt Adapter Bolt Extension Guide Adapter Adapter Pump Cylinder (*1) Guide Frame Frame Rod Rod Nut Bolt Adapter Guide Adapter Bolt Guide Pump Cylinder (*1) Pump Puller (*2) Pump Puller (*2) Cylinder (*1)
Special tools
Necessity Symbol Sketch Qty N/R Part number 791-680-9580 1 791-680-9590 01010-52760 01010-51440 2 790-101-1102 790-101-4300 791-685-9510 791-685-9520 791-685-9530 791-685-9550 3 791-685-9560 791-680-9570 01010-51030 04530-12030 790-101-1102 790-101-4300 4 791-685-9540 791-685-9550 791-685-9510 791-685-9520 N 791-685-9530 791-685-9550 791-685-9560 791-126-0150 5 791-680-5520 791-126-0140 791-680-9570 01010-51030 04530-12030 791-685-9620 791-101-1102 790-101-4300 6 7 790-101-1102 790-101-4200 791-680-5542 791-632-1110 791-685-9510 791-685-9520 9 791-685-9530 791-685-9540 791-685-9550 Part name Adapter Guide Bolt Bolt Pump Cylinder (*1) Frame Frame Rod Nut Bolt Adapter Bolt Eyebolt Pump Cylinder (*1) Rod Nut Frame Frame Rod Nut Bolt Adapter Guide Pusher Adapter Bolt Eyebolt Extension Pump Cylinder (*1) Pump Puller (*2) Adapter Adapter Guide Frame Frame Rod Rod Nut
t 4 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 3 t 4 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 3 t 4 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
791-126-0150 01010-51030 9 791-685-9620 791-680-5542 791-680-5560 790-101-1102 790-101-4300 791-685-9510 791-685-9520 791-685-9530 791-685-9540 791-685-9550 791-685-9560 10 791-126-0150 01010-51030 791-685-9620 791-680-5560 791-632-1110 791-680-9630 N 790-101-1102 790-101-4300 11 790-680-1520 791-685-9510 791-685-9520 791-685-9530 791-685-9540 791-685-9550 791-685-9560 12 791-126-0150 791-680-5560 791-680-9570 01010-51030 791-680-1520 790-101-1102 790-101-4300 13 790-101-1102 790-101-4200 791-680-9501 14 790-101-1102 790-101-4200 790-101-4300
t 1 t 1 t 2 t 2 t 1 t 1 t 1 t 1 t 1 t 3 t 4 t 1 t 1 t 1 t 1 t 1 t 1 t 3 t 1 t 1 t 1 t 3 t 4 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 3
Remover, installer t 1
8 791-680-5580
(*1) : 1,471 kN{150 ton} (*2) : 294 kN{30 ton}
PC600-8
Sketch
Qty
N/R
Disassembly and assembly of 1 link in field 1
SEN01066-03
Disassembly
1. Using two bolts (2), install tool N1 (adapter, guide, bolt) to link (1). a It is also possible to use 2 track bolts for bolt (2).
4.
Set tool N5 (adapter, guide, pusher) in position, then apply hydraulic pressure and remove pin (3). When the cylinder reaches the end of its stroke, insert extension N5 between the adapter and guide, and repeat the operation.
2.
Assemble tool N2 (pump, cylinder 1471 kN {150 t}) and tool N3 (frame, rod, adapter, bolt x 1, eyebolt), then raise chassis and set on track.
5.
Set tool N6 (294 kN {30 ton} puller) and spacer [1] to center of roller tread of link to be disassembled, then apply hydraulic pressure to puller and open link 5 6 mm.
3.
Insert rod of tool N4 from cylinder end, and install with 2 nuts. a Pass the rod through the hole in link (1) to install.
PC600-8
SEN01066-03
Assembly
1. Assemble the link sub-assembly. 1) Set tool N7 to end face of link, then press fit bushing (1). 2) Set tool N7 to end face of link (pin end), and press fit pin (2).
4.
Set tools N9 and N10 in same way as for operation to remove pin, then use tool N9 (adapter, extension, guide, adapter, bolt) for press fitting pin, and tool N10 (extension, guide, adapter, bolt) for press fitting bushing, and press fit in turn.
2.
Set link sub-assembly (3) on link to be connected.
5.
Use tool N13 (294 kN {30 t} puller) in same way as when disassembling, and push open link (5) at bushing end.
3.
Set link (4) on opposite side, and support with tool N8 (guide).
6.
Set link (6) at pin end to link (5) at bushing end, connect with tool N11 (guide), then remove tool N13 (puller).
PC600-8
SEN01066-03
7.
Set tool N9 at pin (7) end, then use tool N12 (adapter, bolt, and guide) to press fit pin (7). 2 Pin press-fitting hole in link: Gasket sealant (LG-11)
PC600-8
SEN01066-03
Removal and installation of idler, recoil spring assembly 1

Removal
1. Remove track shoe assembly. For details, see Removal and installation of track shoe assembly. a Remove lubricator (1).
3.
Disconnect recoil spring assembly (4) from idler assembly (3). [*1]
4 4
Idler assembly: 350 kg Recoil spring assembly: 460 kg
Installation
q
2.
Sling idler and recoil spring assembly (2), and pull out to the front to remove.
4
[*1]
Idler and recoil spring assembly: Approx. 800 kg
Mounting bolt between idler and recoil spring: 824 1,030 Nm {84 105 kgm}
PC600-8
SEN01066-03
Disassembly and assembly of idler assembly

Special tools
Necessity Symbol Part number 1 791-575-1520 L 2 791-601-1000 790-701-3600
4
4.
1
5.
Sketch
Turn over idler assembly, remove pin (6), then remove support (7). Remove shaft (8) from idler.
Qty
Part name Installer Oil pump assembly Adapter
t 1 q 1 q 1
Idler assembly: 350 kg
Disassembly
1. Remove plug (1) and drain oil.
6
N/R
6.
Remove 2 floating seals (4) from idler (7).
Idler: 400 500 cc
7. 2. Set idler assembly (2) on block [1], remove pin (3), then remove support (5). Remove floating seal (4).
Remove bushings (9) and (10) from idler.
3.
PC600-8
SEN01066-03
8.
Remove floating seals (4) from supports (5) and (7).
Assembly
a 1. Clean all parts, and check for dirt or damage. Using tool L1, assemble floating seals (4) to supports (6) and (3).
When installing the floating seal, clean, degrease and completely dry the contact faces of the O-ring and floating seal (hatched parts in the figure below). Take care that dirt does not stick to the contact face of the floating seal. After installing the floating seal, check that its angle is within 1 mm and its projection (a) is 9 11 mm.
2.
Using tool [1], press fit bushings (10) and (9) to idler.
10
PC600-8
SEN01066-03
3.
Using tool L1, assemble floating seal (4) to idler. a For precautions for installing the floating seal, see 1.
8.
Turn over idler, and assemble support (5) to shaft. a When installing the support to the shaft, align their pin hole with each other. Install pin (3) to secure support (5).
9.
4.
Turn over idler and using tool L1, assemble floating seal (4). a For precautions for installing the floating seal, see 1.
10. Using tool L2, supply oil by specified quantity, then tighten plug (1).
5 3
Idler: 400 500 cc (EO30-DH) Plug: 16.66 37.86 Nm {1.7 3.8 kgm}
5. 6.
Install shaft (8) to idler. Assemble support (7) to shaft. a When installing the support to the shaft, align their pin hole with each other. Install pin (6) to secure support (7).
7.
PC600-8
11
SEN01066-03
Disassembly and assembly of recoil spring assembly

Special tools
Necessity Symbol Part number 791-685-8502 791-635-3160 M 1 790-101-1600 790-101-1102 2 790-201-1500 Part name Compressor Extension Cylinder (686 N {70 ton}) Pump Push tool
t 1 t 1 t 1 t 1 t 1
Disassembly
8 7 5 3 4 6 9 11
CEP00054
Sketch
Qty
N/R
2 10
14 12 13 1
1. Remove piston assembly (2) from recoil spring assembly. Disassembly of recoil spring assembly 1) Set tool M1 to recoil spring assembly (1). k The recoil spring is under large installed load, so be sure to set the tool properly. Failure to do this is dangerous. a Installed load of spring: 291.8 kN {29,770 kg} 2)
2.
3)
Apply hydraulic pressure slowly to compress spring, then remove lock plate (3), and remove nut (4). a Compress the spring to a point where the nut becomes loose. a Free length of spring: Approx. 859 mm Remove yoke (6), cylinder (7) and dust seal (8) from spring (5).
3.
M1
Disassembly of piston assembly 1) Remove lock plate (10) from piston (9), then remove valve (11). 2) Remove snap ring (12), then remove Upacking (13) and ring (14).
CEP00055
12
PC600-8
SEN01066-03
Assembly
1. Assembly of piston assembly 1) Assemble ring (14) and U-packing (13) to piston (9), and secure with snap ring (12). 2) Tighten valve (11) temporarily, and secure with lock plate (10). Assembly of recoil spring assembly 1) Using tool M2, assemble dust seal (8) to cylinder (7).
3.
2.
Assemble piston assembly (2) to recoil spring assembly (1). 2 Piston sliding portion and wear ring: Grease (G2-LI) a Assemble the cylinder assembly so that the mounting position of the valve is 90 to the side. a Fill the inside of the cylinder with approx. 200 cc of grease (G2-LI), then bleed the air and check that grease comes out of the grease hole.
M2 8
CEP00062
2)
3)
Assemble cylinder (7) and yoke (6) to spring (5), then set to tool M1. 2 Sliding portion of cylinder: Grease (G2-LI) Apply hydraulic pressure slowly to compress spring, and tighten nut (4) so that installed length of spring is dimension (a), then secure with lock plate (3). a Installed length (a) of spring: 715 mm
4)
Remove recoil spring assembly (1) from tool M1.
PC600-8
13
SEN01066-03
Removal and installation of track roller assembly 1

Removal
1. Lower work equipment to ground, then loosen lubricator (1), and relieve track tension. [*1] k The adjustment cylinder is under extremely high pressure, so never loosen the lubricator more than one turn. If the grease does not come out easily, move the machine backwards and forwards.
3.
Lower chassis completely, remove mounting bolts of track roller assembly (3), then jack up machine with work equipment, and remove track roller assembly (3) to outside of machine. [*3]
4
Track roller assembly: Approx. 110 kg
Installation
q
2.
Remove mounting bolts of track roller guard (2), then swing work equipment 90, jack up machine with work equipment, and remove track roller guard (2) towards outside of machine. [*2]
4
[*1] a Adjust the track tension. For details, see Testing and adjusting, Testing and adjusting track shoe tension. [*2]
2 3
Track roller guard: 50 kg
Roller guard mounting bolt: Thread tightener (LT-2) Roller guard mounting bolt: 1,180 1,470 Nm {120 150 kgm}
[*3]
2 3
Track roller assembly mounting bolt: Thread tightener (LT-2) Track roller assembly mounting bolt: 980 1,176 Nm {100 126 kgm}
14
PC600-8
SEN01066-03
Disassembly and assembly of track roller assembly

Special tools
4
t 1 q 1 q 1
Track roller assembly: 110 kg
Disassembly
7 8 5 6 10 4 9 3 1 2 11
CEP00084
1. 2.
Remove pin (1), then remove collar (2). Remove floating seals (3) from collar (2) and roller (4).
Sketch
Qty
N/R
3.
Pull out roller (4) from shaft (5). a It is filled with 540 660 cc. of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty. Remove floating seals (6) on opposite side from roller (4) and collar (8).
4.
PC600-8
15
SEN01066-03
5.
Remove pin (7), then remove collar (8) from shaft (5). Remove bushings (9) and (10) from roller (4).
Assembly
1. Using push tool [1], press fit bushings (9) and (10) to roller (4). Assemble collar (8) to shaft (5), and install pin (7). Using tool L3, install floating seals (6) to shaft (5). a When installing the floating seal, clean, degrease and completely dry the contact faces of O-ring (6c) and floating seal (6a) (hatched parts in the figure below). Take care that dirt does not stick to the contact face of the floating seal. a After installing the floating seal, check that its angle is within 1 mm and its projection (a) is 5 7 mm.
6.
2.
3.
4.
Using tool L3, install floating seals (6) and (3) to roller (4). a For precautions for installing the floating seals (6b), (6d), (3b), and (3d), see 3 above.
16
PC600-8
SEN01066-03
5.
Assemble shaft (5) to roller (4).
9.
Using tool L4, apply standard pressure to roller oil filler port, and check for leakage of air from seal. a Standard pressure: 0.1 MPa {1 kg/cm2} a Method of checking The standard pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down.
L4
6. 7.
Turn over roller (4) and shaft (5) assembly. Using tool L3, install floating seals (3) to collar (2). a For precautions for installing the floating seals (3a) and (3c), see 3 above.
CEP00100
10. Using tool L4, fill track roller assembly with oil, then tighten plug (11).
5 3
Track roller oil: 540 660 cc (EO30-DH) Plug: 16.66 37.86 Nm {1.7 3.8 kgm}
L4
8.
Assemble collar (2) to shaft (5), and install pin (1).
To oil pump 2 1 To vacuum tank

CEP00201
11
5
CEP00099
CEP00202
PC600-8
17
SEN01066-03
Removal and installation of carrier roller assembly

Removal
1.
Installation
Lower work equipment to ground, then loosen lubricator (1), and relieve track tension. [*1] k The adjustment cylinder is under extremely high pressure, so never loosen the lubricator more than one turn. If the grease does not come out, move the machine backwards and forwards.
[*1] a Adjust the track tension. For details, see Testing and adjusting, Testing and adjusting track shoe tension. [*2]
3
Carrier roller assembly mounting bolt: 490 607 Nm {50 62 kgm}
2.
Using hydraulic jacks, push up track to a position where carrier roller assembly can be removed, then remove carrier roller assembly (2). [*2]
4
Carrier roller assembly: 50 kg
18
PC600-8
SEN01066-03
Disassembly and assembly of carrier roller assembly

Special tools
4
5.
Remove floating seal (6) from support (7). Secure support (7) with block [3]. Using push tool [4], push shaft (8) out of support (7) with press.
6. 7.
t 1 q 1 q 1
Carrier roller assembly: 50 kg
Disassembly
1. Remove plug (1) to drain oil.
6
Carrier roller assembly: 135 165 cc
Sketch
Qty
N/R
8. 9.
Remove floating seal (9) from roller (5). Remove bushings (10) and (11).
2. 3. 4.
Remove cover (2). Remove cover (3). Remove shaft (4) from roller (5). a If roller (5) is erected, shaft assembly (4) falls. Take care.
PC600-8
19
SEN01066-03
Assembly
1. Using tool [5], press fit bushing (10) to roller (5). a Press fit bushing (11) similarly. Using tool L5, press fit floating seal (9) to roller (5).
3.
Using push tool [4], press fit shaft (8) to support (7). Using tool L5, press fit floating seal (6) to support (7). a For fitting procedure of the floating seal, see 2 above.
4.
2.
When installing the floating seal, clean, degrease and completely dry the contact faces of the O-ring and floating seal (hatched parts in the figure below). Take care that dirt does not stick to the contact face of the floating seal. After installing the floating seal, check that its angle is within 1 mm and its projection (a) is 9 11 mm.
5. 6.
Install shaft assembly (4) to roller (5). Install cover (3). 3 Mounting bolt: 44.12 53.93 Nm {4.5 5.5 kgm} Install cover (2). 3 Mounting bolt: 44.12 53.93 Nm {4.5 5.5 kgm}
7.
20
PC600-8
SEN01066-03
8.
Using tool L6, apply standard pressure to oil filler to check seal for air leakage. a Standard pressure: 0.1 MPa {1 kg/cm2} a Check method: Keep the standard pressure for 10 seconds, and check that the gauge reading does not drop.
9.
Using tool L6, fill carrier roller assembly with oil, then tighten plug (1).
5 3
Carrier roller: 135 165 cc (EO30-DH) Plug: 30.89 37.75 Nm {3.15 3.85 kgm}
PC600-8
21
SEN01066-03
Removal and installation of revolving frame assembly

Removal
1.
5.
Remove the work equipment assembly. For details, see Removal and installation of work equipment assembly. Stop the engine. Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Remove the counterweight assembly. For details, see Removal and installation of counterweight assembly. Disconnect grease tube from the swing circle. Remove all revolving frame mounting bolts (1), except 3 4 pieces at the front and rear. [*1] a While running the engine and swinging the upper structure, remove the mounting bolts. a If the engine is not started, remove the swing motor and swing the upper structure with a crane.
Disconnect all upper pipes (2) of the center swivel joint. a Before disconnecting each hose, mark it with a tag etc. to indicate its position. a Install oil stopper plugs to the disconnected hoses. Pull out pin (3) and move link (4) toward the frame.
6.
k k
2.
3. 4.
7.
Revolving frame assembly [*1], [*2] 1) Using M46 eyebolts (EB) (Length: Min. 450 mm), install wires to the counterweight mounting portion and boom cylinder pin, sling the revolving frame assembly temporarily. a Use 2 cranes. a Use wires which are not damaged. a When winding wires around the revolving frame without using eyebolts (EB), apply pads to the corners of the revolving frame. 2) Remove the remaining bolts and revolving frame assembly (5).
4
Revolving frame assembly: 11,000 kg
22
PC600-8
SEN01066-03
Installation
q
[*1]
Mounting bolt: Adhesive (LT-2) Mounting bolt: 1,860 1,910 Nm {189 195 kgm}
[*2]
Top of swing circle: Gasket sealant (LG-6)
PC600-8
23
SEN01066-03
Removal and installation of counterweight assembly

Removal
k
Installation
Lower the work equipment to the ground and stop the engine. Sling counterweight assembly (1) temporarily. a No eyebolts are necessary. Remove mounting bolts (2). a Width across flats: 65 mm
1.
2.
[*1] a Evenly adjust the clearance between the door and counterweight and that between the revolving frame and counterweight to 15 5 mm. 3 Counterweight mounting bolt: 3,430 4,212 Nm {350 430 kgm}
3.
Lift off counterweight assembly (1).

4
[*1]
Counterweight assembly: 10,750 kg (For countries other than USA) 13,500 kg (For USA)
24
PC600-8
SEN01066-03
Removal and installation of counterweight remover assembly

Removal
k
a a
Lower the work equipment to the ground and stop the engine. Install oil stopper plugs to the disconnected tubes and hoses. Before disconnecting each hose, mark it with a tag etc. to indicate its position. Remove the mounting bolts and lower counterweight (2). [*1] a Width across flats of mounting bolt: 65 mm Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Remove pin (1) and disconnect counterweight (2).
1.
4. 5.
Disconnect hoses (7) (9). Disconnect clamp (10).
2.
6.
Disconnect clamps (13) (17).
3.
Disconnect hoses (3), (5) and (6). a Prepare an oil receiver.
PC600-8
25
SEN01066-03
7.
Sling counterweight remover assembly (11).
Installation
q
[*1]
Counterweight mounting bolt: 3,430 4,212 Nm {350 430 kgm}
8.
Remove mounting bolts (12) and lift off counterweight remover assembly (11).
4
Counterweight remover assembly: 1,270 kg
26
PC600-8
SEN01066-03
PC600-8
27
SEN01066-03
28
SEN01067-03
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8 PC600LC-8
Machine model
PC600-8 PC600LC-8
Serial number

Hydraulic system
Removal and installation of hydraulic tank assembly...................................................................................... 2 Removal and installation of hydraulic pump assembly ................................................................................... 4 Removal and installation of control valve and solenoid valve assembly......................................................... 7 Disassembly and assembly of control valve assembly ................................................................................... 9 Disassembly and assembly of main control valve assembly ........................................................................ 10 Removal and installation of swing motor assembly ...................................................................................... 14 Removal and installation of center swivel joint assembly ............................................................................. 15 Disassembly and assembly of center swivel joint assembly ......................................................................... 16 Disassembly and assembly of work equipment PPC valve assembly .......................................................... 18 Disassembly and assembly of travel PPC valve assembly........................................................................... 20 Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 23 Disassembly and assembly of grease gun assembly ................................................................................... 29
PC600-8
SEN01067-03
Removal and installation of hydraulic tank assembly

Removal
k k
5.
Disconnect hose (4) from filter (F).
a a 1.
Lower the work equipment to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Disconnect the cable from the negative () terminal of the battery. Install oil stopper plugs to the disconnected tubes and hoses. Before disconnecting each hose, mark it with a tag etc. to indicate its position. Drain the hydraulic oil.
6
6.
Disconnect hoses (5) (8) from under filter (F).
Hydraulic oil: 360 l (Refill capacity)
2. 3. 4.
Remove handrails (1). Remove plate (2). Remove cover (3).
7. 8.
Remove the undercover. Disconnect hoses (9) (12) from the inside rear of hydraulic tank (27).
PC600-8
SEN01067-03
9.
Disconnect hoses (13) (22) from the rear of the hydraulic tank.
13. Remove 4 bolts (26) from the front of the hydraulic tank.
10. Disconnect clamp (23). a There is another clamp under clamp (23). 11. Disconnect connector P22 (24).
14. Remove the mounting bolts and lift off hydraulic tank (27).
4
Hydraulic tank assembly: 430 kg
12. Disconnect suction tube (25). a Since suction hose (SH) is fixed with MIKALOR clamp, do not disconnect it. If it is disconnected, see Removal and installation of hydraulic pump assembly, Installation.
Installation
q
Carry out installation in the reverse order to removal. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
5
PC600-8
SEN01067-03
Removal and installation of hydraulic pump assembly

Special tool
Necessity Symbol Part number 796-660-2010 Part name Oil stopper
7.
Remove cover (3).
q 1
Removal
k k
a a 1.
Lower the work equipment to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Disconnect the cable from the negative () terminal of the battery. Install oil stopper plugs to the disconnected tubes and hoses. Before disconnecting each hose, mark it with a tag etc. to indicate its position. Remove the hydraulic tank strainer and stop the oil with tool S. a When not using tool S, remove the drain plug and drain the oil.
6
Hydraulic tank: 360 l (Refill capacity)
Sketch
Qty
N/R
8. 9.
Lift off cover assembly (5). Disconnect dust indicator hose (6). [*1] [*2]
2.
Remove cover (1).
10. Disconnect hose clamp (7). 11. Remove air cleaner bands (8). 12. Remove air cleaner (9). 13. Remove air cleaner bracket.
3. 4. 5. 6.
Open the engine hood. Remove handrail (2). Disconnect hose (4) from reservoir tank (RT) under cover (3). Disconnect connector P24 from the bottom of reservoir tank (RT).
PC600-8
SEN01067-03
14. Upper side of pump No. 2 1) Remove bracket (11). 2) Disconnect 4 hoses (12). 3) Disconnect hose (13). Upper side of cooling fan pump (G.P.) Disconnect hoses (14) (18).
16. Lower side of pump No. 2 1) Disconnect 3 hoses (28). 2) Disconnect suction connector (29). a Since suction hose (SH2) is fixed with MIKALOR clamp, do not disconnect it. 17. Lower side of cooling fan pump (G.P.) 1) Disconnect suction hose (31). 2) Disconnect suction connector (32). a Since suction hose (SHG) is fixed with MIKALOR clamp, do not disconnect it.
15. Pump No. 1 1) Disconnect hoses (19) (22). 2) Disconnect wiring harness (23). 3) Disconnect hoses (24) (26). 4) Disconnect suction connector (27). a Since suction hose (SH1) is fixed with MIKALOR clamp, do not disconnect it.
18. Lift off each pump

4 4 4
Pump No. 1 assembly (No. 1): 170 kg Pump No. 2 assembly (No. 2): 160 kg Cooling fan pump assembly (G.P.): 90 kg
PC600-8
SEN01067-03
Installation
q
3) 4) a
Carry out installation in the reverse order to removal. Air hose clamps (right and left): 8.3 9.3 Nm {0.85 0.95 kgm} Air cleaner band: 17.6 21.6 Nm {1.8 2.2 kgm}
[*1]
[*2]
Reference When suction hoses (SH), (SH1), (SH2), and (SHG) are disconnected a Since these hoses are fixed with MIKALOR clamps, observe the following precautions when installing them.
Set bridge (BR) under the clamp bolt and adjust its overlap (b) with bridge (BR) to at least 5 mm. Tightening of the clamp. 2 Threads of clamp bolt (BC): Lubricating oil (THREEBOND PANDO 18B) Do not use an impact wrench. q When reusing the hose Install the clamp to the clamp mark made on the hose. 3 Clamp bolt: Min. 6 Nm {0.6 kgm} q When using a new hose Tighten until dimension (a) is as follows. 12 15 mm: SH 7 10 mm: SH1, SH2, SHG
1) 2)
Use new MIKALOR clamps. Set each hose to the original position. Insertion depth: 95 mm (SH) 85 mm (SH1, SH2) 80 mm (SHG) Apply adhesive evenly over the tube side. 2 Apply evenly over the tube side: Adhesive (THREEBOND 4314)
5
Bleeding air Bleed air from the hydraulic circuit. For details, see Testing and adjusting, Bleeding air from each part.
PC600-8
SEN01067-03
Removal and installation of control valve and solenoid valve assembly 1

Removal
k k
a a 1.
Lower the work equipment to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Bleed air from the hydraulic circuit. For details, see Testing and adjusting, Releasing remaining pressure in hydraulic circuit. Disconnect the cable from the negative () terminal of the battery. Before disconnecting each hose, make a match mark on it or fit a tag to it to indicate its position. Install oil stopper plugs to the disconnected tubes and hoses. Remove control valve assembly upper cover (1) and step (2).
3.
Disconnect hoses (18) and (19) between the control valve and swing motor and 2 swing motor suction hoses (20). Disconnect 4 hoses (21) between the control valve and arm and bucket cylinders.
4.
2.
Disconnect the following wiring connectors. q (3) : (P03) (Swing switch) q (4) : (P26) (R pump pressure sensor) q (5) : (P25) (F pump pressure sensor) q (6) : (P02) (Boom lower switch) q (7) : (P04) (Arm in switch) q (8) : (P06) (Boom raise switch) q (9) : (P05) (Bucket dump switch) q (10) : (P01) (Bucket curl switch) q (11) : (V03) (Bucket HI cancel solenoid) q (12) : (P08) (Arm out switch) q (13) : (V07) (CO cancel solenoid) q (14) : (V08) (Main 2-stage relief valve solenoid) q (15) : (V06) (Boom head 2-stage safety valve solenoid) q (16) : (V04) (Travel speed shifting solenoid) q (17) : (V05) (Swing holding brake solenoid)
PC600-8
SEN01067-03
5. 6.
Remove hose (22) between the control valve and return filter. Disconnect 2 hoses (23) between the line filter and control valve. Disconnect 3 return hoses (24). Disconnect hose (25). Disconnect 3 hoses (26).
14. Sling control valve and solenoid valve assembly (32) temporarily and remove it together with the bracket.
4
Control valve and solenoid valve assembly: 330 kg
7. 8. 9.
10. Disconnect connectors P03 (27) and P26 (28).
Installation
q
Carry out installation in the reverse order to removal. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
5
11. Disconnect each tube (29) from the control valve side or opposite side. a Disconnect the tubes from the chassis completely, if necessary. 12. Disconnect all PPC hoses (30) from the front and rear of the control valve. 13. Disconnect all hoses (31) from each solenoid valve.
q
Bleeding air Bleed air from the hydraulic circuit. For details, see Testing and adjusting, Bleeding air from each part.
PC600-8
SEN01067-03
Disassembly and assembly of control valve assembly

Precaution
a
Spools: Take care that the arm Hi (AH), arm Lo (AL), bucket Lo (BKL), and boom Lo (BML) spools must be installed in the correct directions.
Apply liquid seal (SEALEND 242 or equivalent) to the mating faces. 2 Mating faces: Liquid seal (SEALEND 242 or equivalent)
PC600-8
SEN01067-03
Disassembly and assembly of main control valve assembly

Disassembly
10
PC600-8
SEN01067-03
Since the set pressure of the safety valve cannot be adjusted without removing it from the machine, do not disassemble it. The left main control valve is explained below as an example. Main relief valve, jet sensor relief valve Remove main relief valve (1) and jet sensor relief valve (2). Safety valves having suction ports Remove safety valves (3) and (5) having suction ports. Check valve Remove plug (6), then remove spring (7) and check valve (8). Left travel valve 1) Remove case (9). Remove retainer (10), shim (11), spring (12), retainer (13), spring (14), and retainer (15), then remove spool (16). 2) Remove case (17), then remove retainer (18), shim (19), spring (20), retainer (21), spring (22), and retainer (23). q Apply to the spools of the swing valve, right travel valve, boom HI valve (right control valve), and boom LO valve (left control valve). q Swing valve spool (Right control valve) 1] Shim (11) and retainer (13) are not installed. 2] Shim (19) and retainer (21) are not installed. q Boom HI valve (Right control valve) 1] Two shims (11) are installed. 2] Plates are installed instead of items (17) (23) in 2) above. q Boom LO valve spool (Left control valve) 1] Shim (11) is not installed. 2] Items (18) (21) in 2) above are not installed. Arm throttle valve 1) Remove plug (24) and spring (25). 2) Remove plate (26) and pull out spool (27). q Items (24), (25), and (26) of the swing priority valve (right control valve) in 1) and 2) above are installed reversely.
6.
1.
2.
Bucket valve 1) Remove case (28). Remove spring (29) and retainer (30), then pull out spool (31). 2) Remove case (32), then remove spring (33) and retainer (34). q Apply to the spools of the arm LO valve, service valve (right control valve) and arm HI valve (left control valve). q Arm LO valve (Right control valve) A retainer is installed between case (32) and spring (33). q Arm HI (Left control valve) Shim (35) is installed. Straight travel valve 1) Remove plate (36), then remove spring (37). 2) Remove plug (38), then pull out spool (39).
3.
7.
4.
5.
PC600-8
11
SEN01067-03
Assembly
12
PC600-8
SEN01067-03
1.
Straight travel valve 1) Install spool (39) and fit the O-ring, then install plug (38). 2) Install spring (37), then install plate (36). Bucket valve 1) Install spool (31). Install retainer (34) and spring (33), then fit the O-ring and install case (32). 2) Install retainer (30) and spring (29), then fit the O-ring and install case (28). q Apply to the spools of the arm LO valve, service valve (right control valve), and arm HI valve (left control valve). q Arm LO valve (Right control valve) Install the retainer between case (32) and spring (33). q Arm HI valve (Left control valve) Install shim (35). Arm throttle valve 1) Install spool (27) and fit the O-ring, then install plate (26). 2) Install spring (25) and fit the O-ring, then install plug (24). q Reversely reinstall items (24), (25), and (26) of the swing priority valve (right control valve) in 1) and 2) above. Left control valve 1) Install spool (16), then install retainer (23), spring (22), retainer (21), spring (20), shim (19), and retainer (18). Fit the O-ring and install case (17). 2) Install retainer (15), spring (14), retainer (13), spring (12), shim (11), and retainer (10), then fit the O-ring and install case (9). q Apply to the spools of the swing valve, right travel valve, boom HI valve (right control valve), and boom LO (left control valve). q Swing valve spool (Right control valve) 1] Shim (11) and retainer (13) are not installed. 2] Shim (19) and retainer (21) are not installed. q Boom HI valve (Right control valve) 1] Install 2 shims (11). 2] Install plates instead of items (17) (23) in 2) above. q Boom LO valve spool (Left control valve) 1] Shim (11) is not installed. 2] Items (18) (21) in 2 above are not installed.
5.
Check valve Install check valve (8) and spring (7), then fit the O-ring and install plug (6). 3 Plug: 177 216 Nm {18 22 kgm} Safety valves having suction ports Fit the O-ring, then install safety valves (5) and (3) having suction ports. 3 Safety valve having suction port: 216 235 Nm {22 24 kgm} Jet sensor relief valve and main relief valve Install jet sensor relief valve (2) and main relief valve (1). 3 Jet sensor relief valve: 49 58.8 Nm {5 6 kgm} 3 Main relief valve: 177 196 Nm {18 20 kgm}
2.
6.
7.
3.
4.
PC600-8
13
SEN01067-03
Removal and installation of swing motor assembly 1

Removal
k k
Installation
q
Lower the work equipment to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Remove step (1). Disconnect 4 hoses (2) between the control valve and swing motor. a Install tags and oil stopper plugs to all the disconnected hoses. Disconnect 2 suction hoses (3). Disconnect 2 swing holding brake hoses (4). Disconnect 3 drain hoses (5). Remove hose bracket (6). Lift off swing motor assembly (7).
4
1. 2.
[*1] a When installing, apply gasket sealant to the following parts. (Apply the gasket sealant around the bolt hole only at oil check hole (a).) a When applying the gasket sealant to the ring gear, take care. 2 Mating face of swing motor assembly: Gasket sealant (LG-6)
3. 4. 5. 6. 7.
[*1]
q
Swing motor assembly: 60 kg (1 piece)
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Bleeding air Bleed air from the swing motor. For details, see Testing and adjusting, Bleeding air from each part.
14
PC600-8
SEN01067-03
Removal and installation of center swivel joint assembly 1

Removal
k
Installation
q
Carry out installation in the reverse order to removal. Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air Bleed the air from the travel motor. For details, see Testing and adjusting, Bleeding air from each part.
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap of the hydraulic tank slowly to release the pressure inside the hydraulic tank. Disconnect all hoses (1) at bottom of center swivel joint assembly. a Before disconnecting, mark all the hoses with tags to prevent mistakes in the mounting position when installing. Remove elbow (2).
1.
2.
3.
Disconnect all hoses (3) at top of swivel joint assembly. a Before disconnecting, mark all the hoses with tags to prevent mistakes in the mounting position when installing. Pull out pin (4) and move link (5) towards frame. Sling center swivel joint assembly (6), then remove 4 mounting bolts from bottom.
4
4. 5.
Center swivel joint assembly: 45 kg
PC600-8
15
SEN01067-03
Disassembly and assembly of center swivel joint assembly

Special tools
Necessity
2
Sketch Qty N/R
Symbol
Part number 790-101-2501 790-101-2510 790-101-2520 791-112-1180
Part name Push-puller Block Screw Nut Washer Leg Plate Nut Adapter
t 1 t 1 t 1 t 1 t 1 t 2 t 2 t 2 t 2
T1
790-101-2540 790-101-2630 790-101-2570 790-101-2560 790-101-2660
Disassembly
1. 2. 3. 4. Remove cover (1). Remove snap ring (2). Using tools T1, pull out swivel rotor (4) and ring (3) from swivel shaft (5). Remove O-rings (6) and slipper seals (7) from swivel rotor (4).
CEP00381
16
PC600-8
SEN01067-03
Assembly
1. 2. Assemble slipper seals (7) and O-rings (6) to swivel rotor. Set swivel shaft (5) on block [2], then using push tool [1], tap swivel rotor (4) with a plastic hammer to install. 2 Contact surface of rotor, shaft: Grease (G2-LI) a When installing the rotor, be extremely careful not to damage the slipper seal and O-ring.
2 3
CEP00381
3. 4.
Install ring (3) and secure with snap ring (2). Fit O-ring and install cover (1). 3 Mounting bolt: 66.15 7.35 Nm {6.75 0.75 kgm}
PC600-8
17
SEN01067-03
Disassembly and assembly of work equipment PPC valve assembly

Disassembly
1. 2.
1 2 4
Remove nut (1), then remove disc (2) and boot (3). Remove bolts, then remove plate (5). a Do not remove joint (4) unless it is to be replaced. Remove seal (6) and collar (7). Pull out piston (8), and remove retainer (9), springs (10) and (11), and shim (12). a Spring (10) consists of two springs each of two types with different installed loads, so check the mounting position (hydraulic port) and mark with tags to prevent mistakes when installing. Pull out valve (13) from body (14).
3. 4.
5 6 7 8 9 10 11 12 13
5.
14
CEP00424
18
PC600-8
SEN01067-03
Assembly
1. 2. Assemble valve (13) to body (14). Assemble shim (12) and spring (11) to valve (13). a When assembling spring (11), set the end with the small coil diameter (inside diameter) at shim (12) end. Assemble spring (10), retainer (9), and piston (8). a The number of loops in the coil for spring (10) is different for each of the hydraulic ports below, so be careful when installing.
Position of port P1, P2 P3, P4 Free length of spring (mm) 44.4 42.4
7.
Assemble boot (3) and disc (2), and tighten with nut (1). 3 Nut: 112.8 14.7 Nm {11.5 1.5 kgm} a After assembling the disc, adjust the height of the disc. For details, see Testing and adjusting, Adjusting PPC valve.
3.
The position of each port is marked at the bottom of the valve body. 2 Piston: Grease (G2-LI) a When assembling piston (8), coat the outside of the piston and the inside of the hole in the body with grease.
4. 5.
Fit O-ring to collar (7) and assemble in body (14), then install seal (6). Install plate (5). 3 Mounting bolt: 13.2 1.5 Nm {1.35 0.15 kgm} Install joint (4). 2 Sliding portion of joint: Grease (G2-LI) 2 Female thread of body: Thread tightener (LT-2) a Coat two places on the female thread with one drop of thread tightener each as shown in the diagram below. 3 Joint: 44.1 4.9 Nm {4.5 0.5 kgm} a Keep strictly to the tightening torque.
6.
PC600-8
19
SEN01067-03
Disassembly and assembly of travel PPC valve assembly

Special tool
New/Remodel
2 796T-416-1040 Push tool T 3 796T-416-1050 Push tool 4 796T-416-1020 Push tool
t 1 t 1 t 1
Disassembly
1. 2. 3. 4. 5. Remove screw (27) to remove lever (26). Remove mounting bolt (15) to remove case (11), shaft (16) and lever (13) assembly. Remove pin (19). Remove shaft (13), bushings (20) (20a) and lever (12) from the case. Remove mounting bolt (17) to remove plate (14). a Check the thickness and the mounting position of washer (18). a Remove pin (31) from body (1). 6. 7. Remove seal (8) and collar (10). Remove piston (7) to remove retainer (5), springs (6) and (4) and shim (3). a Store shim (3) after checking the thickness and the number of shims at each mounting position. Remove valve (2) from body (1).
Sketch Q Q Q
Symbol
Part No.
Part name
Necessity
Q'ty
8.
20
PC600-8
SEN01067-03
Assembly
Only the precautions for assembling the travel PPC valve assembly are described. a When assembling, clean and inspect the parts closely and take care fully so that dirt, rust, flaw, etc. will not cause a trouble. When installing piston (7), apply grease (G2LI) to its outside and the inside of the body hole. Install spring (4) with its small diameter side on the shim (3) side. q Diameter of spring (Inside diameter) Small diameter side: 4.9, Large diameter side: 5.55 Assemble shaft (13) with the following procedure. 1) Using tool T2, install bushing (20) to case. a Install bushing from 10 chamfered side. a Installing dimension (A) of the bushing should be as follows. q A: 24.8 0.3 mm Do not apply shock load to the bushing directly.
3) 4) 5)
Install lever (12). Install shaft (13). Using tool T4, install pin (19). a Installing dimension (C) of the pin (17) should be as follows. q C: 0 0.5 mm a Do not apply shock load to the pin directly.
2)
Using tool T3, install bushing (20a) to case. a Install bushing from 10 chamfered side. a Installing dimension (B) of the bushing (14a) should be as follows. (End surface of bushing will tightly fit to the end surface of case.) q B: 5.3 0.3 mm a Do not apply shock load to the bushing directly.
Apply grease (G2-LI) to the rocking part of shaft (16) and the contact surfaces of lever (13) and piston (7) and the contact surfaces of damper (21) and pin (20). 2 Quantity of grease (G2-LI) Rocking part of shaft: 4 8 cc/periphery Contact surfaces of lever and piston: 0.3 0.8 cc/place Contact surfaces of plate and pin: 0.3 0.8 cc/place Install washer (18) 1.6 mm thick first. If the difference between both sides at the stroke end of the lever exceeds 0.7, change the washer thickness to reduce the difference to below 0.7. (If the washer thickness is reduced by 0.3 mm, the stroke end angle is increased by 0.39.) q Thickness of washer (t): 1.0, 1.3, 1.6, 1.9, 2.2 mm
PC600-8
21
SEN01067-03 a
Tighten each part to the following torque. q Plug (29): 6 11 Nm {0.6 1.1 kgm} q Plug (28): 4 9 Nm {0.4 0.9 kgm} q Screw (27): 7.8 9.8 Nm {0.8 1.0 kgm} q Bolt (15): 25 30 Nm {2.5 3.2 kgm} q Bolt (17): 27 30 Nm {2.8 3.5 kgm}
22
PC600-8
SEN01067-03
Disassembly and assembly of hydraulic cylinder assembly

Special tools
Necessity Symbol Part number Part name Cylinder repair stand Expander Ring Clamp Push tool kit Grip Bolt Push tool Push tool Push tool Push tool kit Grip Bolt Plate Plate Plate Wrench Pin
4)
Disassemble piston rod assembly as follows. 1] Set piston rod assembly (2) to tool U1.
1 790-502-1003 2 790-720-1000 3 796-720-1670 07281-01279 790-201-1702 790-101-5021 4 U 01010-50816 790-201-1871 790-445-4210 790-201-1881 790-201-1500 790-101-5021 5 01010-50816 790-201-1680 790-201-1970 790-201-1690 6 790-102-4300 790-102-4310
q 1 q 1 q 1 q 1 t 1 1 1 1 1 1 t 1 1 1 1 1 1 t 1 t 2
Sketch
Qty
N/R
2]
Remove piston assembly stopper screw (3). Screw size: M12 pitch 1.75: Boom, Arm, Bucket
Disassembly
1. Piston rod assembly 1) Remove piping from cylinder assembly. 2) Remove mounting bolts, and disconnect head assembly (1). 3) Pull out piston rod assembly (2). a Place a container under the cylinder to catch the oil. a If screw (3) has been caulked strongly and cannot be removed, screw it in fully, then fit a tap to the thread and pull it out.
PC600-8
23
SEN01067-03
3]
Using tool U6, remove piston assembly (4). q When not using tool U6, use the drill holes (10: 2 places) and loosen the piston assembly.
2.
Disassembly of piston assembly 1) Remove ring (11). 2) Remove wear ring (12). a 2 pieces are installed to each of the bucket cylinder and boom cylinder, and 4 pieces to the arm cylinder. 3) Remove piston ring (13). 4) Remove O-ring and backup ring (14).
4] 5] 6]
Remove plunger (5). Remove collar (6). Remove head assembly (7). 3. Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (15). 2) Remove snap ring (16), then remove dust seal (17). 3) Remove rod packing (18). 4) Remove buffer ring (19). 5) Remove bushing (20).
7]
Remove cap (8), and pull out 11 balls (9), then remove cushion plunger (10). q Arm cylinder only
24
PC600-8
SEN01067-03
Assembly
a a Be careful not to damage the packings, dust seals, and O-rings. Do not try to force the backup ring into position. Warm it in warm water (50 60C) before fitting it. Assembly of cylinder head assembly 1) Using tool U4, press fit bushing (20). 2) Assemble buffer ring (19). 3) Assemble rod packing (18). 4) Using tool U5, install dust seal (17), and secure with snap ring (16). 5) Install O-ring and backup ring (15).
2.
Assembly of piston assembly 1) Using tool U2, expand piston ring (13). a Set the piston ring on tool U2, and tu rn the han dle 8 1 0 times to expand the ring. 2) Set tool U3 in position, and compress piston ring (13).
1.
3) 4) 5)
Install O-ring and backup ring (14). Assemble wear rings (12). Assemble rings (11). a Be careful not to open the end gap of the ring too wide. 2 Ring groove: Grease (G2-LI)
PC600-8
25
SEN01067-03
3.
Piston rod assembly 1) Set piston rod assembly (2) to tool U1.
6)
Assemble piston assembly (4) as follows. When using rod and piston assembly (2) again a Wash thoroughly and remove all metal particles and dirt. 1] Screw in piston assembly (4), then use tool U6 to tighten piston assembly so that position of screw thread hole matches. a Remove all burrs and flashes with a file.
2) 3) 4)
Assemble head assembly (7). Fit O-ring and backup ring to collar (6), then assemble. Assemble plunger (5). a After tightening the piston, check that the plunger has a little play.
2]
Tighten screw (3). 2 Threaded part: Adhesive (Locktite No. 262 or equivalent) 3 Screw (3): 58.9 73.6 Nm {6 7.5 kgm} Caulk thread at 4 places with punch.
3]
5)
Set cushion plunger (10) to piston rod, then assemble 11 balls (9), and secure with cap (8). q Arm cylinder only a After installing, check that the cushion plunger end has a little play.
26
PC600-8
SEN01067-03
When using a new part for either or both of rod or piston assembly (2) a For the rod with bottom cushion, mark the cushion plug position on the end face of the rod. q Arm cylinder only 1] Screw in until piston assembly (4) contacts end face of rod, then use tool U6 to tighten. 3 Piston assembly (4): 294 29.4 Nm {30 3.0 kgm} a After tightening the piston, check that there is play in plunger (5). 3] 4] After machining, wash thoroughly to remove all metal particles and dust. Tighten screw (3). 2 Threaded part: Adhesive (Locktite No. 262 or equivalent) Screw: 58.9 73.6 Nm {6 7.5 kgm} Caulk thread at 4 places with punch.
5]
2]
Machine one hole used to install screw (3). a Apply the drill to the V-groove between piston (4) and threaded part of rod (2), and make a hole horizontally. a For the cylinder with bottom cushion (arm cylinder), avoid the cushion plug position when machining. q Screw machining dimension (mm)
Bottom hole depth 36 43 Tap used Tap depth 29 36
Cylinder Bucket Boom Arm
Drill diameter 10.3 10.3
12 x 1.75 12 x 1.75
PC600-8
27
SEN01067-03
7)
Assemble piston rod assembly (2). 2 Seal portion: Grease (G2-LI) a Set the end gap of the ring at the horizontal (side) position, align the axial center of shaft and cylinder tube, then insert. a After inserting, check that the ring is not broken and has not come out, then push in fully.
8)
Tighten head assembly (1) with mounting bolts. 3 Mounting bolt :

Cylinder Bucket, Boom Arm Tightening torque 892 137 Nm {91.0 14 kgm} 1,270 200 Nm {130 20 kgm}
9)
Install piping.
28
PC600-8
SEN01067-03
Disassembly and assembly of grease gun assembly

Disassembly
1. 2. 3. 4. Remove joint (1) from the hose. Remove gun assembly (2) from joint (1). Remove nozzle (3) from gun assembly (2). Remove cap (4) from nozzle (3).
Assembly
1.
Install joint (1) to the hose. a Wind seal tape two to three times around the threaded portion as to bite into it starting from a position one winding away from the end of the threaded portion. 3 Joint screwing portion: 5.9 11.8 Nm {0.6 1.2 kgm} Install gun assembly (2) to joint (1). a Wind seal tape two to three times around the threaded portion as to bite into it starting from a position one winding away from the end of the threaded portion. 3 Joint screwing portion: 3.9 6.9 Nm {0.4 0.7 kgm} Install nozzle (3) to gun assembly (2). a Wind seal tape two to three times around the threaded portion as to bite into it starting from a position one winding away from the end of the threaded portion. Screw in the joint manually. When manual screwing becomes disabled, use the tool and further screw in using nozzle (3). Install cap (4) to nozzle (3).
2.
3.
4.
PC600-8
29
SEN01067-03
30
SEN01068-02
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8 PC600LC-8
Machine model
PC600-8 PC600LC-8
Serial number

Work equipment
Removal and installation of bucket cylinder assembly (Backhoe specification) ............................................. 2 Removal and installation of bucket cylinder assembly (Loading shovel specification) ................................... 4 Removal and installation of arm cylinder assembly (Backhoe specification) .................................................. 6 Removal and installation of arm cylinder assembly (Loading shovel specification)........................................ 8 Removal and installation of boom cylinder assembly (Backhoe specification) ............................................. 10 Removal and installation of boom cylinder assembly (Loading shovel specification) ................................... 12 Removal and installation of bottom dump cylinder assembly (Loading shovel specification) ....................... 14 Removal and installation of bucket assembly (Backhoe specification) ......................................................... 15 Removal and installation of bucket assembly (Loading shovel specification)............................................... 17 Removal and installation of arm assembly (Backhoe specification) ............................................................. 18 Removal and installation of arm assembly (Loading shovel specification) ................................................... 20 Removal and installation of boom assembly (Backhoe specification) .......................................................... 21 Removal and installation of boom assembly (Loading shovel specification) ................................................ 23 Removal and installation of work equipment (Backhoe specification) .......................................................... 25 Removal and installation of work equipment (Loading shovel specification) ................................................ 27
PC600-8
SEN01068-02
Removal and installation of bucket cylinder assembly (Backhoe specification)

Removal
k
5.
Sling bucket cylinder assembly (3) temporarily and remove pin (4) on the bottom side and then remove bucket cylinder assembly. [*2] a Check the quantity and positions of the inserted shims.
4 4
Retract the bucket cylinder piston rod to about 200 mm before the dump stroke end, lower the work equipment to the ground, and set the lock lever in the lock position. Set block [1] under the arm top, block [2] between the link and arm, and block [3] between the bucket cylinder and arm. Remove pin (1) on the head side. [*1]
Pin (4): 25 kg Bucket cylinder assembly: 470 kg
1.
2.
3.
Run the engine and retract the piston rod and bind it with wires etc. to prevent it from coming out. k Stop the engine and release the residual pressure from the hydraulic circuit. For details, see Testing and adjusting, "Releasing remaining pressure in hydraulic circuit." Disconnect right and left hoses (2).
4.
PC600-8
SEN01068-02
Installation
q
Bleeding air Bleed air from the hydraulic cylinder. For details, see Testing and adjusting, "Bleeding air from each part." Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
[*1]
Inside surface of bushing: Molybdenum disulfide lubricant (LM-P) 2 Greasing after installing pin: Molybdenum disulfide grease (LM-G) k When aligning the pin holes, never insert your fingers in them. a Adjust clearance (a) between links (5) and (6) to 1 2 mm with the shim. q Shim thickness: 0.8 mm
[*2]
Inside surface of bushing: Molybdenum disulfide lubricant (LM-P) 2 Greasing after installing pin: Molybdenum disulfide grease (LM-G) k When aligning the pin holes, never insert your fingers in them. a Adjust clearance (b) between the bottom end of cylinder (3) and bracket (7) to below 1 mm with the shim. q Shim thickness: 0.8 mm
PC600-8
SEN01068-02
Removal and installation of bucket cylinder assembly (Loading shovel specification)

Removal
k
3.
Disconnect grease tube (2). Disconnect hose (3).
4.
a 1.
Extend the arm cylinder fully, set the bottom of the bucket horizontal, lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Fit plugs in the hoses after disconnecting them, to prevent dirt or dust from entering. Sling bucket cylinder assembly, and remove plate, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), remove pin (1). [*1]
4
5.
Pin: 40 kg
Sling piston rod end and bottom end, and remove plate, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (4). [*2] a Pull out the pin to a position where the cylinder bottom can be disconnected.
4
Pin: 100 kg
2.
Start engine and retract piston rod fully. k Tie the rod with wire to prevent it from coming out. k After stopping the engine, release the pressure inside the piping. For details, see Testing and adjusting, Releasing pressure in PPC circuit.
6.
Raise bucket cylinder assembly (5) carefully and remove.

4
Bucket cylinder assembly: 410 kg
PC600-8
SEN01068-02
Installation
q
Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole. When aligning the mounting position of the pin, do not insert your fingers in the pin hole. a Adjust with shims so that the clearance at the cylinder bottom end is less than 1 mm. Bleed the air from the work equipment circuit. For details, see Testing and adjusting, Bleeding air from hydraulic cylinder. Refilling with oil a Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
[*1]
[*2]
PC600-8
SEN01068-02
Removal and installation of arm cylinder assembly (Backhoe specification) 1

Removal
k
Extend the arm cylinder piston rod to about 200 mm before the in stroke end, lower the work equipment to the ground, and set the lock lever in the lock position. Set block [2] between the arm cylinder and boom. Disconnect grease hose (1). Pull out head pin (2). [*1] a If the head pin cannot be pulled out, use tool [1].
4
1. 2. 3.
6. 7.
Disconnect grease hose (5). Sling arm cylinder assembly (6) temporarily, remove plate (7), and pull out bottom pin (8). [*2] a If the bottom pin cannot be pulled out, use tool [1]. a Check the quantity and positions of the inserted shims. 4 Pin (8): 40 kg Remove arm cylinder assembly (6).
4
Pin (3): 35 kg
4.
Run the engine and retract the piston rod and bind it with wires etc. to prevent it from coming out. k Release the residual pressure from the hydraulic circuit. For details, see Testing and adjusting, "Releasing remaining pressure in hydraulic circuit." Disconnect hose (3). a Fit an oil stopper plug to the disconnected hose to prevent foreign matter from entering the hose.
8.
Arm cylinder assembly: 730 kg
5.
PC600-8
SEN01068-02
Installation
q
[*1]
Inside surface of bushing: Molybdenum disulfide lubricant (LM-P) 2 Greasing after installing pin: Molybdenum disulfide grease (LM-G) k When aligning the pin holes, never insert your fingers in them. [*2] Inside surface of bushing: Molybdenum disulfide lubricant (LM-P) 2 Greasing after installing pin: Molybdenum disulfide grease (LM-G) k When aligning the pin holes, never insert your fingers in them. a Adjust clearance (a) between the bottom end of cylinder (6) and bracket (9) to below 1 mm with the shim. q Shim thickness: 0.8 mm
2
Bleeding air Bleed air from the hydraulic cylinder. For details, see Testing and adjusting, "Bleeding air from each part." Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
PC600-8
SEN01068-02
Removal and installation of arm cylinder assembly (Loading shovel specification) 1

Removal
k
3. 4.
Disconnect hoses (3). Sling piston rod end and bottom end, and remove plate, then pull out pin (4). [*2] a Pull out the pin to a position where the cylinder bottom can be disconnected.
4
a 1.
Retract boom cylinder fully, and extend arm cylinder, then set the bottom of the bucket horizontal, lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Fit blind plugs in the hoses after disconnecting them, to prevent dirt or dust from entering. Sling arm cylinder assembly, and remove plate, then pull out pin (2). [*1] a Pull out the pin to a position where the piston rod can be disconnected.
4
Pin: 30 kg
Pin: 30 kg
5.
Lift off arm cylinder assembly (5) carefully.

4
Arm cylinder assembly: 600 kg
2.
Start engine and retract piston rod fully. k Tie the rod with wire to prevent it from coming out. k After stopping the engine, release the pressure inside the piping. For details, see Testing and adjusting, Releasing pressure in PPC circuit.
PC600-8
SEN01068-02
Installation
q
[*1]
[*2]
PC600-8
SEN01068-02
Removal and installation of boom cylinder assembly (Backhoe specification) 1

Removal
k
6.
a 1. 2. 3.
Retract the arm and bucket cylinder piston rods fully, lower the work equipment completely to the ground, then put the work equipment lock lever in the LOCK position. Fit blind plugs in the hoses to prevent dust or dirt from entering. Disconnect grease hose (1). Sling boom cylinder assembly (2) temporarily, and remove lock bolt (8). Remove plate (9). a Check the number, thickness, and positions of the shims. Sling boom cylinder assembly (2) temporarily.
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. k Stop the engine and release the remaining pressure in the circuit. For details, see Testing and adjusting, "Releasing remaining pressure in hydraulic circuit." Support boom cylinder assembly (2) with a stand, etc., and disconnect hose (4). Sling boom cylinder assembly and remove plate (6).
7. 8.
4.
9.
Pull out bottom pin (7). [*2] a If the bottom pin cannot be pulled out easily, use the forcing taps (16 x 2).
4
Pin (7): 30 kg
5.
Using tool [1], pull out head pin (3), then disconnect piston rod from boom. [*1]
4
Pin (3): 110kg (1 piece)
10. Remove boom cylinder assembly.

4
Boom cylinder assembly: 550 kg (1 piece)
10
PC600-8
SEN01068-02
Installation
q
Bleeding air Bleed the air. For details, see Testing and adjusting, "Bleeding air from each part." Refilling with oil (hydraulic tank) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
[*1]
Inside surface of bushing: Molybdenum disulfide lubricant (LM-P) 2 Lubrication after fitting pin: Molybdenum disulfide grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Adjust the shim so that gap (a) between rod end of cylinder (2) and plate (9) will be 1 mm maximum. q Thickness of shim: 0.5 mm
[*2]
Inside surface of bushing: Molybdenum disulfide lubricant (LM-P) 2 Lubrication after fitting pin: Molybdenum disulfide grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Adjust with shims so that clearance (b) between bracket (11) and the bottom end face of boom cylinder (2) is less than 1 mm. q Shim thickness: 0.8, 1.5 mm
PC600-8
11
SEN01068-02
Removal and installation of boom cylinder assembly (Loading shovel specification) 1

Removal
k
5.
Lower boom cylinder assembly onto stand, then disconnect hoses (4).
a 1. 2. 3.
Extend the arm and bucket fully, lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Fit plugs in the hoses after disconnecting them, to prevent dirt or dust from entering. Disconnect grease hose (1). Remove plate (2). Sling boom cylinder assembly, pull out pin (3), and disconnect piston rod from boom. [*1] 6. Sling boom cylinder assembly, and remove plate, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out foot pin (5). [*2]
7. 4.
k k
Remove boom cylinder assembly (6).

4
Start engine and retract piston rod fully. Tie the rod with wire to prevent it from coming out. After stopping the engine, release the pressure inside the piping. For details, see Testing and adjusting, Releasing pressure in PPC circuit.
Boom cylinder assembly: 550 kg
12
PC600-8
SEN01068-02
Installation
q
[*1]
[*2]
PC600-8
13
SEN01068-02
Removal and installation of bottom dump cylinder assembly (Loading shovel specification) 1
Removal
k
5.
Remove 3 mounting bolts, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (4). [*2]
4
Pin: 20 kg
a 1. 2.
Set the bottom of the bucket horizontal, and retract the rod to a position where the rod connecting pin of the bottom dump cylinder can be removed. Then fit a block under the bucket, lower the work equipment completely to the ground and stop the engine. Fit plugs in the hoses after disconnecting them, to prevent dirt or dust from entering. Remove cover (1). Sling bottom dump cylinder assembly, and remove lock plate, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (2). [*1]
6.
Lift off bottom dump cylinder assembly (5).

4
Bottom dump cylinder assembly: 120 kg
Installation
q
Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole. When aligning the mounting position of the pin, do not insert your fingers in the pin hole. Bleed the air from the work equipment circuit. For details, see Testing and adjusting, Bleeding air from hydraulic cylinder. Refilling with oil a Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
[*1]
[*2]
3.
Start engine and retract piston rod fully. k After stopping the engine, release the pressure inside the piping. For details, see Testing and adjusting, Releasing pressure in PPC circuit. Remove hoses (3).
4.
14
PC600-8
SEN01068-02
Removal and installation of bucket assembly (Backhoe specification)

Removal
k
Set the back of the bucket facing down, lower the work equipment completely to the ground, then set the work equipment lock lever to the LOCK position. Remove plate (1), then remove connecting pin (2) of the link and bucket. [*1] a Check the number and thickness of the shims, and keep in a safe place.
4
1.
Pin (2): 55 kg
2.
Start engine, and retract piston rod, then tie link to arm with wire to prevent piston rod from coming out. k Stop the engine and release the remaining pressure in the circuit. For details, see Testing and adjusting, "Releasing remaining pressure in hydraulic circuit." Remove plate (3), then remove connecting pin (4) of the arm and bucket. [*2] a Check the number and thickness of the shims, and keep in a safe place.
4
3.
Pin (4): 65 kg
4.
Start engine and raise work equipment, swing work equipment, then remove bucket assembly (5).
4
Bucket assembly: 2,500 kg
PC600-8
15
SEN01068-02
Installation
q
[*1]
Inside surface of bushing: Molybdenum disulfide lubricant (LM-P) 2 Lubrication after fitting pin: Lubricant containing molybdenum disulfide (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. [*2] Inside surface of bushing: Molybdenum disulfide lubricant (LM-P) 2 Lubrication after fitting pin: Lubricant containing molybdenum disulfide (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Insert the O-ring at the end face of the bucket boss securely. a Adjusting of bucket clearance 1) Measure gap (a) between arm (8) and bucket (5). a It is easier to measure if the bucket is moved to one side so that all the play is in one place. 2) Adjust the shim so that gap (a) will be 0.5 1 mm. q Shim thickness: 0.5, 1.0 mm
2
16
PC600-8
SEN01068-02
Removal and installation of bucket assembly (Loading shovel specification)

Removal
k
4.
a 1.
Set the bottom of the bucket horizontal, lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Fit plugs in the hoses after disconnecting them, to prevent dirt or dust from entering. Sling bucket cylinder assembly, and remove plate, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (1). [*1] a Remove the pin on the other side in the same way. Start the engine and retract the piston rod fully. k Bind the piston rod with wires, etc., to prevent it from coming out.
4
Sling bucket assembly, and remove 3 mounting bolts, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (4). [*2] a Remove the pin on the other side in the same way.
4
Pin: 55 kg
2.
5.
Lift off bucket assembly (5).

4
Bucket assembly: 6,000 kg
Pin: 40 kg
After stopping the engine, release the residual pressure in the piping. For details, see Testing and adjusting, Releasing residual pressure in PPC valve hydraulic circuit. Disconnect bottom dump cylinder hose (2).
3.
Installation
q
[*1] [*2] k When aligning the mounting position of the pin, do not insert your fingers in the pin hole. a Bleed the air from the work equipment circuit. For details, see Testing and adjusting, Bleeding air from hydraulic cylinder. After completion of the air bleeding operation, add engine oil to the hydraulic tank to the specified level.
PC600-8
17
SEN01068-02
Removal and installation of arm assembly (Backhoe specification)

Special tools
Necessity Symbol Part number Part name Sketch Q Qty N/R
796T-670-1220 Sleeve 791-775-1130 796-670-1130 796-870-1110 V 1 01643-33080 01803-13034 790-101-4000 790-101-1102 Plate Screw Adapter Washer Nut Puller (490 N {50 ton}) Pump
t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
6.
Removal
1. 2. Remove bucket assembly. For detail, see "Removal of bucket assembly." Secure link to arm with wire. k Extend the arm cylinder piston rod to a point approx. 200 mm before the end of the arm IN stroke, then lower the arm on to block [1] and stand [2], and set the work equipment lock lever to the LOCK position. Then, stop the engine. Set block between arm cylinder and boom. Disconnect grease hose (1). Remove plate (2), and pull out head pin (3) of arm cylinder. [*1] a If the pin does not come out, use tool [1] and remove the pin from the head end.
4
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. k Stop the engine and release the remaining pressure in the circuit. For details, see Testing and adjusting, "Releasing remaining pressure in hydraulic circuit." Disconnect 2 bucket cylinder hoses (4). Remove plate (5), then using tool V1, pull out boom top pin (6). [*2] a There are shims installed, so check the number, thickness, and position, and keep in a safe place.
4
7. 8.
Pin (6): 80 kg
3. 4. 5.
Pin (3): 35 kg
CEP00525
18
PC600-8
SEN01068-02
9.
Start engine, then raise boom and remove arm assembly (7).
4
Installation
q
Arm assembly: 3,200 kg [*1]
Inside surface of bushing: Molybdenum disulfide lubricant (LM-P) 2 Lubrication after fitting pin: Molybdenum disulfide grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. [*2] Inside surface of bushing: Molybdenum disulfide lubricant (LM-P) 2 Lubrication after fitting pin: Molybdenum disulfide grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Adjust with shims so that clearance (a) between boom (8) and the bottom end face of arm (7) is less than 1 mm. q Shim thickness: 1.0 mm
2
CEP00526
PC600-8
19
SEN01068-02
Removal and installation of arm assembly (Loading shovel specification) 1

Removal
1. Remove bucket assembly. For details, see Removal and installation of bucket assembly. Lower the tip of the arm assembly to the ground. Sling arm cylinder assembly (1) temporarily and disconnect the rod side from the arm. For details, see Removal and installation of arm cylinder assembly. a Secure the arm cylinder assembly to the boom with lever block [1]. k After stopping the engine, release the residual pressure in the piping. For details, see Testing and adjusting, Releasing residual pressure in PPC valve hydraulic circuit.
6.
Sling arm assembly, and pull out pin (5). [*1] a Pull out the pin on the other side in the same way to a position where the arm can be disconnected from the boom.
4
Pin: 110 kg
7.
Lift off arm assembly (6).

4
Arm assembly: 2,800 kg
2. 3.
Installation
q
Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole. Bleeding air Bleed the air. For details, see Testing and adjusting, "Bleeding air from each part." Refilling with oil (hydraulic tank) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
[*1]
4. 5.
Disconnect right and left bottom dump cylinder hoses (2). Disconnect right and left bucket cylinder hoses (3) and (4), 2 pieces on each side.
20
PC600-8
SEN01068-02
Removal and installation of boom assembly (Backhoe specification) 1

Special tools
Necessity Symbol Sketch Qty Part number Part name N/R
5. 6.
Sling boom assembly (10). Using tool V1, remove boom foot pin (3), then remove boom assembly (10). [*1] a There are shims installed, so check the number, thickness, and position, and keep in a safe place.
4 4
Boom foot pin: 150 kg Boom assembly: 4,800 kg
t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
Removal
1. Remove arm assembly. For details, see "Removal of arm assembly." k Lower the boom assembly completely to the ground, then set the work equipment lock lever to LOCK position. Disconnect boom cylinder assembly from boom. For details, see "Removal of boom cylinder assembly." Disconnect front lamp wiring. Disconnect bucket cylinder hoses (1) and arm cylinder hoses (2).
2.
3. 4.
10
CEP00299
PC600-8
21
SEN01068-02
Installation
q
[*1]
Inside surface of bushing: Molybdenum disulfide lubricant (LM-P) 2 Lubrication after fitting pin: Molybdenum disulfide grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Adjust with shims so that clearance (a) between end face of foot of boom (10) and revolving frame (11) is less than 1 mm. q Shim thickness: 1.0 mm and 1.5 mm
22
PC600-8
SEN01068-02
Removal and installation of boom assembly (Loading shovel specification) 1

Removal
1. Remove arm assembly. For details, see Removal and installation of arm assembly. Sling bucket cylinder assembly (1), remove plate, then pull out pin (2), and remove bucket cylinder assembly. [*1]
4 4
5.
Disconnect bottom dump cylinder hoses (3), bucket cylinder hoses (4), and arm cylinder hoses (5). a When the hoses are disconnected, oil may spurt out, so loosen the hose flanges slowly before disconnecting.
2.
Pin: 100 kg Bucket cylinder assembly: 410 kg
Remove the bucket cylinder on the other side in the same way.
6. 7.
Disconnect head lamp wiring. Using the tool V1, remove boom foot pins (6), then lift off boom assembly (7). [*2] a Check the number and thickness of the shims, and keep in a safe place.
4
Boom assembly: 3,880 kg
3.
Sling boom, set stand [1] at tip of boom to support boom.
4.
Remove boom cylinder from boom. For details, see Removal and installation of boom cylinder assembly. a Remove the boom cylinder on the other side from the boom in the same way.
PC600-8
23
SEN01068-02
Installation
q
[*1] [*2] k When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
q
24
PC600-8
SEN01068-02
Removal and installation of work equipment (Backhoe specification) 1

Special tools
Necessity Symbol Sketch Qty Part number Part name N/R
5. 6.
Sling boom assembly (10). Using tool V1, remove boom foot pin (3), then disconnect work equipment assembly. [*1] a There are shims installed, so check the number, thickness, and position, and keep in a safe place.
4 4
Boom foot pin: 150 kg Work equipment assembly: 13,800 kg
t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
Removal
1. Remove arm assembly. For details, see "Removal of arm assembly." k Lower the boom assembly completely to the ground, then set the work equipment lock lever to LOCK position. Disconnect boom cylinder assembly from boom. For details, see "Removal of boom cylinder assembly." Disconnect front lamp wiring. Disconnect bucket cylinder hoses (1) and arm cylinder hoses (2). k To prevent oil from spurting out when the engine is started, fit blind plugs securely in the piping at the chassis end.
2.
3. 4.
10
CEP00299
PC600-8
25
SEN01068-02
Installation
q
[*1]
Inside surface of bushing: Molybdenum disulfide lubricant (LM-P) 2 Lubrication after fitting pin: Molybdenum disulfide grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Adjust with shims so that clearance (a) between end face of foot of boom (10) and revolving frame (11) is less than 1 mm. q Shim thickness: 1.0 mm and 1.5 mm
26
PC600-8
SEN01068-02
Removal and installation of work equipment (Loading shovel specification) 1

Removal
k
3. 4.
Disconnect head lamp wiring. Set bottom of bucket horizontal, lower work equipment completely to ground, then sling boom assembly (4).
Retract the boom cylinder fully, extend the arm cylinder, set the bottom of the bucket horizontal, then lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Release the remaining pressure in the circuit. For details, see Testing and adjusting, Releasing pressure in hydraulic circuit. Disconnect boom cylinder from boom. For details, see Removal and installation of boom cylinder assembly. Disconnect bottom dump cylinder hose (1), bucket cylinder hoses (2), and arm cylinder hoses (3). a When the hoses are disconnected, oil may spurt out, so loosen the hose flanges slowly before disconnecting. k To prevent oil from spurting out when the engine is started, fit blind plugs securely in the piping at the chassis end. 5. Using the tool V1, remove boom foot pins (5), then disconnect work equipment assembly. [*1] a Check the number and thickness of the shims, and keep in a safe place.
1.
2.
6.
Start engine, drive machine slowly in reverse, and operate crane to lower boom foot to ground. k Before driving the machine in reverse, check that the boom foot is completely separated from the machine body.
4
Work equipment assembly: 16,200 kg
PC600-8
27
SEN01068-02
Installation
q
Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole. Adjust the lifting height of the boom assembly so that the boom foot is at the height of the mount on the chassis. Bleeding air Bleed the air. For details, see Testing and adjusting, "Bleeding air from each part." Refilling with oil (hydraulic tank) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
[*1] a
28
PC600-8
SEN01068-02
PC600-8
29
SEN01068-02
30
SEN01069-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8 PC600LC-8
Machine model
PC600-8 PC600LC-8
Serial number

Removal and installation of operators cab ..................................................................................................... 2 Removal and installation of operators cab glass (stuck glass) ...................................................................... 5 Removal and installation of front window assembly ..................................................................................... 15
PC600-8
SEN01069-01
Removal and installation of operators cab

Removal
k
6.
Remove air conditioner connector plate (15).
Disconnect the cable from the negative () terminal of the battery. Remove rear covers (1), (2), (3), and (4).
1.
7. 8. 9. 2. 3. 4. Remove duct (5), cover (6), and plate (7). Remove plate (8), duct (9) and the element. a Remove the duct lock clip. Disconnect connector S13 (10).
Disconnect connectors L03 (16), H03 (17), H04 (18), and H05 (19). Disconnect upper and lower duct joints (20) and (21). Remove controller sub-plate (22) and incline it against the air conditioner.
5.
Disconnect cab wiring connectors N02 (11), M10 (12), H08 (13), and H09 (14). a Remove the clip and separate the wiring harness from the cab.
PC600-8
SEN01069-01
10. Remove cover (23) and floor mat (24).
15. Disconnect radio antenna (31). 16. Remove clip (32) and take wiring harness (33) out of grommet (34).
11. Move right console (25) into the cab. 12. Remove monitor panel undercover (26). 17. Take grommet (35) out of the right front of the cab. 18. Disconnect the windshield washer hose from (36). 19. Remove 4 mounting bolts (37) and 5 mounting bolts (38). a Check the types of the bolts.
13. Disconnect cab wiring connector W04 (27) (Wiper motor). 14. Remove ducts (28) and (29). a Both (28) and (29) are 2 in number. a Cut the tie-wrap on the monitor wiring harness. a Sling the monitor assembly and cab together. a When removing the monitor assembly, remove cover (30) in advance.
PC600-8
SEN01069-01
20. Using lever block [1], lift off operator's cab assembly (39).
4
Installation
q
Operator's cab assembly: 300 kg
Reference
Connection of window washer hoses 1) 2) Hose length from clamp end of part A: Connect to the hose on the floor side at 150 mm. Hose length from clamp end of part B: Connect to the hose on the tank side at 200 mm. a Cut the extra part of each hose perpendicularly to it. (See the lower right of the figure.) Insert each hose end (HE) in joint (J) securely until it touches joint (J). (See the upper right of the figure.)
3) a When starting the engine while the operator's cab is removed (for transportation, etc.), use the following brackets. 1) Bracket (41) for controller (40) Part No.: 208-53-13920
2)
Bracket (42) for monitor panel assembly (30) Part No.: 208-53-13910
PC600-8
SEN01069-01
Removal and installation of operators cab glass (stuck glass)
Among the panes of window glass on the 4 sides of the operator's cab, 4 panes (1) (4) are stuck. In this section, the procedure for replacing the stuck glass is explained. When replacing front window glass (4), remove front window assembly (5). (It is impossible to replace only the front window glass while the front window assembly is installed to the operator's cab.) For the procedure for replacing the front window assembly, see "Removal and installation of front window assembly."
Right side window glass Left side rear window glass Door lower window glass Front window glass Front window assembly (Front window glass + Front frame) (6) : Both-sided adhesive tape (16): Center trim seal
(1) : (2) : (3) : (4) : (5) :
PC600-8
SEN01069-01
Special tools
Necessity Symbol Part number Part name Lifter (Suction cup) Adapter Sketch Qty N/R
Installation
1. Using a knife and scraper [5], remove the remaining adhesive and both-sided adhesive tape from the metal sheets (glass sticking surfaces) of the operator's cab. a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surf a c e s . ( I f t h e pa i n t e d s u r f a c e s a r e scratched, adhesion will be lowered.)
1 793-498-1210 2 20Y-54-13180
t 2 t 2
Removal
a 1. Remove the window glass to be replaced according to the following procedure. Using seal cutter [1], cut the adhesive between broken window glass (7) and operator's cab (metal sheet) (8).
2.
If a seal cutter is not available, widening the cut with a screwdriver, cut the adhesive and both-sided adhesive tape with knife [4].
Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and window glass (9) with white gasoline. a If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all black part on the back side of the window glass. a After cleaning the sticking surfaces, leave them for at least 5 minutes to dry.
2.
Remove the window glass.
PC600-8
SEN01069-01
3.
Apply primer (10). a The using limit of primer (10) is 4 months after the date of manufacture. Do not use primer (10) after this limit. a Use the primer within 2 hours after unpacking it. a Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Disc a r d t h e p r i m e r 2 4 h o u r s a ft e r i t i s unpacked.) 1) Stir the primers for paint and glass sufficiently before using them. a If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a day before stirring it. (If the primer is unpacked just after taken out of the refrigerator, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.) 2) When reusing primer brush (11), wash it in white gasoline. a After washing the brush, check it again for dirt and foreign matter. a Prepare respective brushes for the paint primer glass primer.
3)
Evenly apply paint primer to the surfaces to stick both-sided adhesive tapes and the surfaces out of those surfaces on operator's cab (8) which will be coated with the adhesive. 2 Paint primer: SUNSTAR PAINT PRIMER 580 SUPER or equivalent a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
a
q
Parts to be coated with primer: Apply the primer all over dimension (a). Dimension to apply primer (a): 25 mm
PC600-8
SEN01069-01 a
q q
In addition to the above parts, apply the primer to right side window glass (1) and door lower window glass (3). Range to apply primer additionally for right side window glass (1): (b) Range to apply primer additionally for door lower window glass (3): (c) After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry.
4)
Evenly apply glass primer to the sticking surfaces of window glass (9). 2 Glass primer: SUNSTAR GLASS PRIMER 580 SUPER or equivalent a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
a a a Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline.
Parts to be coated with primer: Apply the primer to the sticking surfaces of window glass (9) and all over dimension (d) which will be on both-sided adhesive tape (6) and operator's cab (8). Do not apply the primer to the boarder about 5 mm wide between the black part and transparent part of the glass. After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. Never apply wrong primer. If the paint primer is applied by mistake, wipe it off with white gasoline.
PC600-8
SEN01069-01
4.
Stick both-sided adhesive tape (6) along the inside edge of the glass sticking section. a Do not remove the release tape of the both-sided adhesive tape on the glass sticking side before sticking the glass. a When sticking the both-sided adhesive tape, do not touch the cleaned surface as much as possible. a Take care that the both-sided adhesive tape will not float at each corner of the window frame.
Stick both-sided adhesive tape (6a) additionally for right side window glass (1). Positions to stick additional bothsided adhesive tape for right side window glass: (f) : 50 mm (g) : 90 mm (h) : 250 mm
2) a When sticking both-sided adhesive tape (6) around a frame, do not lap its finishing end over the starting end but make clearance (e) of about 5 mm between them. Stick both-sided adhesive tape (6) for right side window glass (1) as shown in the figure.
Stick both-sided adhesive tape (6) for left side rear window glass (2) as shown in the figure.
1)
3)
Stick both-sided adhesive tape (6) for door lower window glass (3) as shown in the figure.
PC600-8
SEN01069-01 a a a
Stick both-sided adhesive tape (6b) additionally for door lower window glass (3). Positions to stick additional bothsided adhesive tape for door lower window glass: (j) : 110 mm (k) : 90 mm (m) : 200 mm
Stick both-sided adhesive tape (6c) of the lower side of the front window glass along the outside edge of the lower line, differently from other bothsided adhesive tapes (6). (If it is stuck along the inside, it will be seen through the transparent part of the glass.)
5. 4) Stick both-sided adhesive tape (6) for front window glass (4) as shown in the figure.
Position the new window glass. 1) Check the clearance between the window glass and the operator's cab on the right, left, upper, and lower sides, and then adjust it evenly. 2) Stick tapes [6] between window glass (9) and operator's cab (8) and draw positioning line (n). a Stick tapes [6] to the right, left, and lower parts of the right side window glass, left side rear window glass, and door lower window glass for accurate positioning. 3) Cut the tape between window glass (9) and operator's cab (8) with a knife, and then remove the window glass. a Do not remove the tapes left on the window glass and operator's cab before installing the window glass.
10
PC600-8
SEN01069-01
1)
Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle.
When positioning front window glass (4), set its horizontal position to the frame width and set its vertical position so that height difference (p) between it and the frame top will be 3 mm.
2)
Cut the tip of the adhesive nozzle (14) so that dimensions (q) and (r) will be as follows. q Dimension (q): 10 mm q Dimension (r): 15 mm
6.
Apply adhesive. a Use either of the 2 types of the adhesive. 2 Adhesive (Summer): SUNSTAR PENGUINE SEAL 580 SUPER "S" 2 Adhesive (Winter): SUNSTAR PENGUINE SEAL 580 SUPER "W" a The using limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit. a Keep the adhesive in a dark place where the temperature is below 25C. a Never heat the adhesive higher than 30C. a When reusing the adhesive, remove the all hardened part from the nozzle tip.
3)
Set adhesive cartridge (12) to caulking gun [7]. a An electric caulking gun is more efficient.
4)
Remove the release tape of the bothsided adhesive tape on the glass side.
PC600-8
11
SEN01069-01
5)
Apply adhesive (15) to the outside of bothsided adhesive tape (6) of the operator's cab.
7. a Apply adhesive (15) to dimensions (s) and (t) of both-sided adhesive tape (6) of operator's cab (8). q Dimension (s): 10 mm q Dimension (t): 15 mm Apply adhesive (15) thicker than both-sided adhesive tape (6). Apply the adhesive evenly.
a a
Install the window glass. 1) Install window glass (9), matching it to the lines of the positioning tapes drawn in step 5. a Since the window glass cannot be removed and stuck again, stick it very carefully. a Stick the glass within 5 minutes after applying the adhesive. 2) After sticking window glass (9), press all around it until it is stuck to the both-sided adhesive tape. a Press the corners of the window glass firmly.
Apply adhesive (15) additionally for additional both-sided adhesive tape (6a) of the right side window glass and additional both-sided adhesive tape (6b) of door lower window glass.
You can perform this work efficiently by pulling window glass (9) from inside of the operator's cab with suction cup (Y1).
12
PC600-8
SEN01069-01
8.
Fix the window glass. 1) After installing right window glass (1) to the operator's cab, insert stopper rubbers (Y2) to 2 places (v) at the bottom of the glass to fix the glass.
After installing front window glass (4), fill the clearances between it and center trim seal (16) with caulking material in range (s) to dimensions (t) and (u). After applying the primer to glass (4) of section A A, apply adhesive as caulking material. q Caulking dimension (t): 2 mm q Caulking dimension (u): 5 mm a When caulking, mask the glass side and form the adhesive with a rubber spatula as shown in the figure. a Wipe off projected adhesive. 2 Glass primer: SUNSTAR GLASS PRIMER 580 SUPER 2 Adhesive: SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W" 2) Using styrene foam blocks [9] and rubber bands [10], fix the window glass and double-sided adhesive tape to fit them completely.
PC600-8
13
SEN01069-01
9.
After installing the window glass, remove the primer and adhesive from the operator's cab and window glass. a Using white gasoline, wipe off the adhesive before it is dried up. a When cleaning the glass, do not give an impact to it.
10. Protect the stuck window glass. 1) Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours (at temperature of 20C and humidity of 60%). 2) After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait at least 14 hours, at least 24 hours in total, before operating the machine actually.
14
PC600-8
SEN01069-01
Removal and installation of front window assembly 1

k
3. 4.
Release the rear locks of the cab. Lower the front window assembly carefully a little. Put out rollers (8) and (9) under the right and left sides of the front window through the portion from which the corner block was removed in step 2 (the portion where the rail is open) and hold them. Remove rollers (8) and (9) under the right and left sides of the front window.
Lower the work equipment to the ground and stop the engine. To replace the front window glass, the front window assembly must be removed from the operator's cab. The procedure for removing and installing the front window assembly (front frame and front window glass) is explained below.
5.
Removal
1. 2. Raise front window assembly (13) to the ceiling and fix it with the rear locks (right and left). Remove left corner block (1). [*1] a There is not a right corner block. a Left striker bolt (2) will be used to hang the pull-up assist cable in step 6.
PC600-8
15
SEN01069-01
6.
Remove left lower pin (10). [*2] a If left lower pin (10) is removed, plate (12) at the end of pull-up assist cable (11) comes off. a Hang plate (12) on the left striker bolt. k The return load of 58.8 N {6 kg} is applied to the rear of the operator's cab. Accordingly, take care when removing left lower pin (10) to disconnect pull-up assist cable (11).
8.
Lower front window assembly (13) completely. a Do not let the front window assembly touch the monitor. Twist front window assembly (13) to the right and left to remove both upper rollers (14) and (15) from the rails, and then remove front window assembly (13).
9.
Installation
7. Put out the bottom of front window assembly (13) through the rail opening portion and lower it gradually.
q
Carry out installation in the reverse order to removal. Adjust opening and closing of the front window assembly according to the following procedure. Open and close the front window to check that it does not interfere with the rails and the rollers are not hitch. If there is any problem in opening or closing of the front window, loosen the mounting bolts of roller adjustment brackets (16) and (17) and adjust the condition of the front window, and then tighten the mounting bolts again. 3 Mounting bolt: 34.3 Nm {3.5 kgm}
[*1]
q
1.
2.
16
PC600-8
SEN01069-01
5.
Adjust the striker bolt (Adjust the "close" lock side of the front window assembly) according to the following procedure. 1) Tighten left striker bolt (2) and right striker bolt (3) at roughly right positions so that cab-side trim seal (18) will be fitted to front window glass (19). 2) Open and close the front window assembly and check the working condition of right and left locks (20). 1] If both locks do not work normally, move the striker bolts toward the rear of the cab and tighten them again. 2] After moving the striker bolts, check the fitness of front window glass (19) and cab-side trim seal (18) which was checked in step 1). 3] Repeat the work in 1] and 2] until the fitness of the front window glass and the working condition of both locks (20) are acceptable, and then tighten the striker bolts.
3.
Raise the front window assembly and fix it with the rear locks (on both sides). a Check that the locks in the rear of the operator's cab are applied securely. Install left corner block (1). a Tighten striker bolt (2) permanently after adjusting it in step 5 below. a Install the left corner block so that there will be no level difference at rolling surface (R) of the roller. a Install left corner block (1) so that level difference (a) between it and the rail will be 0 1.0 mm.
4.
6.
After adjusting the striker bolts, splash water heavily over the front window glass and check that the water does not leak into the cab.
PC600-8
17
SEN01069-01
7.
Adjust the "open" lock side of the front window assembly. 1) After adjusting the "close" lock side of the front window in step 5, raise the front window assembly to the ceiling. 2) Check the following on the "close" lock side of the front window assemblies at the rear right and left of the operator's cab. q Check the working condition of right and left locks (20). q Check that right and left stopper rubbers (22) are in contact with the front window assembly and they have bending allowance of 1.5 3.0 mm. q Check that limit switch (23) is pushed back 4 7 mm by the front window assembly. a Since the position of limit switch (23) cannot be adjusted, the "open" position of the front window assembly is decided within the functioning range of this switch. a Limit switch (23) is installed so that the wiper will not move even if the wiper switch is turned ON by mistake while the front window assembly is "open". If the wiper operates while there is not the front glass, it will fall into the cab and break down. a To see if limit switch (23) is effective, turn the key switch ON and then turn the wiper switch ON while the front window assembly is "open". If limit switch (23) is effective, the wiper does not operate at this time. q After the above check, if the front window assembly needs to be adjusted, perform the following. 3) Close front window assembly (13). 4) Loosen striker plate (24). 5) Remove cover (25).
6)
Loosen locknuts (26) of right and left rubber stoppers (22) and move right and left rubber stoppers (22) back so that the front window assembly will not touch the right and left rubber stoppers (22) when it is "open".
7)
8)
Set the rubber stoppers so that limit switch (23) will be pushed back 4 7 mm by the front window assembly (13) (while it is "open"). Adjust the working condition of lock (20) and tighten 2 striker plate mounting bolts (27).
18
PC600-8
SEN01069-01
9)
Adjusting right and left rubber stoppers (22) 1] Bring right and left rubber stoppers (22) in contact with front window assembly (13) (while it is "open"). 2] Close front window assembly (13).
3]
4]
Rotate right and left rubber stoppers (22) to the left by 1.5 turns. a Rotating rubber stoppers (22) to the left by 1 turn is equivalent to compressing the rubber about 1.5 mm. a While the front window assembly is "open", it must compress right and left rubber stoppers (22) by 1.5 3.0 mm. Tighten locknuts (26) of right and left rubber stoppers (22).
9.
Check the latching effort of the front window assembly. 1) After finishing steps 5 8, check that latching efforts of right and left locks (20) and (21) are even. a Check the latching efforts on both "close" side (at the front of the operator's cab) and "open" side (at the rear of the operator's cab).
8.
Adjust front window assembly stopper (28). 1) Adjust and fix right and left stoppers (28) so that stoppers (D) of front window assembly (13) will be in contact with faces (c) of stoppers (28) when front window assembly (13) is pulled up.
[*2]
3 2
Left lower pin: 27 34 Nm {2.75 3.47 kgm} Mounting bolt: Adhesive (LT-2)
PC600-8
19
SEN01069-01
20
SEN01070-02
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8 PC600LC-8
Machine model
PC600-8 PC600LC-8
Serial number

Electrical system
Removal and installation of air conditioner unit assembly .............................................................................. 2 Removal and installation of engine controller assembly ................................................................................. 4 Removal and Installation of KOMTRAX terminal assembly ............................................................................ 6 Removal and installation of pump controller assembly ................................................................................... 6 Removal and installation of monitor assembly................................................................................................ 7
PC600-8
SEN01070-02
Removal and installation of air conditioner unit assembly

Removal
k k
7.
Remove ducts (10) and (11).
Disconnect the cable from the negative () terminal of the battery. If you drain the coolant or if you disconnect the heater hose when the coolant temperature in the radiator is high, you may be scalded. In this case, wait until the coolant temperature lowers and then drain the coolant or disconnect the heater hose. Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. [*1] a Ask professional traders for collecting and filling operation of refrigerant. a Never release the refrigerant to the atmosphere. k If refrigerant gets in your eyes, you may lose your sight. Accordingly, put on protective goggles, gloves and working suits with long sleeves while you are collecting the refrigerant or filling the air conditioner circuit with the refrigerant. Collecting and filling work must be conducted by a qualified person. q Refrigerant quantity: 1,260 50 g Swing the upper structure by 90. Drain the coolant.
6
1.
8.
Disconnect connectors D01 (12), D02 (13), S30 (14), R09 (15), R18 (16), R08 (16-1), R10 (16-2), and K01 (17). Remove and sling controller (18).
9.
10. Remove plate (19). 11. Disconnect air conditioner unit connectors M27 (20) and M33 (21).
2. 3.
Coolant: 58 l
4.
Remove rear covers (1), (2), (3), and (4).
12. Remove the air conditioner unit undercover. a Part (A)
5. 6.
Remove duct (5), cover (6), and plate (7). Remove plate (8) and duct (9). a Remove the duct lock clip.
PC600-8
SEN01070-02
13. Remove mounting bolt (24) and connector (25). [*1] 14. Disconnect heater hoses (22) and (23) and air conditioner hose (26). [*1] a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them.
Installation
q
Carry out installation in the reverse order to removal. a a a a When installing the air conditioner circuit hoses, take care that dirt, water, etc. will not enter them. When connecting each air conditioner hose, check that the O-ring is fitted to the joint. Check that each O-ring is free from flaw and deterioration. Coat the O-ring with compressor oil for R134a (DENSO: ND-OIL 8, ZEXEL: ZXL 100 PG (PAG 46 or equivalent)) and tighten the nuts with 2 spanners.
[*1]
15. Remove the 7 mounting bolts and air conditioner unit assembly (27). a (18): Removed controller.
Hose clamp (M6 bolt): 7.84 11.8 Nm {0.8 1.2 kgm} Hose screw of M16 x 1.5: 11.8 14.7 Nm {1.2 1.5 kgm} Hose screw of M22 x 1.5: 19.6 24.5 Nm {2.0 2.5 kgm} Hose screw of M24 x 1.5: 29.3 34.3 Nm {3.0 3.5 kgm}
Filling air conditioner circuit with refrigerant (R134a) Fill the air conditioner circuit with refrigerant (R134a). a Quantity of refrigerant: 1,260 50 g Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again.
5
Coolant: 58 l
PC600-8
SEN01070-02
Removal and installation of engine controller assembly

Removal
k
5.
1
6.
Disconnect connector (8). a Use a hexagonal wrench of 4 mm. Remove engine controller assembly (9). [*1]
Disconnect the cable from the negative () terminal of the battery. Remove cover (1).
1.
2.
Remove controller cover (2).
3.
Disconnect connectors CE02 (3) and CE03 (4). a Use a hexagonal wrench of 4 mm. Disconnect clamps (5).
4.
PC600-8
SEN01070-02
Installation
q
[*1] When connecting connectors (3), (4), and (8), check that there is no dust, dirt, etc. in them. Reference Method of replacing O-ring seal of power connector (4) O-ring seal: 1010-074-0406 (NIHON-DEUTSCH LIMITED) 1) Using tweezers [1], hold the claw and remove cover (6).
2)
Using tweezers [1], remove O-ring (7).
PC600-8
SEN01070-02
Removal and Installation of KOMTRAX terminal assembly

Removal
k
Removal and installation of pump controller assembly 1

Removal
k
Disconnect the negative () terminal of battery. Remove covers (1), (2), and (3).
Disconnect the cable from the negative () terminal of the battery. Remove covers (1), (2), and (3).
1.
1.
2. 3. 4.
Disconnect GPS connector (4) and antenna wire (5). Disconnect connector G01 (6). Remove 4 mounting bolts and KOMTRAX terminal assembly (7). remove
2. 3.
Disconnect pump controller wiring connectors C01 (4), C02 (5), and C03 (6). Remove the 4 mounting bolts and pump controller assembly (7).
Installation Installation
q q
PC600-8
SEN01070-02
Removal and installation of monitor assembly

Removal
k
Installation
Disconnect the cable from the negative () terminal of the battery. Remove cover (1) and disconnect wiring connector P15 of air conditioner sunlight sensor (2). a Raise and remove the cover. Remove the 3 mounting screws and monitor assembly (3). a Disconnect monitor panel wiring connectors P01, P02, and P70 before removing the monitor assembly.
1.
2.
PC600-8
SEN01070-02
SEN00144-02
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8
90 Diagrams and drawings

Hydraulic diagrams and drawings
Hydraulic circuit diagram (1/3) (Backhoe specification).................................................................................. 3 Hydraulic circuit diagram (2/3) (Loading shovel specification) ....................................................................... 5 Hydraulic circuit diagram (3/3) (Loading shovel specification) ....................................................................... 7
PC600-8
SEN00144-02
PC600-8
Hydraulic circuit diagram (1/3) (Backhoe specification)
Hydraulic circuit diagram (1/3) PC600, 600LC-8
SEN00144-02 PC600-8
Hydraulic circuit diagram (2/3) (Loading shovel specification)
SEN00144-02 PC600-8
Hydraulic circuit diagram (3/3) (Loading shovel specification)
SEN00144-02 PC600-8
SEN00144-02
PC600-8
SEN00144-02
2008 KOMATSU All Right Reserved Printed in Japan 05-08 (01)
10
SEN00145-04
HYDRAULIC EXCAVATOR
PC600-8 PC600LC-8

Electrical diagrams and drawings
Electrical circuit diagram (1/6) ........................................................................................................................ 3 Electrical circuit diagram (2/6) ........................................................................................................................ 5 Electrical circuit diagram (3/6) ........................................................................................................................ 7 Electrical circuit diagram (4/6) ........................................................................................................................ 9 Electrical circuit diagram (5/6) .......................................................................................................................11 Electrical circuit diagram (6/6) ...................................................................................................................... 13 Connector arrangement diagram.................................................................................................................. 15 Electrical circuit diagram for air conditioner .................................................................................................. 17
PC600-8
SEN00145-04
PC600-8
Electrical circuit diagram (1/6)
Electrical circuit diagram (1/6) PC600, 600LC-8
SEN00145-04 PC600-8
SEN00145-04 PC600-8
SEN00145-04 PC600-8
SEN00145-04 PC600-8
SEN00145-04 PC600-8
11
SEN00145-04 PC600-8
13
Connector arrangement diagram

Connector No. A01 A02 A03 A05 A06 A07 A09 A10 A11 A13 A15 A16 A26 B01 B02 B03 B11 B12 B13 B14 B15 B16 B17 B18 B19 B21 B22 B23 B24 B25 B26 B27 B28 B29 BP CE02 CE03 CM01 CM02 CM03 CN1 CN2 CN3 CN4 CN5 CN6 CP01 CP02 CP03 D01 D02 D03 D04 E22 EGR ENG F01 G G01 G02 G03 G04 G05 H01 H02 H03 H04 H05 H06 H07 H08 H09 J01 J02 J03 J04 J05 J06 J07 J08 J11 J12 J13 J14 J15 J16 J17 J18 J19 J20 J21 J22 J23 J24 J25 J26 J27 J28 J1939 JM01 JM02 JM03 JM04 JM05 JM06 JM07 JM08 K01 K01 K02 K03 L01 L02 L03 L04A L04B L05 L06
PC600-8
Connector arrangement diagram PC600, 600LC-8
Model X X DT DT DT SWP SWP DT DT DT X DT X HD30 DT DT Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal DT-T DRC DRC 70 40 40 DT DT DT DT DT DT DRC OTP DRC SWP SWP SWP SWP DT DT-T DRC SUMITOMO X X X X M S S S S S090 M
Number of pins 4 4 12 12 12 16 8 6 6 2 2 2 2 21 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 50 4 12 20 16 2 2 2 2 2 2 24 40 40 8 8 8 8 6 2 60 20 2 1 1 1 1 8 8 16 16 12 20 1
Component name Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector (To boom working lamp) Intermediate connector (Flash light) Intermediate connector (To fan reverse solenoid) Intermediate connector (Travel pressure switch) Intermediate connector (Circuit breaker) Intermediate connector (Circuit breaker) Intermediate connector (Circuit breaker) Circuit breaker (1) Circuit breaker (2) Circuit breaker (3) Circuit breaker (4) Circuit breaker (5) Circuit breaker (6) Circuit breaker (7) Circuit breaker (8) Circuit breaker (9) Circuit breaker (1) Circuit breaker (2) Circuit breaker (3) Circuit breaker (4) Circuit breaker (5) Circuit breaker (6) Circuit breaker (7) Circuit breaker (8) Circuit breaker (9) Bypass valve Engine controller Engine controller Machine monitor Machine monitor Machine monitor Injector #1 Injector #2 Injector #3 Injector #4 Injector #5 Injector #6 Pump controller Pump controller Pump controller Assembled-type diode Assembled-type diode Assembled-type diode Assembled-type diode Intermediate connector EGR valve Engine controller Fuse G sensor Inspection connector Inspection connector Inspection connector Inspection connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector
Address of stereogram W-1 W-1 Q-2 W-1 Q-1 V-1 Q-2 R-1 F-1 D-9 D-1 G-9 Q-1 A-7 C-9 B-9 K-2 K-2 K-1 L-4 L-1 L-1 M-4 M-3 M-1 K-3 K-3 K-2 L-4 M-3 L-1 M-4 M-3 M-2 AI-7 I-8 J-8 Q-6 Q-5 Q-5 AI-6 AK-9 AI-6 AI-3 AI-3 AN-7 Y-9 X-9 X-9 AB-2 AB-2 U-1 T-1 J-6 AJ-8 AK-2 X-2 AI-4 Z-9 Y-9 Y-9 Z-9 Z-9 AE-9 W-9 V-9 V-9 Q-7 W-1 AA-6 AA-5 Y-2 Y-3 Y-3 Z-3 Z-3 Z-3 Z-3 AA-4
Connector Number Model No. of pins L07 DT 2 M01 PA 9 M02 KES0 2 M03 KES0 2 M04 YAZAKI 2 M05 M 6 M06 KES 2 M07A Terminal 1 M07B Terminal 1 M08A Terminal 1 M08B Terminal 1 M09 M 2 M10 M 2 M11 M 3 M12 M 2 M13 M 2 M14 D 2 M15 M 6 M16 X 2 M23 Terminal 1 M26 S 12 M27 18 M29 20 M30 16 M33 4 M34 X 1 N01 90 4 N02 DT 12 NE FRAMATOME 2 P01 AMP 3 P02 X 2 P03 X 2 P04 AMP 3 P05 X 2 P06 X 2 P08 X 2 P09 X 2 P13 X 2 P17 2 P20 M 2 P21 DT 2 P22 DT 2 P23 DT 2 P24 DT 2 P25 DT 3 P26 DT 3 P29 DT 2 P31 Y050 2 P44 DT 2 PAMB FRAMATOME 3 PCV1 SUMITOMO 2 PCV2 SUMITOMO 2 PEVA PFUEL PIM POIL R01 R02 R03 R04 R05 R06 R07 R08 R09 R10 R15 R16 R17 R18 R30 R31 RES S01 S02 S04 S05 S06 S07 S08 S10 S11 S12 S13 S14 S21 S22 S25 S30 SBP SEGR ST T01 T02 T04 T05 T06 T07 T08 T09 T10 TETR TFUEL TIM TWTR V01 V03 V04 V05 V06 V07 V08 V11 V13 V17 V20 V21 FRAMATOME AMP AMP SUMITOMO Terminal Terminal Terminal Terminal Relay Relay Relay Relay Relay Relay Terminal Terminal Terminal Relay Relay DT Terminal M M M M M M Y090 Y090 Y090 M M Terminal Terminal 90 S DT DT DT Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal PACKARD PACKARD PACKARD DT DT DT DT DT DT DT DT DT DT DT DT 4 3 3 3 1 1 1 1 5 5 5 5 5 5 1 1 1 5 5 4 2 6 3 4 2 3 2 2 2 2 2 2 2 6 6 16 8 4 4 2 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Component name Flash light (If equipped) Radio Speaker (Left) Speaker (Right) Cigarette lighter Wiper motor Window washer motor Horn (High tone) Horn (High tone) Horn (Low tone) Horn (Low tone) Optional power supply Intermediate connector (Optional power supply) DC/DC converter 12V socket 12V socket Travel alarm Lower wiper Electric grease gun Intake air heater Intermediate connector (Air conditioner) Air conditioner unit Auto air conditioner control unit Auto air conditioner control unit Air conditioner unit Air conditioner compressor electromagnetic clutch Boot program Network bus NE sensor Bucket curl pressure switch Boom lower pressure switch Swing pressure switch Arm IN pressure switch Bucket dump pressure switch Boom raise pressure switch Arm OUT pressure switch Travel pressure switch Bottom dump switch (For loading shovel) Air conditioner high/low pressure switch Fuel control dial Fuel level sensor Hydraulic oil temperature sensor Air cleaner clogging sensor Radiator coolant level sensor Front pump pressure sensor Rear pump pressure sensor Ambient temperature sensor (Intake air temperature) Daylight sensor Engine oil level switch Ambient pressure sensor Supply pump 1 Supply pump 2 EG valve inlet pressure sensor (PEVA is abolished after engine serial number 530885) Common rail pressure Boost pressure Engine oil pressure sensor Battery relay (E) terminal Battery relay (BR) terminal Battery relay (M) terminal Battery relay (B) terminal Light relay Starting motor cutout relay (PPC lock) Starting motor cutout relay (Personal code) Horn relay Step light relay Flash light relay (If equipped) Intake air heater relay (Inlet) Intake air heater relay (Outlet) Intake air heater relay (Drive coil inlet) Intake air heater relay drive relay Blower relay Compressor relay Resistor (620z) Starting switch Light switch Swing lock switch Machine pushup switch Boom shockless switch Rotary lamp switch Lower wiper switch Horn switch Knob switch Rear limit switch Step light switch PPC oil pressure lock switch Emergency pump drive switch Swing holding brake release switch Intermediate connector (To right console emergency switch) Model selector connector Bypass valve EGR valve position sensor Starting motor S, R circuit Floor frame ground Cab ground Revolving frame ground Revolving frame ground Revolving frame ground Revolving frame ground Revolving frame ground Engine body ground Revolving frame ground Fuel temperature sensor Boost temperature sensor Coolant temperature sensor PPC basic pressure lock solenoid Bucket high cancel solenoid Travel high/low selector solenoid Swing holding brake solenoid Boom head 2-stage safety valve solenoid (Machine pushup) CO cancel solenoid 2-stage relief solenoid TVC solenoid Fan pump EPC solenoid Fan reverse solenoid Bottom dump close (For loading shovel) Bottom dump open (For loading shovel)
Address of stereogram X-2 AH-8 AG-8 Q-3 AC-4 H-1 C-1 C-1 B-2 B-2 AA-5 AA-6 AA-6 AA-7 AA-8 J-5 D-1 A-6 J-7 AA-4 AA-6
AA-5 J-7 AA-7 AM-2 H-1 I-9 H-9 I-8 J-2 I-2 G-9 S-1 H-1 U-1 R-8 A-6 J-4 H-9 J-6 H-9 H-9 G-9 Q-5 J-8 AK-1 AI-5 AI-5 AK-9 AJ-2 AN-5 AJ-2 M-8 K-8 L-9 M-9 R-8 S-8 T-9 Z-2 Z-2 Z-1 M-7 M-7 K-7 Z-2 AA-7 AA-4 AL-8 Q-7 S-8 S-9 T-9 X-2 X-2 Q-7 V-1 AF-9 F-1, AH-2 V-1 U-9 U-9 T-9 Z-2 AI-7 AI-8 Y-3 AH-3 B-2 A-2 A-3 A-3 A-4 J-7 C-1 AN-4 AN-6 AN-7 G-1 H-1 F-9 F-9 D-9 E-9 E-9 J-4 J-6
J J J J J J J J Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal DT Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal DRC M DT DT DT DT M YAZAKI YAZAKI YAZAKI YAZAKI
20 20 20 20 20 20 20 20
3 6 6 10 4 3 3 4 6 40 2 3 3 2 2 2 2 2 2 2
Joint connector (Black) Joint connector (Black) Joint connector (Green) Joint connector (Green) Joint connector (Pink) Joint connector (Orange) Joint connector (Orange) Joint connector (Pink) Centralized terminal (Horn signal) Centralized terminal (Horn signal) Centralized terminal Centralized terminal Centralized terminal Centralized terminal Centralized terminal Centralized terminal Centralized terminal Centralized terminal Centralized terminal Centralized terminal Centralized terminal Centralized terminal Centralized terminal Centralized terminal Centralized terminal Centralized terminal CAN connector Centralized terminal (Engine) Centralized terminal (Engine) Centralized terminal (Engine) Centralized terminal (Engine) Centralized terminal (Engine) Centralized terminal (Engine) Centralized terminal (Engine) Centralized terminal (Engine) KOMTRAX (If equipped) Resistor (30z) CAN terminal resistance CAN terminal resistance Working lamp (Boom) Right headlamp Room light Headlamp Headlamp Rotary lamp (If equipped) Step light
F-1 E-1 E-1 D-1
D-1 I-2
AL-8 AM-1 AL-1 AL-1 AN-3 AN-4 AM-8 AM-8 Y-9 Z-1 Q-4 A-5 AE-8 AD-7 AC-7 AD-8
SEN00145-04
15
Electrical circuit diagram for air conditioner
Electrical circuit diagram for air conditioner PC600, 600LC-8
SEN00145-04 PC600-8
17
SEN00145-04
PC600-8
19
SEN00145-04
2008 KOMATSU All Right Reserved Printed in Japan 08-08 (01)
20

SM PC600 (LC) - 8 30001-Up Sen00128-12

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SM PC600 (LC) - 8 30001-Up Sen00128-12

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SEN00128-12

PC600- 30001 PC600LC- 30001

00 Index and foreword

00 Index and foreword

Composition of shop manual

00 Index and foreword

00 Index and foreword

00 Index and foreword

00 Index and foreword

00 Index and foreword

00 Index and foreword

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PC600, 600LC-8 Hydraulic excavator Form No. SEN00130-12

2009 KOMATSU All Rights Reserved Printed in Japan 07-09

Machine model PC600-8 PC600LC-8

Serial number 30001 and up 30001 and up

00 Index and foreword

00 Index and foreword

6 Safety check before starting work 7 8

9 Good physical condition and preparation 10

00 Index and foreword

00 Index and foreword

00 Index and foreword

00 Index and foreword

Example of O-ring (Fitted to every joint of hoses and tubes)

00 Index and foreword

How to read the shop manual

00 Index and foreword

00 Index and foreword

Explanation of terms for maintenance standard

Example: Standard size 120 a

Tolerance 0.022 0.126

Example: Standard size 60 Tolerance Shaft Hole 0.030 +0.046 0.076 +0

00 Index and foreword

00 Index and foreword

Handling of electric equipment and hydraulic component

00 Index and foreword

00 Index and foreword

00 Index and foreword

00 Index and foreword

Connection (Example of incomplete setting of (a))

00 Index and foreword

00 Index and foreword

00 Index and foreword

00 Index and foreword

00 Index and foreword

Handling of connectors newly used for engines

00 Index and foreword

00 Index and foreword

00 Index and foreword

How to read electric wire code

Heat-resistant low-voltAEX age wire for automobile

00 Index and foreword

8 50/0.45 7.95 3.7 5.5 5.3

15 84/0.45 13.36 4.8 7.0 7.0

20 41/0.80 20.61 6.0 8.2 8.2

30 70/0.80 35.19 8.0 10.8 10.8

40 85/0.80 42.73 8.6 11.4 11.4

f of nominal No. denotes flexible.