SM PC600LC 8 30001 UP SEN00128 16 Comprimido

SEN00128-16
HYDRAULIC PC600 -8
EXCAVATOR
PC600LC -8
PC600- 30001
SERIAL NUMBERS and up
PC600LC- 30001
SEN00130-16
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model Serial number
PC600-8 30001 and up

PC600LC-8 30001 and up
00 Index and foreword

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

Table of contents .................................................................................................................................................. 4
PC600-8 1
SEN00130-16 00 Index and foreword
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 Form Number
Shop Manual, contents binder, binder label and tabs SEN00128-16
00 Index and foreword SEN00129-16

Index SEN00130-16 q
Foreword and general information SEN00131-04
01 Specification SEN00132-03
Specification and technical data SEN00133-03
10 Structure, function and maintenance standard SEN00134-08

Engine and cooling system SEN00135-02
Power train SEN00136-01
Undercarriage and frame SEN00137-01
Hydraulic system, Part 1 SEN00138-01
Work equipment SEN00140-03
Cab and its attachments SEN00141-00
Electrical system SEN00142-05
20 Standard value table SEN00394-04

Standard service value table SEN00395-04
30 Testing and adjusting SEN00443-04

Testing and adjusting, Part 1 SEN00444-04
40 Troubleshooting SEN00446-06
Failure code table and fuse locations SEN03960-04
General information on troubleshooting SEN00447-04
Troubleshooting by failure code (Display of code), Part 1 SEN00448-03
Troubleshooting of electrical system (E-mode) SEN00451-03
Troubleshooting of hydraulic and mechanical system (H-mode) SEN00452-02
Troubleshooting of engine (S-mode) SEN00453-02
2 PC600-8
50 Disassembly and assembly SEN01061-06

General information on disassembly and assembly SEN01062-04
Engine and cooling system, Part 1 SEN01063-02
Undercarriage and frame SEN01066-04 q
Hydraulic system SEN01067-03
90 Diagrams and drawings SEN00143-05

Hydraulic diagrams and drawings SEN00144-03
Electrical diagrams and drawings SEN00145-04
PC600-8 3
Table of contents
00 Index and foreword
Index SEN00130-16
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
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 ....................................................................................................................................... 2
Power train.................................................................................................................................... 2
Final drive ..................................................................................................................................... 5
Sprocket........................................................................................................................................ 8
Swing circle................................................................................................................................... 10
Swing machinery .......................................................................................................................... 12
Undercarriage and frame ................................................................................................................. 2
Track frame, recoil spring ............................................................................................................. 2
Idler............................................................................................................................................... 4
Carrier roller.................................................................................................................................. 6
Track roller .................................................................................................................................... 7
Track shoe .................................................................................................................................... 8
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
4 PC600-8

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 ............................................................................................................................... 2
Work equipment............................................................................................................................ 2
Dimensions of work equipment .................................................................................................... 6
Cab and its attachments................................................................................................................... 2
Air conditioner piping .................................................................................................................... 2
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

Tools for testing, adjusting and troubleshooting ........................................................................... 4
Measuring engine speed .............................................................................................................. 7
Measuring intake air pressure (boost pressure) ........................................................................... 8
Measuring exhaust gas temperature ............................................................................................ 9
Measuring exhaust gas color........................................................................................................ 10
Adjusting valve clearance ............................................................................................................. 11
Measuring compression pressure ................................................................................................ 12
Measuring blow-by pressure ........................................................................................................ 14
Measuring engine oil pressure ..................................................................................................... 14
Testing EGR valve and bypass valve drive oil pressure ............................................................... 15
Handling equipment in fuel circuit................................................................................................. 16
Releasing remaining pressure in fuel system ............................................................................... 16
Measuring fuel pressure ............................................................................................................... 17
PC600-8 5
Reduced cylinder mode operation ................................................................................................ 18

No-injection cranking .................................................................................................................... 18
Testing leakage from pressure limiter and return rate from injector.............................................. 19
Bleeding air from fuel circuit ......................................................................................................... 21
Testing fuel system for leakage .................................................................................................... 23
Testing and adjusting alternator belt tension ................................................................................ 24
Testing and adjusting air conditioner compressor belt tension ..................................................... 25
Testing clearance of swing circle bearing ..................................................................................... 26
Testing and adjusting track shoe tension...................................................................................... 27
Testing and adjusting work equipment, swing, and travel circuit oil pressures............................. 28
Testing and adjusting control circuit oil pressure .......................................................................... 33
Testing and adjusting piston pump control oil pressure ................................................................ 35
Testing servo piston stroke ........................................................................................................... 41
Measuring PPC valve output pressure ......................................................................................... 42
Measuring outlet pressures of solenoid valve and PPC shuttle valve .......................................... 46
Adjusting work equipment, swing PPC valve................................................................................ 52
Testing and adjusting travel deviation........................................................................................... 53
Measuring fan speed .................................................................................................................... 55
Measuring fan circuit oil pressure ................................................................................................. 55
Inspection of locations of hydraulic drift of work equipment ......................................................... 56
Measuring oil leakage................................................................................................................... 57
Releasing remaining pressure in hydraulic circuit ........................................................................ 61
Bleeding air from each part........................................................................................................... 62
Inspection procedures for diode ................................................................................................... 65
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 SEN03960-04
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
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
6 PC600-8
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
Failure code [CA322] Inj #1 (L#1) Open/Short Error .................................................................... 4
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 7
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
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 [DA22KK] Pump Solenoid Power Low Error ............................................................ 10
Failure code [DA25KP] Press. Sensor Power Abnormality .......................................................... 12
Failure code [DA2SKQ] Model Selection Abnormality.................................................................. 14
Failure code [DA80MA] Auto. Lub Abnormal................................................................................ 16
Failure code [DA2RMC] Pump Comm. Abnormality..................................................................... 18
Failure code [DAFRMC] Monitor Comm. Abnormality .................................................................. 20
Failure code [DGE5KY] Ambi. Temp. Sensor S/C ........................................................................ 22
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C ................................................................... 23
Failure code [DHPAMA] F pump P. Sensor Abnormality .............................................................. 24
Failure code [DHPBMA] R pump P. Sensor Abnormality.............................................................. 26
Failure code [DV20KB] Travel Alarm S/C ..................................................................................... 28
Failure code [DW43KA] Travel Speed Sol. Disc. .......................................................................... 30
Failure code [DW43KB] Travel Speed Sol. S/C ............................................................................ 32
Failure code [DW45KA] Swing Brake Sol. Disc............................................................................ 34
Failure code [DW45KB] Swing Brake Sol. S/C............................................................................. 36
Failure code [DW48KA] CO Cancel Sol. Disc. ............................................................................. 38
Failure code [DW48KB] CO Cancel Sol. S/C ............................................................................... 40
Failure code [DW7BKA] Fan Reverse Sol. Disc. .......................................................................... 42
Failure code [DW7BKB] Fan Reverse Sol. S/C ............................................................................ 43
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc. ........................................................... 44
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C ............................................................. 46
Failure code [DWK0KA] 2-stage Relief Sol. Disc. ........................................................................ 48
Failure code [DWK0KB] 2-stage Relief Sol. S/C .......................................................................... 50
Failure code [DX16KA] Fan Pump EPC Sol. Disc. ....................................................................... 52
Failure code [DX16KB] Fan Pump EPC Sol. S/C ......................................................................... 54
Failure code [DXA0KA] TVC Sol. Disc. ........................................................................................ 56
Failure code [DXA0KB] TVC Sol. S/C .......................................................................................... 58
Failure code [DY20KA] Wiper Working Abnormality..................................................................... 60
Failure code [DY20MA] Wiper Parking Abnormality ..................................................................... 62
Failure code [DY2CKB] Washer Drive S/C ................................................................................... 66
Failure code [DY2DKB] Wiper Drive (For) S/C ............................................................................. 68
Failure code [DY2EKB] Wiper Drive (Rev) S/C ............................................................................ 72
Troubleshooting of electrical system (E-mode) SEN00451-03
Before carrying out troubleshooting E-mode ................................................................................ 4
Information contained in troubleshooting table ............................................................................. 6
E-1 Engine does not start (Engine does not rotate)...................................................................... 8
E-2 Preheater does not operate ................................................................................................... 12
E-3 Auto engine warm-up device does not work .......................................................................... 14
E-4 Auto-decelerator does not operate......................................................................................... 15
E-5 All work equipment, swing and travel do not move ................................................................ 16
E-6 Power max. function does not operate................................................................................... 18
E-7 Machine push-up function does not operate normally ........................................................... 19
E-8 Any item is not displayed on machine monitor....................................................................... 21
E-9 Part of display on machine monitor is missing ....................................................................... 22
E-10 Machine monitor displays contents irrelevant to the model ................................................. 22
E-11 Fuel level monitor red lamp lights up while engine is running .............................................. 23
E-12 Engine coolant temperature gauge does not display correctly ............................................ 24
E-13 Hydraulic oil temperature gauge does not display correctly................................................. 26
8 PC600-8
E-14 Fuel gauge does not display correctly ................................................................................. 27

E-15 Swing lock monitor does not display correctly ..................................................................... 28
E-16 When monitor switch is operated, nothing is displayed ....................................................... 30
E-17 Wiper and window washer do not work ............................................................................... 32
E-18 "Boom Raise" is not correctly displayed in monitoring function ........................................... 40
E-19 "Boom Lower" is not correctly displayed in monitoring function........................................... 42
E-20 "Arm IN" is not correctly displayed in monitoring function.................................................... 44
E-21 "Arm OUT" is not correctly displayed in monitoring function................................................ 45
E-22 "Bucket CURL" is not correctly displayed in monitoring function ......................................... 46
E-23 "Bucket DUMP" is not correctly displayed in monitoring function ........................................ 47
E-24 "Swing" is not correctly displayed in monitoring function ..................................................... 48
E-25 "Travel" is not correctly displayed in monitoring function ..................................................... 50
E-26 Air conditioner does not work............................................................................................... 52
E-27 Step light does not light up or go off..................................................................................... 54
E-28 Electric grease gun does not operate .................................................................................. 58
E-29 Travel alarm does not sound or does not stop sounding ..................................................... 60
E-30 Horn does not sound............................................................................................................ 62
E-31 Bottom dump does not move ............................................................................................... 64
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
PC600-8 9
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
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
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
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
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
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
10 PC600-8
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
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
Removal and installation of operator’s cab................................................................................... 2
Removal and installation of operator’s cab glass (stuck glass) .................................................... 5
Removal and installation of front window assembly ..................................................................... 15
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 SEN00144-03
Hydraulic circuit diagram (1/4) (Backhoe specification)................................................................ 3
Hydraulic circuit diagram (2/4) (ATT specification) ....................................................................... 5
Hydraulic circuit diagram (3/4) (Loading shovel specification)...................................................... 7
Hydraulic circuit diagram (4/4) (Loading shovel specification)...................................................... 9
Electrical diagrams and drawings SEN00145-04
Electrical circuit diagram (1/6) ...................................................................................................... 3
Connector arrangement diagram.................................................................................................. 15
Electrical circuit diagram for air conditioner .................................................................................. 17
PC600-8 11
PC600, 600LC-8 Hydraulic excavator
Form No. SEN00130-16
©2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11
12
SEN00131-04
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8
PC600LC-8
PC600-8 30001 and up

00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling 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 1
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
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, fork-
lift, service car, etc.
2 PC600-8
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
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 parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, 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
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l 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
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
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.
PC600-8 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is 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.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 PC600-8
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
PC600-8 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 PC600-8
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
PC600-8 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

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

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 PC600-8
Explanation of terms for maintenance standard 1

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

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

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

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
PC600-8 9
2. Standard clearance and standard value 5. Clearance limit

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

able 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 prod-
uct 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 vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 PC600-8
Handling of electric equipment and hydraulic component 1

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

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

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

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
PC600-8 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

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

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 PC600-8
3. Removing, installing, and drying connec-

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

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

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

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
PC600-8 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 PC600-8
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
PC600-8 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
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 con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 PC600-8
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
PC600-8 17
Points to remember when handling hydraulic equipment

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

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

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

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 PC600-8
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
PC600-8 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
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 fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 PC600-8
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

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

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

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

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
PC600-8 21
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
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 PC600-8
How to read electric wire code 1

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

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

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

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
PC600-8 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 PC600-8
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
PC600-8 25
Precautions when carrying out operation 1

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

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

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 PC600-8
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
PC600-8 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 PC600-8
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC600-8 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 PC600-8
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
PC600-8 31
Standard tightening torque table 1

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

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 PC600-8
2. Table of tightening torques for split flange bolts

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

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

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

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

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

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
PC600-8 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 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).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
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.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 PC600-8
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 Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
PC600-8 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

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

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

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 PC600-8
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC600-8 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 PC600-8
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC600-8 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 PC600-8
PC600-8 41
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)
42
SEN00133-03
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up

01 Specification
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 1
SEN00133-03 01 Specification

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

Working ranges Unit PC600-8 PC600LC-8
A Max. digging reach mm 13,020 13,020

B Max. digging depth mm 8,490 8,490
C Max. digging height mm 11,880 11,880
D Max. vertical wall digging depth mm 7,510 7,510
E Max. dumping height mm 7,960 7,960
F Max. digging reach at ground level mm 12,800 12,800
4 PC600-8
PC600-8 PC600LC-8
Working ranges Unit
A Max. digging reach mm 9,190 9,190
B Max. digging reach at ground level mm 8,850 8,850
C Max. digging height mm 10,090 10,090
D Max. digging depth mm 3,495 3,495
E Min. digging radius at ground level mm 5,135 5,135
Min. turning radius of work
F mm 5,515 5,515
equipment
PC600-8 5
Specifications
PC600-8
Machine model PC600-8
Serial number 30001 and up

Bucket capacity m3 2.7
Weight of machine kg 57,300
Max. digging depth mm 8,490
Working ranges
Max. vertical wall depth mm 7,510

Max. digging reach mm 13,020
Max. reach at ground level mm 12,800
Max. digging height mm 11,880
Max. dumping height mm 7,960
Performance
Max. digging force kN {kg} 294.3 {30,000}

(using power max. function) (316.9 {32,300})
Swing speed rpm 8.3
Swing max. slope angle deg. 17
Travel speed km/h Low speed: 3.0
High speed: 4.9
Gradeability deg. 35
2
Ground pressure (standard triple kPa {kg/cm } 102 {1.04}
grouser shoe width: 600 mm)
Overall length (for transport) mm 12,910
Overall width mm 3,195
Overall width of track mm 3,900
Overall height (for transport) mm 4,300
Overall height to top of cab mm 3,435
Ground clearance of mm 1,365
counterweight
Dimensions
Min. ground clearance mm 780

Tail swing radius mm 3,900
Min. swing radius of work mm 5,370
equipment
Height of work equipment mm 10,020
at min. swing radius
Length of track on ground mm 4,250
Track gauge mm 3,300
Height of machine cab mm 3,070
6 PC600-8
Machine model PC600-8

Model KOMATSU SAA6D140E-5
Type 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler (air cooled)
No. of cylinders – bore × stroke mm 6 – 140 × 165
Piston displacement l {cc} 15.24 {15,240}
Performance
Flywheel horsepower kW/rpm {HP/rpm} 323/1,800 {432/1,800}

Engine
Max. torque Nm/rpm {kgm/rpm} 1,944/1,400 {198.4/1,400}

Max. speed at no load rpm 1,950
Min. speed at no load rpm 800
Starting motor 24V, 11 kW

Alternator 24V, 50A
Battery 12V, 175 Ah × 2
Radiator core type CF68-4
Fan system Undercarriage
Carrier roller 3 on each side
Track roller 8 on each side
Track shoe Assembly-type triple grouser, 49 on each side
Fan pump Type Variable swash plate type: LPV75
Type Fixed swash plate type: LMF75

Fan motor
Set pressure MPa {kg/cm2} 24.5 {250}
Hydraulic motor Control valve Hydraulic pump
Type × No. Variable displacement piston type: HPV95+95 × 2,

piston + gear type: LPV75 + SAL(2)56 + (2)8
Delivery l /min Piston type: 410 × 2, gear type: 137
Set pressure MPa {kg/cm2} Piston type: 34.3 {350}, gear type: 2.9 {30}
Hydraulic system
Type × No. 4-spool + 5-spool type × 1
Control method Hydraulic
Travel motor KMV335ADT, Piston type

(with brake valve, shaft brake): × 2
Swing motor KMF90ABE-3, Piston type

(with safety valve, shaft brake, reverse prevention valve): × 2
Boom Arm Bucket

Double-acting Double-acting Double-acting
Type
Hydraulic cylinder
piston piston piston

Inside diameter of cylinder mm 185 200 185
Hydraulic system
Diameter of piston rod mm 120 140 130

Stroke mm 1,725 2,045 1,425
Max. distance between pins mm 4,182 4,933 3,577
Min. distance between pins mm 2,457 2,888 2,152
Hydraulic tank Box-shaped, sealed
Hydraulic filter Tank return side
Hydraulic cooler CF42-1 (Air cooled)
PC600-8 7
PC600LC-8
Machine model PC600LC-8

Bucket capacity m3 2.7
Working ranges
Max. vertical wall depth mm 7,510

Performance
Max. digging force kN {kg} 294.3 {30,000}
(using power max. function) (316.9 {32,300})
Swing speed rpm 8.3
Swing max. slope angle deg. 17
High speed: 4.9
Ground pressure (standard triple kPa {kg/cm2} 96 {0.98}

counterweight
Dimensions
equipment
8 PC600-8
Machine model PC600LC-8

Performance

Engine


Alternator 24V, 50A
Track shoe Assembly-type triple grouser, 52 on each side

Fan motor
Set pressure MPa {kg/cm2} 24.5 {250}

Hydraulic system


Boom Arm Bucket

Double-acting Double-acting Double-acting
Type
Hydraulic cylinder
piston piston piston

Inside diameter of cylinder mm 185 200 185
Hydraulic system
Diameter of piston rod mm 120 140 130

Stroke mm 1,725 2,045 1,425
Max. distance between pins mm 4,182 4,933 3,577
Min. distance between pins mm 2,457 2,888 2,152
PC600-8 9

PC600-8
PC600-8
Machine model
3
Bucket capacity m 4.0
Working ranges
Max. vertical wall depth mm —

Performance

Max. digging force kN {kg} 386 {39,400}
Swing speed rpm 8.3
Swing max. slope angle deg. 15.5
High speed: 4.9
2
counterweight
Dimensions

equipment
10 PC600-8
PC600-8
Machine model
Performance

Engine

Alternator 24V, 50A
Track shoe Assembly-type double grouser, 49 on each side

Fan motor
2
Set pressure MPa {kg/cm } 24.5 {250}
Hydraulic system


Boom Arm Bucket Bottom dump

Double-acting Double-acting Double-acting Double-acting
Type
Hydraulic cylinder
piston piston piston piston

Inside diameter of cylinder mm 185 200 160 140
Hydraulic system
Diameter of piston rod mm 130 140 110 90

Stroke mm 1,410 1,500 1,400 335
Max. distance between pins mm 4,147 3,878 3,750 1,235
Min. distance between pins mm 2,737 2,378 2,350 900
PC600-8 11
PC600LC-8
PC600LC-8
Machine model
3
Bucket capacity m 4.0
Working ranges
Max. vertical wall depth mm —

Performance

Max. digging force kN {kg} 386 {39,400}
Swing speed rpm 8.3
Swing max. slope angle deg. 15.5
High speed: 4.9
2
counterweight
Dimensions

equipment
12 PC600-8
PC600LC-8
Machine model
Performance

Engine

Alternator 24V, 50A
Track shoe Assembly-type double grouser, 52 on each side

Fan motor
2
Set pressure MPa {kg/cm } 24.5 {250}
Hydraulic system


Boom Arm Bucket Bottom dump

Double-acting Double-acting Double-acting Double-acting
Type
Hydraulic cylinder
piston piston piston piston

Inside diameter of cylinder mm 185 200 160 140
Hydraulic system
Diameter of piston rod mm 130 140 110 90

Stroke mm 1,410 1,500 1,400 335
Max. distance between pins mm 4,147 3,878 3,750 1,235
Min. distance between pins mm 2,737 2,378 2,350 900
PC600-8 13
Weight table
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model PC600-8 PC600LC-8
Serial number 30001 and up 30001 and up
Engine assembly 2,610 2,610

• Engine 1,965 1,965
• PTO (incl. lubricating piping) 285 285
• Hydraulic pump 305 305
• Fan, control and PTO lubrication pump 55 55
Radiator, oil cooler assembly 268 268
Hydraulic tank, filter assembly (excl. hydraulic oil) 455 455
Fuel tank (excl. fuel) 520 520
Revolving frame 4,640 4,640
Operator's cab 280 280
Operator's seat 35 35
Counterweight 10,750 10,750
Swing machinery 743 743
Control valve 301 301
Swing motor 61 × 2 61 × 2
Travel motor 268 × 2 268 × 2
Fan motor 25 25
Center swivel joint 43 43
Track frame assembly 15,152 15,664
(Excluding step, roller guard, shoe assembly, and
lower piping)
• Center frame 3,998 3,998
• Track frame 2,207 × 2 2,355 × 2
• Swing circle 1,136 1,136
• Idler 342 × 2 342 × 2
• Idler cushion 452 × 2 452 × 2
• Carrier roller 50 × 6 50 × 6
• Track roller 108 × 16 108 × 18
• Final drive (incl. travel motor) 994 × 2 994 × 2
14 PC600-8
Unit: kg
Machine model PC600-8 PC600LC-8
Track shoe assembly

• Standard triple grouser shoe (600 mm) 5,930 6,290
• Wide triple grouser shoe (750 mm) 6,750 7,170
Boom assembly 4,820 4,820
Arm assembly 3,250 3,250
Bucket assembly 2,430 2,430
Boom cylinder assembly 496 × 2 496 × 2
Arm cylinder assembly 734 734
Bucket cylinder assembly 482 482
Link assembly (large) 345 345
Link assembly (small) — —
Boom pin 149 + 26 × 2 + 76 + 104 + 36 149 + 26 × 2 + 76 + 104 + 36
Arm pin 32 + 55 32 + 55
Bucket pin 55 + 62 55 + 62
Link pin 45 × 2 45 × 2
PC600-8 15

Unit: kg
PC600-8 PC600LC-8
Machine model
Engine assembly 2,610 2,610

• Engine 1,965 1,965
• PTO (incl. lubricating piping) 285 285
• Hydraulic pump 305 305
• Fan, control and PTO lubrication pump 55 55
Radiator, oil cooler assembly 268 268
Hydraulic tank, filter assembly (excl. hydraulic oil) 455 455
Fuel tank (excl. fuel) 520 520
Revolving frame 4,640 4,640
Operator's cab 280 280
Operator's seat 35 35
Counterweight 10,750 10,750
Swing machinery 743 743
Control valve 301 301
Swing motor 61 × 2 61 × 2
Travel motor 268 × 2 268 × 2
Fan motor 25 25
Center swivel joint 43 43
Track frame assembly 15,152 15,664
(Excluding step, roller guard, shoe assembly, and
lower piping)
• Center frame 3,998 3,998
• Track frame 2,207 × 2 2,355 × 2
• Swing circle 1,136 1,136
• Idler 342 × 2 342 × 2
• Idler cushion 452 × 2 452 × 2
• Carrier roller 50 × 6 50 × 6
• Track roller 108 × 14 108 × 14
• Final drive (incl. travel motor) 994 × 2 994 × 2
16 PC600-8
Unit: kg
PC600-8 PC600LC-8
Machine model
Track shoe assembly

• Standard double grouser shoe (600 mm) 5,760 6,120
• Wide triple grouser shoe — —
Boom assembly 3,880 3,880
Arm assembly 2,770 2,770
Bucket assembly 6,080 6,080
Boom cylinder assembly 524 × 2 524 × 2
Arm cylinder assembly 569 569
Bucket cylinder assembly 406 × 2 406 × 2
Bottom dump cylinder assembly 114 × 2 114 × 2
Boom pin 149 + 26 × 2 + 104 + 97 149 + 26 × 2 + 104 + 97
Arm pin 110 + 32 110 + 32
Bucket pin 55 × 2 + 37 × 2 55 × 2 + 37 × 2
Bucket connecting pin 19 × 2 + 10 × 2 + 17 × 2 19 × 2 + 10 × 2 + 17 × 2
PC600-8 17
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
Unit: l
PC600, PC600LC-8
Supply point
Specified capacity Refill capacity
Engine oil pan 48 40
PTO case 7.2 7.2
Swing machinary case 13 13
Final drive case (each) 10.5 10
Hydraulic system 520 360
Fuel tank 880 —
Cooling system 58 —
PC600-8 19
©2008 KOMATSU
All Rights Reserved
20
SEN00135-02
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up

10 Structure, function and

maintenance standard
Engine and cooling system

Parts related to engine.................................................................................................................................... 2
PTO ................................................................................................................................................................ 4
Fan, control and PTO lubrication pump .......................................................................................................... 6
Radiator, oil cooler .......................................................................................................................................... 7
PC600-8 1
SEN00135-02 10 Structure, function and maintenance standard

Parts related to engine
1. Air cleaner 4. Front engine mount

2. Intake connector 5. Rear engine mount
3. Muffler
2 PC600-8
Unit: mm
No. Check item Criteria Remedy
Free height of front mount Standard size Repair limit

6
rubber 126 —
Replace
Free height of rear mount
7 134 —
rubber
PC600-8 3
PTO
1. Connection plate a. Center of crankshaft (Center of SAL56 shaft)

2. PTO case b. Center of HPV95+95 shaft
3. Driven gear (No. of teeth: 40) c. Center of HPV95+95 shaft
4. Drive gear (No. of teeth: 36)
5. Oil level gauge Specifications
6. Main shaft Lubricating oil: 7.2 l
7. Breather Reducation ratio: Input shaft (SAL56 shaft) = 1
HPV95+95 shaft = = 0.9
4 PC600-8
Unit: mm
Backlash between drive gear Standard clearance Clearance limit

8
and driven gear 0.23 – 0.74 —
Backlash of SAL56 pump
9 0.273 – 0.374 — Adjust
input shaft
Backlash between main
10 shaft and connecting hub 0.074 – 0.226 —
assenbly
PC600-8 5
Fan, control and PTO lubrication pump

LPV75 + SAL56 + 8
Unit: mm
Model Standard clearance Clearance limit

Clearance between
1 gear case and side SAL56 0.13 – 0.18 0.22
plate
SAL8 0.10 – 0.15 0.19
Clearance between
SAL56 0.067 – 0.125 0.20
bearing inner dia.
2
and gear shaft outer
SAL8 0.067 – 0.125 0.20 Replace
dia.
Standard size Tolerance Repair limit
3 0
12 —
Pin insertion depth –0.5
0
4 12 —
–0.5
Delivery Standard Delivery
Delivery Speed
pressure delivery limit
Oil: EO10-CD SAL56 (rpm)
(MPa {kg/cm2}) (l/min.) (l/min.)
— Oil temp.: 45 – 55°C —
2,500 2.9 {30} 134 124
SAL8 2,500 2.9 {30} 19 17
6 PC600-8
Radiator, oil cooler
PC600-8 7
©2009 KOMATSU
All Rights Reserved
8
SEN00136-01
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up


Power train
Power train
Power train ..................................................................................................................................................... 2
Final drive ....................................................................................................................................................... 5
Sprocket.......................................................................................................................................................... 8
Swing circle .................................................................................................................................................. 10
Swing machinery .......................................................................................................................................... 12
PC600-8 1
Power train
Power train
2 PC600-8
1. Idler 11. Control pump (SAL56)

2. Center swivel joint 12. PTO lubrication pump
3. Swing motor (KMF90ABE-3) 13. No. 1 pump (HPV95+95)
4. Control valve 14. Swing machinery
5. Final drive, sprocket 15. Swing circle
6. Travel motor (KMV335ADT) 16. Travel speed solenoid valve
7. Engine 17. Swing brake solenoid valve
8. PTO
9. No. 2 pump (HPV95+95) A. Control valve
10. Fan pump (LPV75) B. Swing brake solenoid valve
PC600-8 3
4 PC600-8
Final drive
1. Level plug
2. Drain plug
3. No. 1 planetary gear (No. of teeth: 50)
4. No. 1 sun gear (No. of teeth: 12)
6. No. 1 planetary carrier
8. Cover
9. No. 1 ring gear (No. of teeth: 114)
10. Hub
11. Sprocket
12. Floating seal
13. Travel motor
15. No. 2 ring gear (No. of teeth: 70)
Specifications
14+70
Reduction ratio: – 12+114 x +1
12 14
= – 62.000
PC600-8 5
6 PC600-8
Unit: mm
Backlash between No. 2 Standard clearance Clearance limit

16
planet carrier and motor 0.06 – 0.21 —
Backlash between No. 2 planet
17 0.21 – 0.69 1.10
gear and No. 2 ring gear
Backlash between No. 1
18 planet gear and No. 1 ring 0.18 – 0.63 1.10
gear
Backlash between No. 2 sun Replace
19 0.17 – 0.62 1.00
gear and No. 2 planet gear
Backlash between No. 1 sun
20 0.14 – 0.45 1.00
Backlash between No. 1
21 planet carrier and No. 2 sun 0.16 – 0.56 1.00
gear
22 End play of sprocket shaft 0.10 – 0.15 —
Standard size Repair limit Rebuild or
23 Sprocket tooth width
104 101.5 replace
24 Wear of sprocket teeth Repair limit: 6 Replace
PC600-8 7
Sprocket
Unit: mm
Standard size Repair limit

1 Wear of tooth tip
350.1 338.1
Rebuild or
2 Thickness of tooth root 24.4 18.4
replace
3 Width of tooth 104 101.5
4 Wear of tooth shape Repair limit: 6 (measure with sprocket tooth shape)
8 PC600-8
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 9
Swing circle
STD
1. Swing circle inner race (No. of teeth: 100) Specifications

2. Ball
Reduction raito: – 100 = – 7.692
3. Swing circle outer race 13
Amount of grease: 31 l (G2-LI)
a. Inner race soft zone "S" position
b. Outer rae soft zone "S" position
Unit: mm
Clearance of bearing in axial Standard clearance Clearance limit
4 direction (when mounted on Replace
machine) 0.10 – 0.25 3.2
10 PC600-8
If equipped
PC600-8 11
Swing machinery
12 PC600-8
1. Swing pinion (No. of teeth: 13) Specifications

2. Cover 16+95 21+95
3. Case Reduction raito: x
16 21
4. Coupling = 38.321
6. Ring gear (No. of teeth: 95)
8. Cover
9. Swing motor
10. Oil level gauge
Unit: mm
Backlash between swing Standard clearance Clearance limit

15 motor shaft and No. 1 sun
gear 0.15 – 0.49 —

16 0.38 – 0.66 1.20
carrier and No. 2 sun gear
17 0.17 – 0.57 1.00
gear and ring gear
18 0.15 – 0.49 0.90
19 0.06 – 0.25 —
carrier and coupling Replace
Clearance between plate and
20 0.38 – 0.82 —
coupling
21 0.15 – 0.49 1.00
Backlash between swing pinion
22 0 – 0.126 2.00
and swing circle
Backlash between coupling
23 0.07 – 0.23 —
and swing pinion
24 0.15 – 0.57 1.10
gear and ring gear
Standard size Repair limit Repair hard
Wear of swing pinion oil seal
25 0 chrome plat-
contact surface 140.3 –0.100 — ing or replace
PC600-8 13
©2009 KOMATSU
All Rights Reserved
14
SEN00137-01
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up


Undercarriage and frame

Track frame, recoil spring ............................................................................................................................... 2
Idler................................................................................................................................................................. 4
Carrier roller.................................................................................................................................................... 6
Track roller ...................................................................................................................................................... 7
Track shoe ...................................................................................................................................................... 8
PC600-8 1

Track frame, recoil spring
1. Idler • The dimensions and number of track rollers may dif-

2. Track frame fer according to the model, but the basic structure is
3. Carrier roller the same.
4. Center frame • No. of track rollers.
5. Final drive
6. Track roller Model No. of rollers (each side)
7. Track shoe
PC600-8 8
8. Center guard
PC600LC-8 9
2 PC600-8
Unit: mm

Free length Installed Installed Free Installed
9 Recoil spring x OD length load length load Replace
292 kN 233.6 kN
859 x 299 715 —
{29,770 kg} {23,816 kg}
Standard
Tolerance Repair limit
size
Top-to-bottom width of idler +4
10 Track frame 163.5 163.5 0 167.5
guide
+1 Rebuild or
Idler support 161 161 0 159
replace
+4
Track frame 329 329 0 334
Left-to-right width of idler
11
guide
Idler support 324 — 322
PC600-8 3
Idler
4 PC600-8
Unit: mm
Outside diameter of Standard size Repair limit

1
protruding part 761 —
Outside diameter of tread
2 716 704 Rebuild or
surface
replace
3 Height of tread 22.5 28.5
4 Thickness of tread 26 20
5 Overall width 234 —
6 Width of tread 56 62
Standard Tolerance Standard Clearance

Clearance between shaft and size Shaft Hole clearance limit
7
bushing
–0.120 +0.480 0.540 –
110 — Replace
–0.207 +0.420 0.687
bushing
Standard Tolerance Standard Interfer-
Interference between idler size Shaft Hole interference ence limit
8
and bushing
+0.087 –0.036 0.073 –
120 —
+0.037 –0.136 0.223
Standard clearance Clearance limit
9 Play of axial direction Replace
0.35 – 0.88 —
PC600-8 5
Carrier roller
Unit: mm

1 Outside diameter of flange
210 —
2 Outside diameter of tread 180 170
3 Width of tread 53 —
4 Thickness of tread 42.5 37.5
5 Width of flange 15 —

6 Replace
bushing
+0.09 +0.43 0.09 –
68 —
+0.07 +0.18 0.36
Standard Tolerance Standard Interfer-

Interference between roller size Shaft Hole interference ence limit
7
and bushing
+0.38 +0.24 0.09 –
73 —
+0.33 +0.21 0.17
8 Play of roller in axial direction
0.62 – 0.93 —
6 PC600-8
Track roller
Unit: mm

1 Outside diameter of flange
260 —
Outside diameter of tread
2 220 208
surface
Rebuild or
3 Thickness of tread 56.2 50.2 replace
4 Overall width 325 —
5 Width of tread 63 —
6 Width of flange 39.5 —

7
bushing
–0.140 +0.390 0.470 –
100 1.5
–0.207 +0.330 0.597 Replace
Tolerance bushing
Standard Standard Interfer-
Interference between roller size Shaft Hole interference ence limit
8
and bushing
+0.087 +0.020 0.017 –
107.6 —
+0.037 –0.015 0.102
9 Play of axial direction Replace
0.5 – 1.1 —
PC600-8 7
Track shoe
a P portion shows the link of buhing press fitting end.
8 PC600-8
Unit: mm

1 Link pitch
228.9 231.9
Reverse or
When turned
Standard size replace
2 Bushing outside diameter Normal load Impact load
79 74 —
Standard size Repair limit Adjust or
3 Thickness of bushing metal
14.6 9.6 replace
Rebuild or
4 Link height 133 123
replace
Thickness of link metal
5 33.75 23.75
(bushing press-fitting portion)
6 219.8 Replace
7 Shoe bolt pitch 169
8 76.2
9 Inside width 122.4
Overall Repair or
10 Link 61.4
width replace
11 Tread width 54.5
12 Protrusion of pin 3.7
13 Protrusion of regular bushing 9.6
Adjust or
14 Overall length of pin 290
replace
15 Overall length of bushing 200.6
16 Thickness of spacer —
17 Bushing 127.4 – 343 kN {13 – 35 ton}
Press-fitting
18 Regular pin 196.1 – 490 kN {20 – 50 ton} —
force
*19 Master pin 156.9 – 431 kN {16 – 44 ton}
*:Dry type track link
PC600-8 9
Unit: mm
Tightening torque Additional tightening

a. Regular (Nm {kgm}) angle (deg.)
link
784.5±78.5 {80±8} 120±10
20 Shoe bolt Retighten
Tightening torque Additional tightening Lower limit torque
b. Master (Nm {kgm}) angle (deg.) (Nm {kgm})
link
— — —
Tolerance Standard
Standard size
Interference between bushing Shaft Hole interference
21
and link
+0.050 –0.326
72.9 0.326 – 0.450
+0.050 –0.400
Interference between regular +0.180 –0.238
22 48.8 0.318 – 0.480
pin and link +0.080 –0.300
Tolerance Standard
Standard size
Clearance between regular pin Shaft Hole clearance
23
and bushing
–0.62 +0.6 Adjust or
49.6 0.62 – 1.32
–0.72 +0.6 replace
Tolerance Standard
Standard size
Interference between master Shaft Hole interference
*24
pin and link
+0.030 –0.238
48.8 0.238 – 0.330
+0.030 –0.300
Tolerance Standard
Standard size
Clearance between master pin Shaft Hole clearance
*25
and bushing
–0.65 +0.60
49.2 0.65 – 1.35
–0.75 +0.60
*: Dry type track link
10 PC600-8
Double shoe
Unit: mm

1 Height
48 27
2 Height 48
3 Thickness 17
4 34 Rebuild or
Length at bottom
5 34 replace
6 26
Length at tip
7 26
8 Thickness
65 44
PC600-8 11
Triple grouser shoe
Unit: mm

1 Height
37 22
2 Thickness 18
3 33
Length of bottom
4 27 Rebuild or
5 25.5 replace
6 Length at tip 17.5

7 23.5
8 Thickness
55 40
12 PC600-8
Standard shoe
Model
PC600-8 PC600LC-8
Item
Shoe width (mm)
600 600
(triple shoe)
Link pitch (mm) 228.6 228.6
No. of shoes
49 52
(each side)
Selection of track shoe

• Select the most suitable track shoe from the following table
PC600-8 PC600LC-8
Cate- Cate-
Specifications Specifications
gory gory
Standard 600 mm triple A 600 mm triple A
If equipped 700 mm triple B –– ––
If equipped 750 mm triple B 750 mm triple B
If equipped 900 mm triple B 900 mm triple B
Category Use Precautions when using

Rocky ground, • Travel in Lo speed when traveling on rough ground with obstacles such as large
A
normal river soil boulders and fallen trees.
• Cannot be used on rough ground where there are large obstacles such as boulders
Normal soil, soft and fallen trees.
B
land • 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.
Extremely soft • Cannot be used on rough ground where there are large obstacles such as boulders
C ground (swampy and fallen trees
ground) • 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.
D Paved surface • The shoes are flat, so they have low gradeability
E Paved surface • The shoes are made of rubber, so be careful when traveling on rough ground
a Categories “B” and “C” are wide shoes, so there a When selecting the shoe width, select the nar-
are restrictions on their use. Therefore, before rowest shoe possible within the range that will
using, check the restrictions and consider care- give no problem with flotation and ground pres-
fully the conditions of use before recommending sure.
a suitable shoe width. If necessary, give the cus- If a wider shoe than necessary is used, there will
tomer guidance in their use. 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
©2006 KOMATSU
All Rights Reserved
14
SEN00138-01
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up


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 1

Hydraulic piping drawing
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Center swivel joint
5. Boom LOWER regeneration valve
6. Swing motor
7. Quick return valve (Arm)
8. Oil cooler
9. Cooling fan motor
10. Control valve
11. PPC shuttle valve
12. Hydraulic filter
13. Cooling fan pump
14. Hydraulic pump
15. L.H. travel motor
16. Hydraulic tank
17. PPC lock valve
18. L.H. PPC valve
19. R.H. PPC valve
20. Travel PPC valve
21. Boom holding valve
22. Accumulator
23. Active solenoid valve (swing)
24. 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
2 PC600-8
PC600-8 3
Hydraulic tank, hydraulic filter
4 PC600-8
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 5
Hydraulic pump (piston pump)

No. 1 main pump
Model: HPV95+95
PA1 : Front pump discharge port 1. Front pump

PA2 : Rear pump discharge port 2. Front servo valve
PD11 : Drain port 3. Front CO+NC valve
PD21 : Drain port 4. Rear servo valve
PCF : CO selector pilot port 5. Rear CO+NC valve
PCR : CO selector pilot port 6. TVC valve
PD : Jet sensor downstream pressure IN port 7. Rear pump
PS : Pump suction port
PT : Jet sensor upstream pressure IN port
PSV : Servo basic pressure IN port
PECN : CO+NC valve output pressure output port
6 PC600-8
No. 1 main pump
PSV1 : Servo valve basic pressure port

PSV1A : Servo piston output port
PSV1B : Servo valve output port
PC600-8 7
1. Front shaft 8. Front end cap 15. Rear case

2. Front cradle 9. Coupling 16. Rocker cam
3. Front case 10. Impeller 17. Rear cradle
4. Rocker cam 11. Rear end cap 18. Rear shaft
5. Piston 12. Valve plate 19. Servo piston
6. Cylinder block 13. Cylinder block
7. Valve plate 14. Piston
8 PC600-8
Servo valve
1. Servo valve assembly (No. 1 front)
P1 : Main pump pressure IN port 1. CO+NC valve

PE : TVC valve output pressure front, rear 2. Servo valve
interconnection port
PCO : CO selector pilot port
PD : Jet sensor downstream 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
PC600-8 9
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
3. Servo valve assembly (No. 1 rear)
P1 : Main pump pressure IN port 1. TVC valve

P2 : Main pump pressure IN port 2. CO+NC valve
PCO : CO selector pilot port 3. Connector
PAC : Servo actuator port 4. Servo valve
PD : Jet sensor downstream pressure IN port
PE : TVC valve output pressure front, rear
interconnection port
PC600-8 11
4. Servo valve (No. 1 rear)

PDR : CO+NC valve drain IN port
PPO : Servo basic pressure OUT port
12 PC600-8
Structure
(The following illustration shows the servo valve for No. 1 rear.)
1. Locknut 7. Pin 13. Sleeve

2. Cover 8. Piston 14. Piston
3. Plug 9. Locknut 15. Spring
4. Spring 10. Plug 16. Plug
5. Valve body 11. Locknut 17. Cover
6. Arm 12. Cover 18. 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 dis-
charge 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
1) Operation in direction of increase of pump discharge amount (max. angle)
Operation
• The control pump pressure PPO is taken to port • At the same time, port a is interconnected with
a. port h, so the pressure oil flows through port i to
• Signal pressure PECN from the NC valve is tak- servo piston chamber j, pushes servo piston (19)
en from port b to chamber c. to the right, increases the swash plate angle in
• When signal pressure PECN rises, piston (8) is the main piston pump and increases the pump
pushed to the right by the pressure in chamber c, discharge amount.
and stops at a point where it balances the pres- • When servo piston (19) moves, arm (6) rotates
sure of springs (4) and (4A). counterclockwise with its center at pin (7) and
• At the same time, arm (6) uses servo piston (19) moves guide spool (13) to the left. Port a, port d
as a fulcrum and sways to the right in the same and port h close, so the discharge increases by
way as piston (8). This moves guide spool (13) to an amount that matches signal pressure PECN.
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.
14 PC600-8
2) Operation in direction of decrease of pump discharge amount (min. angle)
Operation
• When signal pressure PECN goes down, piston • At the same time, port a is interconnected with
(8) moves to the left and stops at a point where port d, so the oil flows through port g to servo pis-
the pressure in chamber c balances the pressure ton chamber f, pushes servo piston (19) to the
of springs (4) and (4A). left, decreases the swash plate angle in the main
• At the same time, arm (6) uses servo piston (19) piston pump and decreases the pump discharge
as a fulcrum and sways to the left in the same amount.
way as piston (8). This moves guide spool (13) to • When servo piston (19) moves, arm (6) rotates
the left. counterclockwise with its center at pin (7). Guide
• When guide spool (13) moves, port a and port h spool (13) is moved to the right and closes port
are closed and port h is connected to drain a, port d and port h, so the discharge decreases
chamber e. As a result, servo piston chamber j is by an amount that matches signal pressure
also interconnected with drain chamber e PECN.
through port i and port h.
PC600-8 15
TVC valve
PPO : Servo basic pressure IN port 1. Spring 5. Sleeve

P1 : Main pump pressure IN port 2. Spool 6. Piston
P2 : Main pump pressure IN port 3. Piston 7. Body
PDR : TVC valve drain OUT port 4. Piston 8. Solenoid
PE : TVC valve output pressure OUT port
16 PC600-8
Function
• When the power mode is P-mode or E-mode, the • When the emergency pump drive switch is
pump discharge amount is set properly with the turned ON, the pump discharge amount is con-
command current sent from the controller ac- trolled according to the pump discharge pressure
cording to the engine speed. (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 • As a result, ports "a" and "b" are opened almost
actuates solenoid push pin (9) and spool (2) fully and almost all the oil from the control pump
moves. When this happens, spool (2) stops at a is output as TVC valve output pressure PE.
point where it balances the total of the force of Then, TVC valve output pressure PE and signal
spring (1), the force of push pin (9), and the force pressure PECN increase, thus the pump dis-
of TVC output pressure PE acting on piston (3). charge amount increases.
At this time, since the command current and the
force of push pin (9) are small, spool (2) is bal-
anced on the lower side.
PC600-8 17
2) When command current value from controller is large in P and E mode
Operation
• The command current sent from the controller • As a result, the oil flow from the control pump is
moves push pin (9), which moves spool (2). reduced between ports "a" and "b" and the open
Spool (2) stops at a position where it is balanced areas of port "b" and port "c" (drain port) in-
with spring (1). At this time, since the command crease. Then, TVC valve output pressure PE
current and the force of push pin (9) are large, and signal pressure PECN lower, thus the pump
spool (2) is balanced on the upper side. discharge amount decreases.
18 PC600-8
3) When emergency pump drive switch is turned ON and pump load is small
Operation
• If the emergency pump drive switch is turned • Since main pump discharge pressures P1 and
ON, the command current increases and the P2 are low, spring (1) keeps pressing spool (2)
force of solenoid push pin (9) becomes larger. down. As a result, control pump discharge pres-
As a result, spring (1) is kept compressed. sure PPO becomes equal to TVC valve output
pressure PE. At this time, TVC valve output
pressure PE and the pump discharge amount in-
crease.
PC600-8 19
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
CO+NC valve
1. CO+NC valve (No. 1 front)
P : Main pump pressure IN port PD : Jet sensor downstream pressure IN port

PEFR : TVC valve output pressure front, rear inter- PT : Jet sensor upstream pressure IN port
connection port PDR : CO+NC valve drain OUT port
PE : TVC valve output pressure detection port PECN : CO+NC valve output pressure OUT port
PC600-8 21
2. CO+NC valve (No. 1 rear)
P1I :
Main pump pressure IN port (front) PD : Jet sensor downstream pressure IN port
P1O :
Main pump pressure OUT port PT : Jet sensor upstream pressure IN port
P2I :
Main pump pressure IN port (rear) PDRI : TVC valve drain IN port
P2O :
Main pump pressure OUT port PDRO : CO+NC valve drain OUT port
PEFR :
TVC valve output pressure front, rear inter- PPOI : Servo basic pressure IN port
connection port PPOO : Servo basic pressure OUT port
PEI : TVC valve output pressure IN port PECN : CO+NC valve output pressure OUT port
22 PC600-8
CO valve NC valve
1. Plug 7. Plug
2. Piston 8. Sleeve
3. Spring 9. Piston
4. Spool 10. Spool
5. Piston 11. Spring
6. Plug 12. Plug
PC600-8 23
3. CO valve
Function
• When the load becomes large during operations • At the same time, it has a cut-off cancel function
and the main pump discharge pressure rises to a actuated by the pilot pressure from the heavy-lift
point close to relief pressure, the cut-off function solenoid valve.
of the CO valve acts to reduce the pump dis- • The CO valve is controlled by balancing the
charge in order to reduce relief loss. 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 re-
sult, 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, sig-
nal pressure PECN, and pump discharge
amount become maximum.
24 PC600-8
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 re-
duced by the notch of the spool and the open ar-
eas of port "b" and port "c" (drain port) increase.
Accordingly, CO valve output pressure PEC and
signal pressure PECN lower and the pump dis-
charge amount becomes minimum.
PC600-8 25
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 pis-
ton (2) is pressed down. Accordingly, seat (6)
touches seat (7) and locks spool (4).
• As a result, even if main pump discharge pres-
sure 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
4. NC valve
Function
• The NC valve controls the main pump discharge • The main pump discharge amount is controlled
amount to reduce the neutral loss and fine con- by balance of the sum of jet sensor upstream
trol loss according to the moving distance of the pressure PT and NC valve output pressure
control valve spool. 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 • As a result, spool (11) is pushed down, so the
differential pressure (PT – PD) becomes the flow from port c to port b is throttled, and the area
maximum, and the force of jet sensor output of the opening of port b and port a (drain port) be-
pressure PT pushing piston (10) becomes larger comes larger. In this way, NC valve output pres-
than the total of the force of spring (12) and the sure PECN becomes the minimum, and the main
force of jet sensor output pressure PD pushing pump discharge amount also becomes the mini-
the bottom of spool (11). mum.
PC600-8 27
2) When control lever is operated
Operation
• When the control lever is moved, the jet sensor
differential pressure (PT – PD) goes down in ac-
cordance 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 be-
comes 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
No. 2 main pump

Model: HPV95+95
PA1 : Front pump discharge port 1. Front pump

PA2 : Rear pump discharge port 2. Front servo valve
PD12 : Drain port 3. Rear servo valve
PD22 : Drain port 4. Rear pump
PS : Pump suction port
PSV : Servo basic pressure IN port
PECN : CO+NC valve output pressure port
PC600-8 29
No. 2 main pump

30 PC600-8
1. Front shaft 8. Front end cap 15. Rear case

2. Front cradle 9. Coupling 16. Rocker cam
3. Front case 10. Impeller 17. Rear cradle
4. Rocker cam 11. Rear end cap 18. Rear shaft
5. Piston 12. Valve plate 19. Servo piston
6. Cylinder block 13. Cylinder block
7. Valve plate 14. Piston
PC600-8 31
Servo valve
1. Servo valve (No. 2 front)
P1 : Main pump pressure IN port 1. Servo valve

P2 : Main pump pressure IN port
32 PC600-8
2. Servo valve (No. 2 rear)
P2 : Main pump pressure IN port 1. Servo valve

PC600-8 33
Line oil filter
1. Cover Outline
2. Element There are two line oil filters installed to the discharge
3. Case side of the main pump. They protect the circuit and
equipment by removing all dirt and dust from the oil.
A: From main pump
B: To control valve
34 PC600-8
PC600-8 35
Cooling fan pump

LPV75
P1 : Pump discharge port PD2 : Pump drain port

PS : Pump suction port PD3 : Pump drain port
Pa : Pump control basic pressure PD4 : Pump drain port
Pe : Pump control pressure
P1C : Pump pressure detection port
Pen : Pump control pressure detection port
36 PC600-8
1. Shaft 7. Cylinder block

2. Oil seal 8. Valve plate
3. Case 9. Spring
4. Rocker cam 10. Servo piston
5. Shoe 11. Ball
6. Piston 12. End cap
PC600-8 37
Function
• The rotation and torque of the engine are trans- Structure
mitted to the shaft of this pump and converted • Cylinder block (7) is supported on shaft (1)
into hydraulic energy in this pump. This pump through spline a. Shaft (1) is supported by the
discharges the pressurized oil according to the front and rear bearings.
load. • The end of piston (6) has a spherical hollow
• The discharge of this pump can be changed by which is combined with shoe (5). Piston (6) and
changing the swash plate angle in it. 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 hy-
draulic 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
Operation
1. Operation of pump
• Cylinder block (7) rotates together with shaft (1)
and shoe (5) slides on plane A. At this time, rock-
er 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 rock-
er 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 vol-
umes 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
2. Control of discharge
• If swash plate angle is increased, the differ-
ence 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
Servo valve
P : EPC valve basic pressure

T : Drain
PE : Control piston pressure
PH : Pump discharge pressure
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
PC600-8 41
Function
• The servo valve controls the current input to the • The relationship between the input current to the
EPC valve and the swash plate angle of the EPC valve and the output pressure of EPC valve
pump so that they will be related as shown in the F is as follows.
figure below.
42 PC600-8
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 pas-
sage is connected to the pump discharge pas-
sages 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
Cooling fan motor

Type: LMF75
Specifications
P : From fan pump Type: LMF75
TC : To tank Capacity: 75 cm3/rev
T : From oil cooler to tank 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
1. Output shaft 9. Center spring

2. Case 10. Check valve spring
3. Thrust plate 11. Check valve
4. Shoe 12. Pilot valve
5. Piston 13. Reversible valve spool
6. Cylinder block 14. Safety valve
7. Valve plate 15. Reversible valve spring
8. End cover
PC600-8 45
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)] ro-
tates cylinder block (5) through the piston.
• Since cylinder block (5) is coupled with the out-
put shaft by means of spline, the output shaft re-
volves to transmit the torque.
46 PC600-8
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, howev-
er, 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 mo-
tor 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 iner-
tia 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
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 hy-
draulic oil flows in to revolve the motor in reverse
(counterclockwise).
48 PC600-8
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 sys-
tem 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 pres-
sure in port P is prevented.
PC600-8 49
©2006 KOMATSU
All Rights Reserved
50
SEN00139-04
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up



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
PC600-8 1

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 P1AL : From L.H. travel PPC valve
A2L : To boom cylinder bottom P2AL : From boom PPC valve
A3L : To bucket cylinder head P3AL : From bucket PPC valve
A1R : To swing motor MA port P4AL : From arm PPC valve
A3R : Service P1AR : From swing PPC valve
A4R : To arm cylinder head P3AR : Service
A5R : To R.H. travel motor PA port P4AR : From arm PPC valve
B1L : To L.H. travel motor PA port P5AR : From R.H. travel PPC valve
B2L : To boom cylinder head P1BL : From L.H. travel PPC valve
B3L : To bucket cylinder bottom P2BL : From boom PPC valve
B1R : To swing motor MB port P3BL : From bucket PPC valve
B3R : Service P1BR : From swing PPC valve
B4R : To arm cylinder bottom P3BR : Service
B5R : To R.H. travel motor PB port P4BR : From arm PPC valve
NCAL : To rear NC valve P5BR : From R.H. travel PPC valve
NCBL : To rear NC valve PL : From rear main pump
NCAR : To front NC valve PR : From front main pump
NCBR : To front NC valve PRL : From 2-stage relief solenoid valve
P3 : From arm PPC shuttle valve PRR : From 2-stage relief solenoid valve
P4 : From boom, bucket PPC shuttle valve T : To tank
P5 : From swing PPC shuttle valve TS : To tank
P6 : Work equipment oil pressure switch
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)
2 PC600-8
4-spool valve + 5-spool valve (with travel shuttle valve)
PC600-8 3
Cross-sectional diagram
(1/4)
1. Spool return spring 6. Jet sensor orifice

2. Spool (L.H. travel) 7. Jet sensor relief valve
3. Spool (boom Lo) 8. Main relief valve
4. Spool (bucket Lo) 9. Spool (straight-travel)
5. Spool (arm Hi) 10. Spool (arm throttle)
4 PC600-8
Unit: mm

11 Spool return spring x OD length load length load Replace
spring if
192 N 154 N damaged or
87.6 x 21.2 54.5 —
{19.6 kg} {15.7 kg} deformed
324 N 259 N
12 Spool return spring 58.1 x 26.5 52.5 —
{33.0 kg} {26.4 kg}
PC600-8 5
(2/4)
1. Spool return spring 6. Spool (R.H. travel)

2. Spool (swing) 7. Jet sensor relief valve
3. Spool (boom Hi) 8. Jet sensor orifice
4. Spool (service / bucket Hi) 9. Main relief valve
5. Spool (arm Lo) 10. Spool (swing priority)
6 PC600-8
Unit: mm

Replace
spring if
11 Spool return spring x OD length load length load
damaged or
104 N 83.4 N deformed
53.8 x 26.5 52.5 —
{10.6 kg} {8.50 kg}
PC600-8 7
(3/4)
1. Check valve 8. Spool (boom Lo)

2. Check valve spring 9. Check valve
3. Spool (L.H. travel) 10. Spool (boom Hi)
4. Spool (straight-travel) 11. Suction valve
5. Spool (swing priority) 12. Suction valve
6. Spool (swing) 13. Suction valve
7. Suction valve
8 PC600-8
Unit: mm

14 Check valve spring x OD length load length load
12.7 N 10.2 N
20.8 x 12.2 13.5 —
{1.3 kg} {1.04 kg}
0.98 N 0.78 N
15 Check valve spring 31.8 x 7.6 26.5 —
{0.10 kg} {0.08 kg}
255 N 204 N
16 Spool return spring 30.7 x 32.5 26.5 — Replace
{26.0 kg} {20.8 kg}
spring if
125 N 100 N
{12.7 kg} {10.2 kg}
207 N
19 Spool return spring 21.0 x 16.9 18.2 — —
{21.1 kg}
125 N 100 N
{12.7 kg} {10.2 kg}
7.85 N 6.28 N
{0.80 kg} {0.64 kg}
PC600-8 9
(4/4)
1. Suction-safety valve 7. Spool (arm Lo)

2. Spool (bucket Lo) 8. Suction-safety valve
3. Spool (arm throttle) 9. Check valve
4. Spool (service / bucket Hi) 10. Spool (R.H. travel)
5. Spool (arm Hi) 11. Suction-safety valve
6. Check valve 12. Suction valve
10 PC600-8
Unit: mm

125 N 100 N
54.8 x 34.0 53.5 —
{12.7 kg} {10.2 kg}
255 N 204 N
14 Spool return spring 30.7 x 32.5 26.5 — Replace
{26.0 kg} {20.8 kg}
spring if
125 N 100 N
{12.7 kg} {10.2 kg}
125 N 100 N
{12.7 kg} {10.2 kg}
7.85 N 6.28 N
{0.80 kg} {0.64 kg}
PC600-8 11
Travel shuttle valve
12 PC600-8
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 equip-
ment, 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 • When the travel REVERSE is operated, the pres-
pressure oil flows from the L.H. travel circuit to sure oil is sent to port P2 and pushes the spool
port P1 and pushes the spool to the right. Ports to the left.
P3, P4, and P5 are interconnected with port P0
through the groove in the spool to the straight-
travel valve.
• However, when the work equipment and swing
control levers are at NEUTRAL, the pilot pres-
sure oil from the PPC valve does not flow, so it
also does not flow to the straight-travel valve.
PC600-8 13
2. During simultaneous operation
Operation
• When the arm and travel FORWARD are operat- • The pilot pressure oil from the swing PPC shuttle
ed at the same time, pilot pressure oil flows from valve flows from port P5 Æ port P0 Æ straight-
the L.H. travel circuit to port P1 and pushes the travel valve, and the pilot pressure oil from the
spool to the right. boom and bucket PPC shuttle valves flows from
• When the arm is operated, pilot pressure oil also port P4 Æ port P0 Æ straight-travel valve.
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.
14 PC600-8
Straight-travel valve
Function
• When the travel is operated at the same time as • To prevent this, the straight-travel valve is
the swing, boom, arm, or bucket, the pressure oil switched to interconnect the left and right travel
flowing to the left and right travel circuits is divid- circuits. This ensures that the amount of oil sup-
ed and sent to the boom, arm, or bucket circuit. plied to the left and right travel motors is equal.
• If the oil in one travel circuit is divided off, the • As a result, the left and right travel motors both
amount of oil supplied to the travel motor will be rotate at the same speed, and there is little travel
less than in the travel circuit which is not divided, deviation.
so the drop in the supply of oil to the travel motor
will cause the machine to deviate.
1. When travel is operated independently
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 interconnect-
ed, and each circuit remains independent.
PC600-8 15
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
Swing priority valve
Function
• When the swing and arm are operated at the • To overcome this, the swing priority valve is ac-
same time, a large amount of the pressure oil tuated to throttle the pressure oil flowing to the
flows to the arm circuit where the load is small, so arm Lo control valve in order to restrict the arm
little pressure oil flows to the swing circuit. speed and improve the simultaneous operation
• This makes the arm speed too fast for the swing performance.
speed, and causes poor combination in simulta-
neous operation.
1. When swing is at HOLD
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
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 perform-
ance.
18 PC600-8
Arm throttle valve
Function
When arm and boom are operated at same time When arm and bucket are operated at same time
• When the arm and boom are operated at the • The arm is actuated by the merged flow from two
same time, a large amount of the pressure oil pumps and the bucket is actuated by the oil from
flows to the arm circuit where the load is small, so one pump.
little pressure oil flows to the boom circuit. • In this condition, if the arm and bucket are oper-
• This makes the arm speed too fast for the boom ated at the same time, a large amount of the
speed, and causes poor combination in simulta- pressure oil flows to the arm circuit, so little pres-
neous operation. This is a particular problem sure oil flows to the bucket circuit. This makes
when the arm OUT and boom RAISE are operat- the arm speed too fast for the bucket speed, and
ed at the same time. causes poor combination in simultaneous opera-
• To overcome this, the arm throttle valve is actu- tion. This is a particular problem when the arm
ated to throttle the pressure oil flowing to the arm OUT and bucket CURL are operated at the same
Hi control valve in order to restrict the arm speed time.
and improve the simultaneous operation per- • To overcome this, the arm throttle valve is actu-
formance. ated to throttle the pressure oil flowing to the arm
Hi control valve in order to restrict the arm speed
and improve the simultaneous operation per-
formance.
1. When arm is operated independently
Operation
• No pilot pressure oil flows from the travel shuttle • For this reason, all the pressure oil from the rear
valve, so the arm throttle valve is not actuated. main pump passes through port PL and flows to
the arm Hi control valve.
PC600-8 19
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 throt-
tled, and the arm speed is restricted to improve
the simultaneous operation performance.
20 PC600-8
Swing motor
Model: KMF90ABE-3 (with reverse prevention valve)
T1 : To tank Specifications
S : From control valve Model: KMF90ABE-3
MA : From control valve Theoretical delivery: 87.8 cc/rev
MB : From control valve Safety valve set pressure: 25.5 MPa {260 kg/cm2}
B : From swing brake solenoid valve Rated speed: 2,320 rpm
Brake release pressure: 2.06 MPa {21.0 kg/cm2}
PC600-8 21
1. Drive shaft 8. Housing 15. Safety valve

2. Spacer 9. Reverse prevention valve 16. Check valve
3. Case 10. Center spring 17. Check valve spring
4. Disc 11. Cylinder block 18. Shuttle valve
5. Plate 12. Valve plate 19. Shuttle valve spring
6. Brake ring 13. Piston 20. Brake spring
7. Brake piston 14. Center shaft
22 PC600-8
Unit: mm

21 Check valve spring x OD length load length load Replace
spring if
3.04 N 2.45 N damaged or
62.5 x 20.0 39 —
13.7 N 11 N
22 Shuttle valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.12 kg}
PC600-8 23
Swing brake
Operation
1. When swing brake solenoid valve is de-ener-
gized
• If the swing brake solenoid valve is de-ener-
gized, 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) to-
gether, and the brake is applied.
2. When swing brake solenoid valve is ener-

gized
• When the swing brake solenoid valve is ener-
gized, 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 over-
comes 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
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 prob-
lem. It acts to release the abnormally high pres-
sure 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 pass-
es through the control valve and is supplied to
port MA.
• When this happens, the pressure at port MA ris-
es 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
2. When stopping swing

• When the swing control lever is returned to the
neutral position, no more pressurized oil is sup-
plied from the pump to port MA. At the same
time, the oil from the outlet port of the motor re-
turns 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 pres-
sure 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 re-
lieved oil and oil from back pressure valve is sup-
plied to port MA through check valve (3) to
prevent cavitation at port MA.
26 PC600-8
Reverse prevention valve
MA : Port 1. Valve body

T1 : Port 2. Spool (MA side)
MB : Port 3. Spring (MA side)
T2 : Port 4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
PC600-8 27
Explanation of effect
28 PC600-8
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 ma-
chinery system, the compressibility of the hy-
draulic 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 posi-
tioning 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 se-
cured.
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 gener-
ated 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 estab-
lished.
• 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, there-
by preventing the second reversal.
PC600-8 29
Center swivel joint
1. Cover A1. From control valve port A5R D1. From control valve port B1L
2. Body A2. To R.H. travel motor REVERSE port PB D2. To L.H. travel motor FORWARD port PB
3. Slipper seal B1. From control valve port A1L E1. From travel speed EPC valve
4. O-ring B2. To L.H. travel motor REVERSE port PA E2. To L.H. and R.H. travel motors port P
5. Shaft C1. From control valve port B5R T1. To tank
C2. To R.H. travel motor FORWARD port PA T2. From L.H. and R.H. travel motors port T
Unit: mm
Clearance between rotor and Standard size Standard clearance Clearance limit
6 Replace
shaft 90 0.056 – 0.105 0.111
30 PC600-8
Travel motor
Model: KMV335ADT
P : From travel speed solenoid valve Specifications

T : To tank Model: KMV335ADT
PA : From control valve Theoretical delivery: Minimum 217 cc/rev
PB : From control valve 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
1. Output shaft 8. Plug 15. Spool return spring

2. Motor case 9. Regulator piston 16. Safety valve
3. Piston 10. Plate 17. Regulator valve
4. Cylinder block 11. Disc 18. Spring
5. Valve plate 12. Check valve spring 19. Brake spring
6. End cover 13. Check valve 20. Brake piston
7. Slow return valve 14. Counterbalance valve
32 PC600-8
Unit: mm

Replace
427 N 341 N
62.5 x 32 42.0 — spring if
{43.5 kg} {34.8 kg}
damaged or
3.04 N 2.45 N deformed
{0.31 kg} {0.25 kg}
98.1 N 78.5 N
23 Regulator piston spring 55.0 x 9.0 50.0 —
{10.0 kg} {8.0 kg}
PC600-8 33
1. At low speed (motor swash plate angle at maximum)
Operation
• When the solenoid valve is de-energized, the pi- • Because of this, propulsion force equal to the dif-
lot pressure oil from the control pump does not ference in area of chambers a and b (Ab – Aa)
flow to port P. For this reason, regulator valve of regulator piston (9) acts in a downward direc-
(17) is pushed upward in the direction of the ar- tion.
row by spring (18). • As a result, valve plate (5) and cylinder block (4)
• The main pressure oil from the control valve move in the maximum swash plate angle direc-
pushes shuttle valve (7), goes through end cover tion, the motor capacity becomes the maximum,
(6), and acts on chamber a of regulator piston and the system is set to low speed.
(9). At the same time, the main pressure passes
through passage c and acts on chamber b
through regulator valve (17).
34 PC600-8
2. At high speed (motor swash plate angle at minimum)
Operation
• When the solenoid valve is energized, the pilot • As a result, valve plate (5) and cylinder block (4)
pressure oil from the control pump flows to port move in the minimum swash plate angle direc-
P, and pushes regulator valve (17) down. tion, the motor capacity becomes the minimum,
• Because of this, the main pressure oil and the oil and the system is set to high speed.
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 up-
ward.
PC600-8 35
Parking brake
1. When starting to travel
Operation
• When the travel lever is operated, the pressu-
rized 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
2. When stopping travel
Operation
• When the travel lever is placed in neutral, coun- • As a result, plate (10) and disc (11) are pushed
terbalance valve spool (14) returns to the neutral together, and the brake is applied.
position and the circuit to the parking brake is • A time delay is provided by having the pressu-
closed. rized oil pass through a throttle in slow return
• The pressurized oil in chamber e of brake piston valve (7) when the brake piston returns, and this
(20) passes through the throttle of slow return ensures that the brake is applied after the ma-
valve (7) until spool (14) of the counterbalance chine stops.
valve returns to neutral.
• When spool (14) of the counterbalance valve re-
turns to the neutral position, the oil is drained in-
side the case from throttle f of brake piston (20)
and brake piston (20) is pushed fully to the left by
spring (19).
PC600-8 37
Brake valve
Operation of brake valve
• The brake valve consists of a check valve, coun-
terbalance 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 ma-
chine 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 extreme-
ly dangerous.
• To prevent this, these valves act to make the ma-
chine travel according to the engine speed
(pump discharge amount).
Operation when pressurized oil is supplied

rized 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 pis-
ton to chamber S1. When the pressure in cham-
ber 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
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 re-
turned 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 gener-
ated 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 down-
hill), 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 be-
come 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 equip-
ment.
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 be-
cause 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] over-
comes 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
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 be-
cause 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] over-
comes 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
Set pressures varying mechanism

Function
1. When starting travel (high-pressure setting)
rized 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 counterbal-
ance valve spool (14) returns to the neutral posi-
tion.
• While the counterbalance valve spool is return-
ing to the neutral position, the pressurized oil in
chamber J passes through passage H, and es-
capes to chamber PA from chamber G. The pis-
ton 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 : 27.5 MPa {280 kg/cm2}

(at stopping)
PC600-8 41
Valve control
Lever positions
1. Travel PPC valve 10. Solenoid valve A. NEUTRAL J. Swing RIGHT
2. Service PPC valve 11. Control valve B. Boom RAISE K. Swing LEFT
3. Service pedal 12. Hydraulic pump C. Boom LOWER L. NEUTRAL
4. L.H. travel lever 13. Shuttle valve D. Bucket DUMP M. Travel REVERSE
5. R.H. travel lever 14. PPC safety lock E. Bucket CURL N. Travel FORWARD
6. Right PPC valve solenoid valve F. NEUTRAL
7. Right work 15. Left work equipment G. Arm IN
equipment lever lever H. Arm OUT
8. Solenoid valve 16. Left PPC valve
9. Accumulator
42 PC600-8
PC600-8 43
Work equipment, swing PPC valve
P : From safety lock solenoid valve P1 : L.H. PPC: Arm OUT/R.H. PPC: Boom LOWER
T : To tank P2 : L.H. PPC: Arm IN/R.H. PPC: Boom RAISE
P3 : L.H. PPC: Right swing/R.H. PPC: Bucket CURL
P4 : L.H. PPC: Left swing/R.H. PPC: Bucket DUMP
44 PC600-8
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for connecting lever)
Unit: mm

Centering spring
12 x OD length load length load
(for P3, P4)
Replace
9.81 N 7.85 N
38.7 x 15.5 34.0 — spring if
{1.0 kg} {0.8 kg}
damaged or
Centering spring 17.7 N 14.1 N deformed
13 42.5 x 15.5 34.0 —
(for P1, P2) {1.8 kg} {1.44 kg}
16.7 N 13.3 N
14 Metering spring 26.5 x 8.2 24.9 —
{1.7 kg} {1.36 kg}
PC600-8 45
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 Æ 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)
46 PC600-8
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 5
to drain chamber D, and the pressurized oil at
port P1 is released. 4
• If the pressure at port P1 drops too much, spool
(1) is pushed down by metering spring (2), so 3
D
fine control hole f is shut off from drain chamber
2
D. At almost the same time, it is connected to
pump pressure chamber PP, so the pressure at f T
port P1 supplies the pump pressure until the
pressure recovers to a pressure equivalent to the P
position of the lever. f'
• When the control valve spool returns, oil in drain 1
chamber D flows in from fine control hole f´ of the PP
valve on the side that is not moving. It passes P1 P2
through port P2 and goes to chamber B to
charge the oil. (Fig. 3)
A Control valve B
(Fig. 3)
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. 5
• Therefore, the pilot pressure oil from the control
pump passes through fine control hole f and 4
flows to chamber A from port P1 to push the con-
trol valve spool.
9 D
• The return oil from chamber B passes from port
P2 through fine control hole f´ and flows to drain
chamber D. (Fig. 4)
f T
P
f'
1
Pp
P1 P2
A Control valve B
(Fig. 4)
SBP00278
PC600-8 47
Travel PPC valve
P : From main pump P1 : L.H. travel REVERSE

T : To tank P2 : L.H. travel FORWARD
P3 : R.H. travel REVERSE
P4 : R.H. travel FORWARD
a The travel PPC valve operates similarly to the work equipment and swing PPC valves.
48 PC600-8
Service PPC valve
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Lever
6. Plate
7. Retainer
8. 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

9 Centering spring x OD length load length load Replace
spring if
124.5 N 100 N damaged or
33.9 x 15.3 28.4 —
16.7 N 13.7 N
10 Metering spring 22.7 x 8.1 22 —
{1.7 kg} {1.4 kg}
50 PC600-8
PPC accumulator
SBP00290
1. Gas plug Specifications

2. Shell Actual gas volume: 500 cc
3. Poppet
4. Holder
5. Bladder
6. Oil port
PC600-8 51
PPC shuttle valve

For arm, swing
1. Plug
2. Body
3. Ball
a. Port P1B (right swing)

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

b. Port P3A (bucket CURL)
c. Port P4A (boom LOWER)
d. Port P2A (boom RAISE)
e. Port P5 (travel shuttle valve)
f. Port P3B (bucket CURL)
g. Port P1B (bucket DUMP)
h. Port P2B (boom RAISE)
i. Port P4B (boom LOWER)
52 PC600-8
Solenoid valve
For CO cancel, 2-stage relief, boom Hi 2-stage safety valve, swing brake, travel speed solenoid
valve
1. CO cancel solenoid valve T : To tank

2. 2-stage relief solenoid valve A1 : To No. 1 pump (NC valve)
3. Boom Hi 2-stage safety valve solenoid valve A2 : To left and right travel motors
4. Swing brake solenoid valve A3 : To boom LOWER 2-stage safety valve
5. Travel speed solenoid valve A4 : To main valve (relief valve)
A5 : To swing motor
P1 : From control pump
ACC : To accumulator
PPC : To PPC valve
PC600-8 53
1. Connector
2. Moving core
3. Solenoid
4. Cage
5. Spool
6. Block
7. 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 actua-
tor. At the same time, port T is closed, and this
stops the oil from flowing to the tank.
54 PC600-8
Bucket curl Hi cancel
1. Connector
2. Moving core
3. Solenoid
4. Spool
5. Body
6. Spring
7. Plug
Operation
• The signal current does not flow from the con-
nector, so solenoid (3) is de-energized.
For this reason, spool (4) is returned to the neu-
tral 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 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 di-
rection 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 con-
trol valve.
At the same time, port A and port T are intercon-
nected, and the oil from the control valve is
drained to the tank.
PC600-8 55
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
1. Connector 7. Spool
2. Solenoid 8. Body
3. Moving core 9. Plug
4. Body 10. Spring
5. Plug 11. Spool
6. Spring
Operation
• 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 actu-
ator.
At the same time, the oil from the actuator flows
from port A2 to port T and is drained to the tank.

• When the signal current flows from the PPC hy-
draulic 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
Boom holding valve
T : To tank 1. Safety-suction valve

V : From control valve 2. Pilot spring
CY : To boom cylinder bottom 3. Pilot spool
PI : From PPC valve (pilot pressure) 4. Poppet spring
5. Poppet
58 PC600-8
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
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
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 in-
side 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 pres-
surized oil flows from port CY to port V, and then
flows to the control valve.
• If any abnormal pressure is generated in the cir-
cuit at the bottom end of the boom cylinder, safe-
ty valve (1) is actuated to drain oil from port CY
to port T.
PC600-8 61
Boom LOWER regeneration valve
T : To tank
PB : From boom cylinder bottom
PM : From boom cylinder head
PI : From boom LOWER PPC valve
62 PC600-8
1. Body
2. Spool
3. Check valve
4. Spring
Unit: mm

5 Spring (check valve) x OD length load length load
Replace
29.4 N 23.5 N
83.5 x 25.5 22 — spring if
{3.0 kg} {2.4 kg}
damaged or
58.8 N 47.1 N deformed
6 Spool return spring (small) 41.1 x 9.6 35 —
{6.0 kg} {4.8 kg}
207 N 166 N
7 Spool return spring (large) 49.4 x 25.7 47 —
{21.1 kg} {16.9 kg}
PC600-8 63
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 bot-
tom 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 dur-
ing 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
Quick return valve

Function Operation
• When arm OUT is operated, this valve reduces 1. Arm at OUT
the pressure loss of the large amount of oil re- When arm OUT is operated, the pilot pressure
turning from the cylinder bottom. from the PPC valve pushes pilot spool (1), and
the pressure oil from chamber b inside the pop-
pet 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 ød1 –
Area of ød2) because of the difference in the out-
side 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
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 ød1 – Area of ød2) 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
PC600-8 67
Hydraulic cylinder
Boom cylinder
Arm cylinder
Bucket cylinder
68 PC600-8
Unit: mm
Name of Standard Tolerance Standard Clearance

cylinder size Shaft Hole clearance limit
Clearance –0.036 +0.263 0.084 –

Boom 120 0.453
between –0.090 +0.048 0.353 Replace
1
piston rod and bushing
–0.043 +0.256 0.082 –
bushing Arm 140 0.662
–0.106 +0.039 0.362
–0.043 +0.256 0.083 –
Bucket 130 0.462
–0.106 +0.040 0.362
–0.043 +0.495 0.438 –
Boom 125 1.5
Clearance –0.106 +0.395 0.601
between
–0.043 +0.495 0.438 –
2 piston rod Arm 125 1.5
–0.106 +0.395 0.601
support shaft
and bushing –0.036 +0.457 0.406 –
Bucket 110 1.5
–0.090 +0.370 0.547 Replace pin,
–0.036 +0.151 0.110 – bushing
Boom 110 1.5
Clearance –0.090 +0.074 0.241
between
–0.036 +0.457 0.406 –
3 cylinder bottom Arm 120 1.5
–0.090 +0.370 0.547
support shaft
and bushing –0.036 +0.457 0.406 –
Bucket 110 1.5
–0.090 +0.370 0.547
PC600-8 69

Boom cylinder
Arm cylinder
Bucket cylinder
Bottom dump cylinder
70 PC600-8
Unit: mm
Name of Standard Tolerance Standard Clearance

cylinder size Shaft Hole clearance limit
–0.043 +0.256 0.083 –

Boom 130 0.662
Clearance –0.106 +0.040 0.362
between –0.043 +0.263 0.090 – Replace
1 Arm 140 0.662
piston rod and –0.106 +0.047 0.369 bushing
bushing
–0.036 +0.261 0.083 –
Bucket 110 0.662
–0.090 +0.047 0.351
–0.036 +0.257 0.084 –
Bottom dump 90 0.647
–0.090 +0.048 0.347
–0.043 +0.495 0.438 –
Boom 125 1.5
–0.083 +0.395 0.578
Clearance –0.043 +0.495 0.438 –
between Arm 125 1.5
–0.106 +0.395 0.601
2 piston rod
support shaft –0.043 +0.495 0.438 –
Bucket 125 1.5
and bushing –0.083 +0.395 0.578
–0.036 +0.457 0.406 –
Bottom dump 90 1.5
–0.090 +0.370 0.547 Replace pin,
–0.036 +0.161 0.110 – bushing
Boom 110 1.5
–0.090 +0.074 0.251
Clearance –0.043 +0.495 0.438 –
between Arm 125 1.5
–0.106 +0.395 0.601
3 cylinder bottom
support shaft –0.036 0 0.016 –
Bucket 115 1.5
and bushing –0.090 –0.020 0.090
–0.036 +0.457 0.406 –
Bottom dump 90 1.5
–0.090 +0.370 0.547
PC600-8 71
©2011 KOMATSU
All Rights Reserved
72
SEN00140-03
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up


Work equipment
Work equipment
Work equipment.............................................................................................................................................. 2
Dimensions of work equipment ...................................................................................................................... 6
PC600-8 1
Work equipment
Work equipment
2 PC600-8
Unit: mm

Clearance between bushing size clearance limit
Shaft Hole
1 and mounting pin of boom
and revolving frame –0.043 +0.148 0.100 –
140 1.5
–0.106 +0.057 0.254
Clearance between bushing
–0.043 +0.407 0.368 –
2 and mounting pin of boom and 130 1.5
–0.106 +0.325 0.513
arm
–0.036 +0.360 0.320 –
3 and mounting pin of arm and 110 1.5
–0.090 +0.284 0.450 Replace
link
–0.036 +0.326 0.259 –
–0.090 +0.223 0.416
bucket
–0.036 +0.354 0.311 –
5 and mounting pin of link and 110 1.5
–0.090 +0.275 0.444
link
–0.036 +0.382 0.315 –
6 and mounting pin of link and 115 1.5
–0.090 +0.279 0.472
bucket
Adjust
7 Bucket clearance 0.5 – 1.0
shims
PC600-8 3
4 PC600-8
Unit: mm

Clearance between bushing size clearance limit
Shaft Hole
1 and mounting pin of boom and
revolving frame –0.043 +0.148 0.100 –
140 1.5
–0.106 +0.057 0.254
–0.043 +0.542 0.485 –
2 and mounting pin of boom and 140 1.5
–0.106 +0.442 0.648 Replace
arm
–0.043 +0.523 0.503 –
–0.106 +0.460 0.629
bucket
–0.036 +0.457 0.406 –
4 and mounting pin of front 95 1.5
–0.090 +0.370 0.547
bucket and rear bucket
PC600-8 5
Dimensions of work equipment
1. Arm
6 PC600-8
Unit: mm
Model PC600, PC600LC-8
No. 2.9 m Arm 3.5 m Arm 4.3m Arm 5.2m Arm

1 ø125 ø125 ø125 ø125
2 148 148 148 148
3 458 458 458 458
4 ø130 ø130 ø130 ø130
5 499 582 627.7 666.9
6 460.6 321.7 338 352
7 1,188.9 1,187.2 1,182.7 1,178.6
8 2,863.2 3,465.2 4,256.6 5,188.1
9 3,624 3,324.2 3,315.9 3,308.2
10 471.3 497.6 497.6 497.6
11 910 810 810 810
12 700 700 700 700
13 678 608 608 608
14 2,197 2,166 2,166 2,166
15 ø115 ø115 ø115 ø115
16 456 ± 0.5 456 ± 0.5 456 ± 0.5 456 ± 0.5
17 ø115 ø115 ø115 ø115
Arm as 0 0 0 0
448 -0.5 448 -0.5 448 -0.5 448 -0.5
individual part
18
When press-
464 464 464 464
fitting bushing
Min. 2,380 2,152 2,152 2,152
19
Max. 3,990 3,577 3,577 3,577
PC600-8 7
2. Bucket
8 PC600-8
Unit: mm
Model PC600, PC600LC-8
No. 2.0 m3, 2.3m3, 2.7m3 Bucket 3.5 m3 Bucket

1 599.7 ± 0.5 665 ± 0.5
2 100.1 ± 0.5 132.5 ± 0.5
3 — —
4 — —
5 2,148 2,179
6 280 280
7 — —
8 — —
9 ø115 +0.1
0 ø115 +0.1
0
10 457 +20 457 +20
11 84.5 84.5
12 80.5 80.5
Press fit hole 13 ø135 +0.063

0 ø135 +0.063
0
for bushing 14 75.5 75.5
15 — —
16 — —
17 — —
18 — —
19 — —
20 — —
21 488.5 +20 488.5 +20
22 79 79
23 ø115 +0.1
0 ø115 +0.1
0
24 — —
9 PC600-8
©2008 KOMATSU
All Rights Reserved
10
SEN00141-00
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up


Cab and its attachments

Air conditioner piping ...................................................................................................................................... 2
PC600-8 1

Air conditioner piping
For the electric circuit diagram of the air conditioner, see “Others”.
1. Air conditioner unit A : Fresh air

2. Duct B : Recirculated air
3. Refrigerant piping C : Hot air/cold air
4. Air conditioner compressor
5. Condenser
6. Receiver tank
7. Hot water return piping
8. Hot water pickup piping
2
©2005 KOMATSU
All Rights Reserved
4
SEN00142-05
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up


Electrical system
Engine control ...................................................................................................................................................... 2
Machine control system diagram ......................................................................................................................... 7
Monitor system................................................................................................................................................... 31
Sensors.............................................................................................................................................................. 46
KOMTRAX system ............................................................................................................................................. 50
PC600-8 1
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 start-
ing switch is at the STOP position, it cuts the sig-
nal to the supply pump drive solenoid to stop the
engine.
2 PC600-8
2. Components of system
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. 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 3
Engine controller
4 PC600-8
Input and output signals
CN-CE01
Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
1 NC — 48 NE sensor (–) —
2 NC — 49 NC —
3 Ambient press. sensor Input 50 NC —
4 Supply pump #1 (+) Output 51 Injector #2 (–) Output
5 Supply pump #1 (–) Output 52 Injector #3 (–) Output
Input/ 53 Injector #1 (–) Output
6 CAN (–) Output 54 Injector #2 (+) Output
7 NC — 55 Injector #3 (+) Output
Input/
8 CAN (+) 56 Injector #4 (+) Output
Output
57 Injector #6 (+) Output
9 Supply pump #2 (+) Output
58 Injector #4 (–) Output
10 Supply pump #2 (–) Output
11 EGR valve (–) Output
12 NC —
13 Engine oil press. sensor Input CN-CE02
14 NC —
Input/
15 Water temp. sensor Input Pin No. Signal name Output
16 Sensor power (+5V) Output 1 NC —
17 NC — 2 NC —
18 NC — 3 NC —
19 EGR position sensor Input 4 NC —
20 EGR in press. sensor Input 5 NC —
21 NC — 6 NC —
22 EGR valve (+) Output 7 NC —
23 Boost temp. sensor Input 8 NC —
24 NC — 9 Fuel dial (+) Input
25 Common rail press. sensor Input 10 NC —
26 G sensor (+) Input 11 NC —
27 NE sensor (+) Input 12 NC —
28 NC — 13 NC —
29 Bypass valve position sensor Input 14 NC —
30 Fuel temp. sensor Input 15 NC —
31 Bypass valve (+) Output 16 NC —
32 NC — 17 NC —
33 Sensor power (+5V) Output 18 NC —
34 NC — 19 NC —
35 NC — 20 NC —
36 NC — 21 NC —
37 Sensor power (+5V) Output 22 Fuel dial (+5V) Output
38 GND — 23 Fuel dial (–) —
39 NC — 24 NC —
40 NC — 25 NC —
41 NC — 26 NC —
42 NC — 27 NC —
43 NC — 28 NC —
44 Boost press. sensor Input 29 NC —
45 Injector #1 (+) Output 30 NC —
46 Injector #5 (+) Output 31 NC —
47 G sensor (–) — 32 NC —
PC600-8 5
Input/
Pin No. Signal name Output
33 NC —
34 NC —
35 NC —
36 NC —
37 NC —
38 NC —
39 Key switch (ACC) Input
Electrical intake air heater sub relay
40 Output
(output)
41 NC —
Electrical intake air heater sub relay
42 Output
(return)
43 NC —
44 NC —
45 NC —
Input/
46 CAN (+) Output
Input/
47 CAN (–) Output
48 NC —
49 NC —
50 NC —
CN-CE03
Input/
1 GND —
2 NC —
3 Power (+24V) —
4 NC —
6 PC600-8
Machine control system diagram
OFF (Cancel)
Auto deceleration function
ON E0
P E1
3-mode selector type torque control E
E2
Electronic OLSS function Cut-off control L
Flow control E3
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
Swing control function
system
Engine automatic warming-up,

Overheat prevention function,
Turbo protect function
Travel control function
Fixed to Lo (Low speed)

Travel speed
selection function
Travel pressure Automatic travel speed shifting between
increasing function Hi (High speed) and Lo (Low speed)
Normal rotation
Fan rotation control
Reverse rotation
PC600-8 7
Machine control system diagram
8 PC600-8
PC600-8 9
1. Auto deceleration system
Function
• If all the control levers are at neutral when wait-
ing for work or waiting for a dump truck, the en-
gine 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
Operation
1. When auto-deceleration switch is turned ON
Control levers at neutral When control lever is operated

• If the engine is running at above the deceleration • If any control lever is operated when the engine
actuation speed (approx. 1,400 rpm), and all the speed is at No. 2 deceleration, the engine speed
control levers are returned to neutral, the engine will immediately rise to the speed set by the fuel
speed drops immediately to approx. 100 rpm be- control dial.
low the set speed to the No. 1 deceleration posi-
tion.
• If another 4 seconds passes, the engine speed is
reduced to the No. 2 deceleration position (ap-
prox. 1,400 rpm), and is kept at that speed until
a lever is operated.
2. When auto-deceleration switch is turned OFF
Control lever at neutral When control lever is operated

• If the engine is running at a speed above 1,750 • If any control lever is operated under the condi-
rpm and all the control levers are returned to tion shown at left (after the engine speed drops
neutral, the engine speed drops to approx. 1,750 to approx. 1,750 rpm), the engine speed will im-
rpm after 4 seconds and is kept at that speed un- mediately rise to the speed set by the fuel control
til a lever is operated. dial.
PC600-8 11
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
1) Control method in each mode

P, E, L mode
• Matching point in P, E and L mode: Rated output point
Model PC600-8R
Cut-off 2-stage relief Relief pressure
Mode PC600LC-8R
P 1,800 rpm Q × 31.9 MPa {325 kg/cm2}
E0 1,720 rpm
E1 1,680 rpm
Q × 31.9 MPa {325 kg/cm2}
E2 1,640 rpm
E3 1,580 rpm
L 1,730 rpm × Q 37.3 MPa {380 kg/cm2}
• When the load on the pump rises and the pres-

sure 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
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 actuat-
ed to reduce the relief loss.
3) Cut-off cancel function

• The cut-off cancel function acts to stop the oper-
ation 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 func-
tion is set automatically by operating the power
max. switch, or travel lever.
• Cut-off function and actuation of each switch

Switch Working mode Power max. Swing lock
Travel lever
switch switch switch
Function P E L ON OFF ON OFF ON OFF
Cut-off function Actuated Actuated Cancel Cancel Actuated Cancel Actuated Cancel 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
3. Power max. function
Function
• This is a function to increase the power for a
fixed period when the L.H. knob switch is opre-
Power max.
rated. It makes it possible to obtain a sudden
switch
burst of power to match the working conditions. OFF ON
Mode,
• If knob switch on the work equipment control le-
function
ver is turned ON, the following functions are ac-
tuated.
CO function Actuated Canceled
Main relief valve 31.9 MPa 34.3 MPa

set pressure {325 kg/cm2} {350 kg/cm2}
Canceled
after 8.5 sec
Operating time —
even when
kept pressed
PC600-8 15
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 dig-
ging efficiency by reducing the digging resist-
ance of the boom, and increased ease of
operation by increasing the thrusting force for ex-
cavation, digging square holes, carrying out twist
turns, or escaping from soft ground.
16 PC600-8
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}.
Machine push-up Machine push-up Safety valve set
Mode Effect
switch solenoid valve pressure
By reducing the boom pushing force, it is

made easier for the boom to escape auto-
Boom pushing
14.7 MPa matically in the RAISE direction and to
force Energized
{150 kg/cm2} reduce the number of times that the boom
(low mode)
is operated. At the same time it also
makes the digging operation smoother.
By increasing the thrust force for boom

Boom pushing LOWER, the ease of operation is improved
28.4 MPa
force De-energized for excavation, digging square holes, car-
{290 kg/cm2}
(high mode) rying out twist turns, or escaping from soft
ground.
PC600-8 17
5. Swing control function
Function
• The system is provided with a swing lock and
swing holding brake function.
18 PC600-8
Swing lock, swing holding brake function

• The swing lock (manual) can be locked at any a Swing brake solenoid valve
desired position, and the swing lock and swing For details of the structure and function, see
holding brake (automatic) are interconnected “Solenoid valve”.
with the swing, so they prevent any hydraulic drift a Swing motor
after the swing is stopped. For details of the structure and function, see
“Swing motor”.
Actuation
Swing lock Swing lock Swing brake
Mode Actuation
switch monitor solenoid valve
When swing and work equipment levers are placed at
neutral, swing brake is applied after approx. 10 sec;
when any swing or work equipment lever is operated,
brake is canceled and swing can be operated freely.
Swing holding See diagram

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

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

• If any abnormality should occur in the controller, Swing lock ON OFF
and the swing holding brake is not actuated nor- prolix (when controller is (when controller is
mally and the swing cannot be operated, the switch abnormal) normal)
swing lock prolix switch can be operated to can- Swing lock
cel the swing lock and allow the swing to be op- ON OFF ON OFF
switch
erated.
a Even when the swing lock prolix switch is turned Swing
Swing Swing Swing
Swing holding
ON, the swing lock switch stays ON and the lock lock lock
brake brake
swing brake is not canceled. applied canceled applied
applied
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.
PC600-8 19
6. Engine automatic warming-up, overheat prevention function, turbo protect function
Function
• If the coolant temperature is low, this automati-
cally raises the engine speed to warm up the en-
gine after it is started. In addition, if the coolant
temperature rises too high during operations, it
reduces the load of the pump to prevent over-
heating.
• To protect the turbocharger bearing during cold
weather, the engine speed is kept below the
fixed speed when the engine is started. In addi-
tion, to improve the starting ability, a small
amount of fuel is injected two or more times be-
fore the main injection.
20 PC600-8
1) Engine automatic warming-up function

• After the engine is started, if the engine coolant
temperature is low, the engine speed is automat-
ically 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 over-
heating when the engine coolant temperature
has risen too high.
• This system is actuated at 105°C and above.
PC600-8 21
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 Turbo protect time
temperature (sec)
More than +10°C 0
Gradually changes
+10°C to –10°C
between 0 and 20
Less than –10°C 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
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 per-
formance.
PC600-8 23
Travel speed selection function

1) Manual selection using travel speed switch
If the travel speed switch is set to Lo, Hi, the Travel speed Lo Hi
pump controller controls the pump flow and switch (Low speed) (High speed)
motor volume at each speed range as shown on
Motor volume Max. Min
the right to switch the travel speed.
2) Automatic selection according to engine speed Travel speed
3.0 4.9
If the engine speed is reduced to below 1,200 (km/h)
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 auto-
matically shift to Lo.
3) Automatic selection according to pump dis-
charge 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 pres-
sure continues at 31.4 MPa {320 kg/cm 2 } for
more than 2.0 sec, the pump volume is automat-
ically 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 Main relief valve Cut-off cancel
CO valve
solenoid valve set pressure solenoid valve
31.9 MPa
When traveling De-energized Energized Canceled
{325 kg/cm2}
31.9 MPa
When not traveling De-energized De-energized Actuated
{325 kg/cm2}
24 PC600-8
Components of system
Engine speed sensor
1. Wire Function
2. Magnet • The engine speed sensor is installed to the ring
3. Terminal gear portion of the engine flywheel. It counts
4. Housing electrically the number of gear teeth that pass in
5. Connector 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 de-
tected from the PPC pressure, and this is sent to
the engine controller and pump controller.
PC600-8 25
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 emer-
gency 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
Pump controller
PC600-8 27
CN-CP01 CN-CP02
Input/ Input/
Output Output
1 NC Input 1 NC Output
2 R pump pressure sensor Input 2 Swing prolix switch Input
3 NC Input 3 NC Input
4 Signal GND — 4 232C_R×D Input
5 (Auto grease-up error) Input 5 (Overload sensor) Input
6 NC Input 6 (Overload caution enable switch) Input
7 NC Input 7 Machine select 4 Input
8 F pump pressure sensor Input 8 NC Output
9 Air temp sensor Input 9 NC Output
10 Signal GND — 10 NC Input
11 Knob switch Input 11 NC Output
12 NC Input 12 CAN shield —
13 NC Input 13 Machine select 5 Input
14 NC Input 14 232C_TxD Output
16 NC Output 16 NC Input
17 Starting switch (C) Input 17 Machine select 3 Input
18 NC Input 18 NC Output
19 NC Input 19 Step light drive relay Output
21 Analog GND — Input/
21 NC Output
22 Power supply (+5V) Output
Input/
23 Starting switch (ACC) Input 22 CAN0_L Output
24 Step light switch Input Input/
23 NC Output
24 Flash memory write enable signal Input
25 Horn switch Input
26 NC Input
27 Machine select 2 Input
28 NC Input
29 NC —
30 NC Input
31 NC —
Input/
32 CAN0_H Output
Input/
33 NC Output
34 GND (232C GND) —
35 Service pressure switch Input
36 NC Input
37 Machine select 1 Input
38 Swing lock switch Input
39 NC —
40 NC Input
28 PC600-8
CN-CP03
Input/
1 Controller power supply Input
2 Solenoid power supply Input
3 SOL_COM —
4 Battery relay drive Output
5 NC Output
6 NC Output
7 NC Output
8 Travel alarm Output
9 Bucket digging pressure switch Input
10 Boom raise switch Input
11 Controller power supply Input
13 SOL_COM —
14 Key signal Input
15 NC Output
16 TVC solenoid Output
17 2-stage relief solenoid Output
18 Flash light drive relay Output
19 Bucket dump pressure switch Input
20 Boom lower pressure switch Input
21 GND —
23 SOL_COM —
24 Key signal Input
25 Fan reverse solenoid Output
26 NC Output
27 Travel speed solenoid Output
28 Cut-off cancel solenoid Output
29 Swing pressure switch Input
30 Arm digging pressure switch Input
31 GND —
32 GND —
33 GND —
34 NC —
35 Fan pump EPC Output
36 NC Output
37 Swing parking brake solenoid Output
38 Bucket Hi cancel solenoid Output
39 Travel pressure switch Input
40 Arm dump pressure switch Input
PC600-8 29
30 PC600-8
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 ma-
chine.
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 con-
stantly (Coolant temperature, hydraulic oil
temperature, fuel level, etc.)
• The monitor panel also has various mode selec-
tor switches and functions to operate the ma-
chine control system.
PC600-8 31
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 Process-
ing 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
CN1 CN3
Input/ Input/
Output Output
1 Key ON Input 1 NC Input
2 Key ON Input 2 NC Input
3 Washer Output 3 NC Input
4 Start Input 4 NC Input
5 Limit switch (W) Input 5 NC Input
6 GND — 6 NC Input
7 GND — 7 RS230C CTS Input
8 VB+ Input 8 RS232C R×D Input
9 Wiper (+) Output Input/
9 RS232C R×D Output
10 Wiper (–) Output
Input/
11 Buzzer on input Input 10 RS232C R×D Output
12 Limit switch (P) Input 11 Boot switch Input
12 NC Input
CN2
13 GND —
Input/
Pin No. Signal name 14 CAN (shield) Input
Output
15 CAN (+) Input
1 (Coolant temp.) Input
16 CAN (–) Input
2 Fuel level Input
3 Coolant level Input
4 (Hydraulic oil level) Input
5 Air filter Input
6 NC Input
7 (Engine oil press.) Input
8 Engine oil level Input
Input/
9 N/W signal Output
Input/
10 N/W signal Output
11 Charge Input
12 Hydraulic oil temp. (a) Input
13 GND —
14 Buzzer drive Input
15 Limit switch (window) Input
16 Buzzer cancel Input
17 Swing lock Input
18 Pre-heating Input
19 Light Input
20 GND —
PC600-8 33
Monitor control, display portion
Monitor portion
1. Wiper monitor 11. Fuel level monitor

2. Preheating monitor 12. Hydraulic oil temperature monitor
3. Swing lock monitor 13. Power Max. monitor
4. Engine coolant temperature monitor 14. Auto-deceleration monitor
5. Hydraulic oil temperature gauge 15. Radiator coolant level caution
6. Engine coolant temperature gauge 16. Battery charge caution
7. Working mode monitor 17. Engine oil pressure caution
8. Service monitor 18. Engine oil level caution
9. Travel speed meter 19. Air cleaner clogging
10. Fuel gauge 20. Maintenance time warning caution
34 PC600-8
Monitor items and display

Display category Symbol Display item Display range Display method
ON INT OFF
Wiper Displays set condition
Working mode Displays set mode
Monitor
Travel speed Displays set speed
Auto-decelera- Displays actuation

ON OFF
tion status
Service meter Lights up when service

Service meter When service meter is working
indicator meter is working
PC600-8 35
Symbol Display item Display method
Swing holding brake

Swing lock switch Swing lock monitor
release switch
OFF OFF OFF
Swing lock
ON OFF ON
SAT00098 OFF ON Flashes
ON ON ON
Continuous set time Preheating monitor status

Up to 30 sec. ON
Preheating
From 30 sec. to 40 sec. Flashes
More than 40 sec. OFF
Power Max. switch status Power Max. monitor status
Lights up but goes out after

Power Max. Being pressed
approx. 9 sec. when kept pressed
Not being pressed Flashes
Engine coolant
temperature
Hydraulic oil
See gauge display on the next page
temperature
Fuel level
36 PC600-8
Gauge display
Gauge Range Temperature, volume Indicator (Symbol) Buzzer sound

A1 105 Red
A2 102 Red
Engine coolant A3 100 Green

temperature (°C) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
Hydraulic oil tempera- B3 100 Green

ture (°C) B4 80 Green
B5 40 Green
B6 20 White
C1 524 Green
C2 382 Green
C3 249 Green
Fuel level (l)
C4 138 Green
C5 101 Green
C6 84 Red
PC600-8 37
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 When engine is When engine is

Symbol Display item
item stopped running
When abnormal,
Engine oil pressure q — lights up and buzzer
SAP00519 sounds
Lights up when
Battery charge q —
abnormal
SAP00522
When abnormal,
Radiator coolant Lights up when
q lights up and buzzer
level abnormal
SAP00520 sounds
Lights up when
Engine oil level q —
abnormal
SAP00523
Lights up when
Air cleaner clogging q —
abnormal
SAP00521
Lights up when there is a warning. Lights up for

Maintenance 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 Color of symbol

Low temperature (below B6 or equivalent) Black on white background
Normal (B6 – B2) No display
High temperature (above B2) White on red background
38 PC600-8
Switches
1. Working mode selector switch

2. Buzzer cancel switch
3. Display brightness, contrast adjustment switch
4. Control switch
5. Window washer switch
6. Wiper switch
7. Maintenance switch
8. Travel speed selector switch
9. Auto-deceleration switch
PC600-8 39
• Working mode selector switch

The condition of the machine changes according Switch that is Working mode status
Display
to the switch that is pressed (Shown in the figure pressed after setting
at right). It is possible to check the condition on
[P] P P mode (default)
the working mode monitor display. The relation-
ship between each working mode and the moni- [E] E E mode
tor display is shown in the table on the right. [L] L L mode
• 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 oper-
ated to switch the working mode, it is automati-
cally set to ON.
• Travel speed selector switch
Display Setting
Each time the travel speed selector switch is
pressed, the travel speed changes. Crawler symbol + Lo Low speed (default)
Lo o Hi o Lo …… Crawler symbol + Hi High speed
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
Wiper actuation
Each time the wiper switch is pressed, the wiper Display Setting
status
setting changes OFF o INT o ON o OFF o
…… Stowing stopped or
None OFF
Use the wiper monitor display to check the pres- now stowing
ent condition. Wiper symbol + INT INT Intermittent actuation
The relationship between the wiper setting and
Wiper symbol + ON ON Continuous actuation
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 mainte-
nance 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.
40 PC600-8
Maintenance function
When the maintenance time for replacement,

inspection, or filling has approached for the 11 main-
tenance 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 lubri-
cation maintenance.
a Maintenance items
Replacement
No. Item
interval (hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel filter 1,000
41 Fuel pre-filter 500
04 Hydraulic filter 1,000
05 Hydraulic tank breather 1,000
06 Corrosion resistor 1,000
07 PTO case oil 1,000
08 Final case oil 2,000
09 Machinery case oil 1,000
10 Hydraulic oil 5,000
a The above replacement intervals are set for

each item, and the time remaining to mainte-
nance is reduced as the machine is operated.
The content of the caution display differs
according to the remaining time. The relation-
ship is as shown in the table below.
Display Condition
Remaining time for mainte-
None nance for all items is more
than 30 hours
There is one or more items
Notice display (black sym-
with less than 30 hours
bol displayed on yellow
remaining time for
background)
maintenance
There is one or more items
Warning display (white
with less than 0 hours
symbol displayed on red
remaining time for
background)
maintenance
PC600-8 41
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 highlight-
ed.
a The display method is the same as de-
scribed on the previous page (relationship
between remaining time and caution dis-
play). 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 con-

firmation 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 re-
set.
42 PC600-8
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 con-

tent.
No. Symbol Content
00 Return mark 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 con-
firmation 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 bright-

ness and contrast as desired.
Control switch Actuation
Flow level bar graph

extends to the right
Flow level bar graph

retracts to the left
PC600-8 43
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 re-
leased, the display goes out.
Note that it takes 3 – 5 seconds after the
switches are pressed for the service meter dis-
play 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 bro-
ken.
User code display function
• If there is any problem in operating the machine,

the user code is displayed on the monitor to ad-
vise the operator of the steps to take.
This code display appears on the operator
screen.
• On the operator screen, the user code is dis-
played on the portion for the hydraulic oil temper-
ature 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.
44 PC600-8
• While the user code is being displayed, if the in-

put 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 tele-
phone number.
For details of inputting and setting the telephone
number, see “Special functions of monitor panel”
in the “Testing and adjusting” section.
PC600-8 45
Sensors
• The signals from the sensors are input directly to The contact type sensors are always connected
the engine controller and the pump controller at one end to the chassis GND.
monitor.
Name of sensor Type of sensor When normal When abnormal Input controller
Coolant level Contact type ON (closed) OFF (open) Monitor
Engine oil level Contact type ON (closed) OFF (open) Monitor
Engine oil pressure Contact type ON (closed) OFF (open) Engine controller
Coolant temperature Resistance type — — Engine controller
Fuel level Resistance type — — Monitor
Air cleaner clogging Contact type OFF (open) ON (closed) Monitor
Hydraulic oil temperature Resistance type — — Monitor
Main pump oil pressure Analog — — Pump controller
Coolant level sensor
1. Sub-tank
2. Float
3. Sensor
4. Connector
46 PC600-8
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Engine oil pressure sensor
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
Air cleaner clogging sensor
PC600-8 47
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
Coolant temperature sensor

Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
48 PC600-8
Main pump oil pressure sensor (0 – 49.0 MPa {0 – 500 kg/cm2})
1. Sensor
2. Nut
3. Case
4. 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
PC600-8 49
KOMTRAX system
(if equipped)
• The KOMTRAX terminal sends various information on the machine by a wireless communication.The KOM-
TRAX 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
50 PC600-8
KOMTRAX terminal
Model name: TC301
The KOMTRAX system uses satellite communication technology.
1. Communication antenna connector

2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)

DEUTSCH-40P [CN-G01]
Input/Output Input/Output
signal signal
1 NC — 21 Operation mode selection 1 Input
2 NC — 22 Operation mode selection 2 Input
3 NC — 23 NC —
4 NC — 24 NC —
5 NC — 25 NC —
6 NC — 26 NC —
7 CAN signal (L) Input/Output 27 Starting switch (C) Input
8 CAN signal (H) Input/Output 28 Alternator (R) Input
9 NC — 29 NC —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 NC —
13 NC — 33 NC —
14 NC — 34 NC —
15 NC — 35 NC —
16 NC — 36 Starting switch (ACC) Input
17 NC — 37 Power source GND —
18 NC — 38 Power source GND —
19 NC — 39 Constant power source (24V) Input
20 Relay output Output 40 Constant power source (24V) Input
Outline
• The KOMTRAX terminal can send information • There are the LED lamp and the 7-segment indi-
via wireless communication antenna, acquiring cator lamp in the display area, and these lamps
various information of the machine from the net- are used for the testing and the troubleshooting.
work signal in the machine and the input signal. • When using TC301 in other countries, the satel-
Also, the controller incorporates CPU (Central lite communication company to contract is differ-
Processing Unit) and provide the wireless com- ent. So, part numbers of TC301 are different in
munication function and the GPS function. other countries. Also, when using TC301 in other
• Use of KOMTRAX terminal must be limited for countries, you must notify the name of the coun-
the countries in which such communication is al- try.
lowed.
PC600-8 51
© 2010 KOMATSU
All Rights Reserved
52
SEN00395-04
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up

20 Standard value table

Standard service value table
Standard value table for engine ........................................................................................................................... 2

Standard value table for chassis .......................................................................................................................... 3
PC600-8 1
SEN00395-04 20 Standard value table
Standard value table for engine

Machine model PC600, 600LC-8
Engine SAA6D140E-5
Item Measurement condition Unit Standard value Permissible value

High idle 1,950 ± 50 1,950 ± 50
Engine speed Low idle rpm 800 ± 25 800 ± 25
Rated speed 1,800 1,800

kPa
Intake air pressure At rated output Min 147 {Min. 1,100} 125 {940}
{mmHg}
Exhaust gas All speed range
°C Max. 650 700
pressure (intake air temp: 20°C)
At sudden acceleration % Max. 25 35
Exhaust gas color (low o high idle) Bosch (Max. 2.5) (3.5)
At high idle index (Max. 1.0) (2.0)
Intake valve 0.35 —
Valve clearance
mm
(at cold)
Exhaust valve 0.57 —
EGR valve and bypass High idle MPa

Min. 1.18 {Min. 12} Min. 1.18 {Min. 12}
valve drive oil pres-
sure Low idle {kg/cm2} Min. 1.43 {Min. 14.6} Min. 1.43 {Min. 14.6}
Compression Oil temperature: 40 – 60°C MPa
Min. 4.1 {Min. 42} 2.8 {29}
pressure Engine speed: 200 – 250 rpm {kg/cm2}
(Coolant temperature: Min. 70°C)
kPa
Blow-by pressure Max. 2.94 {Max. 300} 3.92 {400}
{mmH2O}
At rated output
Oil temperature:
Min. 80°C
SAE0W30E0S Min. 0.34 {Min. 3.5} 0.21 {2.1}
Rated output
(At high idle) SAE5W40E0S
MPa
Oil pressure SAE10W30DH
Oil temperature: {kg/cm2}
SAE15W40DH
Min. 80°C SAE30DH Min. 0.10 {Min. 1.0} 0.08 {0.8}
Rated output
(At low idle)
EGR valve and bypass High idle Min. 1.43 {Min. 14.6} Min. 1.43 {Min. 14.6}
MPa
valve drive oil pres-
{kg/cm2}
sure Low idle Min. 1.18 {Min. 12} Min. 1.18 {Min. 12}
Oil temperature All speed range (inside oil pan) °C 90 – 110 120
Deflection when pressed with finger
Alternator belt tension mm 13 – 16 13 – 16
force of approx. 58.8 N {6 kg}
Air conditioner
Deflection when pressed with finger
compressor belt mm 10 – 15 10 – 15
force of approx. 58.8 N {6 kg}
tension
2 PC600-8
Standard value table for chassis

Applicable model PC600, 600LC-8
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
• Engine coolant temperature:
Within operating range
• Hydraulic oil temperature:
All pumps at relief Within operating range Min. 1,780 Min. 1,780
• Engine at high idle
• Working mode: P
• Boom RAISE relief
Engine speed

Power max. ON
Within operating range rpm
+ Min. 1,730 Min. 1,730
All pumps at relief
• Working mode: P
• Boom RAISE relief + power
max. switch ON
High idle-cut ON • Auto-deceleration switch OFF 1,750 ± 100 1,750 ± 100
• All control levers at neutral
Auto-deceleration
• Auto-deceleration switch ON 1,400 ± 100 1,400 ± 100
ON
Boom Lo control valve
Boom Hi control valve
Arm Lo control valve
Spool stroke
Arm Hi control valve

• Stroke of each side 16 ± 0.5 16 ± 0.5
Bucket Lo control valve
Bucket Hi control valve
Swing control valve
Travel control valve
N o RAISE,
Boom control lever mm 85 ± 10 85 ± 10
LOWER
Arm control lever • Center of N o IN, OUT 85 ± 10 85 ± 10

Travel of control levers
lever knob
• Read max. N o CURL,
Bucket control lever value to end 85 ± 10 85 ± 10
DUMP
of travel
Swing control lever (Exclude play N o R.H., L.H. 85 ± 10 85 ± 10
at neutral.)
• Engine N o F, R
Travel control lever stopped 115 ± 12 115 ± 12
(L.H., R.H.)
Work equipment,
Play of control levers Max. 10 Max. 15
swing, travel
PC600-8 3
Cate-
gory
15.7 ± 3.9 Max. 24.5
Boom control lever
{1.6 ± 0.4} {Max. 2.5}
Operating effort of control levers

• Hydraulic oil temperature: 15.7 ± 3.9 Max. 24.5
Arm control lever
Within operating range {1.6 ± 0.4} {Max. 2.5}
• Center of lever knob 12.7 ± 2.9 Max. 21.6
Bucket control lever • Measure max. value to end of {1.3 ± 0.3} {Max. 2.2}
travel N {kg}
12.7 ± 2.9 Max. 21.6
Swing control lever
{1.3 ± 0.3} {Max. 2.2}
24.5 ± 5.9 Max. 39.2
Lever
Travel control lever, {2.5 ± 0.6} {Max. 4.0}
pedal 74.5 ± 18.6 Max. 107.6
Pedal
{7.6 ± 1.9} {Max. 11}
31.87 +1.47 31.87 +1.47
Normal –0.98 –0.98
+15 +15
{325 –10 } {325 –10 }
34.32 +1.47 34.32 +1.47

RAISE
At power –0.98 –0.98

max. +15 +15
{350 –10 } {350 –10 }
Boom relief pressure 37.2 +1.5 37.2 +1.5

L mode –2.0 –2.0
+15 +15
{380 –20 } {380 –20 }
• Hydraulic oil
temperature: 15.69 ± 1.96 15.69 ± 1.96
Normal
LOWER
Within operat- {160 ± 20} {160 ± 20}

ing range
At machine 27.95 ± 1.96 27.95 ± 1.96
• Engine at high
push-up {285 ± 20} {285 ± 20}
idle
Hydraulic pressure
• Working 31.87 +1.47 31.87 +1.47

mode: P Normal –0.98 –0.98
+15 +15
• Pump outlet {325 –10 } {325 –10 }
Arm relief pressure MPa
pressure {kg/cm2} 34.32 +1.47 34.32 +1.47
when mea- At power max. –0.98 –0.98
sured circuit is +15 +15
{350 –10 } {350 –10 }
relieved
• Relieve either 31.87 +1.47 31.87 +1.47
Normal –0.98 –0.98
travel circuit. +15
{325 –10 }
+15
{325 –10 }
Bucket relief pressure
34.32 +1.47 34.32 +1.47
At power max. –0.98 –0.98
+15 +15
{350 –10 } {350 –10 }
29.91 ± 0.98 29.91 ± 0.98
Swing relief pressure
{305 ± 10} {305 ± 10}
35.30 ± 1.47 35.30 ± 1.47
Travel relief pressure
{360 ± 15} {360 ± 15}
• Hydraulic oil temperature: 3.14 +0.39 3.14 +0.39
Control pressure Within operating range +0 +0
+4 +4
• Engine at high idle {32 +0 } {32 +0 }
4 PC600-8
Cate-
gory
All control
2.25 ± 0.2 Min. 1.76
• Hydraulic oil levers at
{23 ± 2} {Min. 18}
temperature: neutral
Within operat-
TVC valve output ing range Boom RAISE 1.10 +0.20 1.05 +0.20
–0.53 –0.53
pressure • Engine at high relief (Normal) +2.0 +2.0
{11.2 –5.4 } {10.7 –5.4 }
idle
• Working Power max. +
1.02 ± 0.2 0.97 ± 0.2
mode: P Boom RAISE
{10.4 ± 2.0} {9.9 ± 2.0}
relief
• Hydraulic oil All control

Max. 0.4 Max. 0.55
temperature: levers at
{Max. 4} {Max. 5.5}
Within operat- neutral
ing range
Boom RAISE 1.10 +0.20 1.05 +0.20
• Engine at high –0.53 –0.53
relief (Normal) +2.0 +2.0
idle {11.2 –5.4 } {10.7 –5.4 }
CO-NC valve output
• Working
pressure Travel under no
Hydraulic pressure
mode: P Min. 1.7 Min. 1.7

• When track load (Lever at
{Min. 17} {Min. 17}
runs idle, stroke end)
MPa
measure oil Power max. + {kg/cm2} 1.02 ± 0.2 0.97 ± 0.2
pressure on Boom RAISE
idle side. {10.4 ± 2.0} {9.9 ± 2.0}
relief
• Hydraulic oil
All control 1.76 ± 0.2 Min. 1.5
temperature:
levers at neutral {18 ± 2} {Min. 15}
Within operat-
Jet sensor output ing range
differential pressure • Engine at high Travel under no
idle Max. 0.2 Max. 0.2
load (Lever at
• Working {Max. 2} {Max. 2}
stroke end)
mode: P
PPC valve output Within operating range 2.9 +0.54 2.9 +0.54
–0.15 –0.15
pressure • Engine at high idle +5.5 +5.5
{30 –1.5 } {30 –1.5 }
• Control lever at stroke end
Max. 2.0 Max. 2.9
Oil pressure drop • Difference between relief pres-
{Max. 20} {Max. 30}
sure at high idle and that at low
idle
Swing
Overrun when stopping • Hydraulic oil temperature: deg. Max. 45 Max. 60

swing Within operating range (mm) (Max. 775) (Max. 1,040)
• Bucket: No load
• Working mode: P
• Stop after swinging one turn
and measure distance that
swing circle moves
PC600-8 5
Cate-
gory
90° 4.0 ± 0.5 Max. 4.9
• Hydraulic oil tempera-

Time taken to start ture: Within operating sec.
swing range
• Bucket: No load
180° 5.8 ± 0.7 Max. 7.2
• Working mode: P
• Time taken to swing 90°
and 180° from starting
position
Time taken to swing • Hydraulic oil temperature: sec. 34 – 38 Max. 40

• Bucket: No load
• Working mode: P
Swing
• Swing one turn, then measure

time taken to swing next 5 turns

Hydraulic drift of swing • Engine stopped mm 0 0
• 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 min-
utes.
Leakage from swing • Engine at high idle
l/min Max. 5 Max. 10
motor • Swing lock switch: ON
• Leakage in 1 minute during
swing relief
6 PC600-8
Cate-
gory
STD: 54 – 66 STD: 54 – 66
Lo
LC: 57 – 70 LC: 57 – 70

Travel speed ture: Within operating sec.
(Free rotation) range
• Working mode: P
• Raise track on one side STD: 35 – 43 STD: 35 – 43
at a time, rotate one turn, Hi
LC: 37 – 46 LC: 37 – 46
then measure time taken
for next 5 turns with no
load.
Lo 23 – 31 23 – 31

Travel speed ture: Within operating sec.
(Actual travel) range
Travel
• Working mode: P
• On flat place
• Run up for at least 10 m, Hi 15 – 19 15 – 19
and measure time taken
to travel next 20 m on flat
ground.

• Working mode: P
Travel deviation • Travel speed: Lo mm Max. 200 Max. 220
• On hard and flat place
• Measure travel deviation (x) in
travel of 20 m after running up
10 m.
PC600-8 7
Cate-
gory

Hydraulic drift of travel Within operating range mm 0 0
• Engine stopped
• Stop machine on 12° slope with
Travel
sprocket at uphill end of

machine.
• Measure the distance the
machine moves in 5 minutes.
Leakage of travel • Engine at high idle
motor • Travel: Lock sprocket.
• Measure leakage in 1 minute
during travel relief.
Total work equip-

ment
Max. 1,200 Max. 1,800
(hydraulic drift at
tip of bucket teeth)
Hydraulic drift of work equipment

Boom cylinder
(amout of retrac- Max. 60 Max. 90
Work equipment
• On level and flat place

tion of cylinder)
• Work equipment: In above mea-
suring posture with rated load
mm
44 kN {4,500 kg}
• Engine: Stopped
Arm cylinder • Work equipment control lever:
(amount of exten- Neutral Max. 165 Max. 250
sion of cylinder) • Start measuring just after set-
ting machine and measure
every 5 minutes for 15 minutes.
Bucket cylinder
(amount of retrac- Max. 50 Max. 75
tion of cylinder)
8 PC600-8
Cate-
gory
RAISE
5.1 ± 0.5 Max. 5.9

Boom speed • Engine: High idle
• Working mode: P
• Measure time taken to
LOWER
move bucket between
RAISE stroke end and 3.6 ± 0.4 Max. 4.4
ground touch point of
bucket (including operating
time of cylinder cushion).
IN
5.3 ± 0.5 Max. 6.3

Work equipment speed
Work equipment
Arm speed • Hydraulic oil temperature:

Within operating range sec.
• Engine: High idle
• Working mode: P
OUT
move arm between OUT 3.9 ± 0.4 Max. 4.7

stroke end and IN stroke
end (including operating
CURL
3.2 ± 0.4 Max. 4.0

Bucket speed Within operating range
• Working mode: P
DUMP
move bucket between

DUMP stroke end and 3.2 ± 0.4 Max. 4.1
CURL stroke end (including
operating time of cylinder
cushion).
PC600-8 9
Cate-
gory

Boom time lag Within operating range Max. 3 Max. 3
• 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.
Time lag

Arm time lag sec. Max. 3 Max. 3
Work equipment

• Working mode: P
• Move in arm from OUT stroke
start moving arm again after it is
stopped.

Bucket time lag Max. 3 Max. 3
• Working mode: P
• Curl bucket from DUMP stroke
start moving bucket again after
it is stopped.

Cylinder Within operating range Max. 5 Max. 20
Oil leakage

• Relieve cylinder to be mea- cc/min
Center swivel joint sured or travel circuit and mea- Max. 10 Max. 100
sure leakage in 1 minute.
performance
Pump
Hydraulic pump
• See following page. l/min See following page.
discharge amount
10 PC600-8
Cate-
gory
• Hydraulic oil temperature: 45 –
55°C
Fan speed rpm 1,450 ± 50 1,450 ± 50
• Fan: 100% speed mode
55°C MPa 13.2 – 18.1 13.2 – 18.1
Fan
Fan circuit oil pressure

• Engine: High idle {kg/cm2} {135 – 185} {135 – 185}
55°C
Fan pump EPC current mA 490 ± 50 490 ± 50
PC600-8 11

Cate-
gory
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 Standard value Judgement

Average
discharge pressure of for discharge standard lower
Check point pressure
pressure other pump amount Q limit Q
(MPa {kg/cm2})
(MPa {kg/cm2} (MPa {kg/cm2}) (l/min) (l/min)
P1 + P2
As desired P1 P2 P= See graph See graph
2
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 speci-
fied speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of mea-
surement, and use them as a base for calculating the pump discharge amount at the specified speed.
12 PC600-8
Cate-
gory
All pumps at relief Within operating range Min. 1,780 Min. 1,780
Engine speed
• Working mode: P
• Boom RAISE relief
rpm
High idle-cut ON • Auto-deceleration switch OFF 1,750 ± 100 1,750 ± 100
Auto-deceleration
• Auto-deceleration switch ON 1,400 ± 100 1,400 ± 100
ON
Boom Lo control valve
Boom Hi control valve
Arm Lo control valve
Spool stroke
Arm Hi control valve

• Stroke of each side 16 ± 0.5 16 ± 0.5
Bucket Lo control valve
Bucket Hi control valve
Swing control valve
Travel control valve
N o RAISE,
Boom control lever mm 79 ± 10 85 ± 10
LOWER
Arm control lever • Center of N o IN, OUT 79 ± 10 85 ± 10

Travel of control levers
lever knob
• Read max. N o CURL,
Bucket control lever value to end 79 ± 10 85 ± 10
DUMP
of travel
Swing control lever (Exclude play N o R.H., L.H. 79 ± 10 85 ± 10
at neutral.)
• Engine N o F, R
Travel control lever stopped 115 ± 12 115 ± 12
(L.H., R.H.)
Work equipment,
Play of control levers Max. 10 Max. 15
swing, travel
16.7 ± 3.9 Max. 25.5

Boom control lever
{1.7 ± 0.4} {Max. 2.6}
Operating effort of control levers

Arm control lever
Within operating range {1.7 ± 0.4} {Max. 2.6}
• Center of lever knob 13.7 ± 2.9 Max. 22.6
Bucket control lever • Measure max. value to end of {1.4 ± 0.3} {Max. 2.3}
travel N {kg}
13.7 ± 2.9 Max. 22.6
Swing control lever
{1.4 ± 0.3} {Max. 2.3}
24.5 ± 5.9 Max. 39.2
Lever
Travel control lever, {2.5 ± 0.6} {Max. 4.0}
pedal 74.5 ± 18.6 Max. 107.6
Pedal
{7.6 ± 1.9} {Max. 11}
PC600-8 13
Cate-
gory
29.42 +1.47
–0.98 29.42 +1.47
–0.98
Normal
{300 +15
–10 } {300 +15
–10 }
At power
RAISE
— —
max.
34.32 +1.47
–0.98 34.32 +1.47
–0.98
Boom relief pressure L mode {350 +15
–10 } {350 +15
–10 }
(When Boom Raise (When Boom Raise
is single) is single)
15.69 ± 1.96 15.69 ± 1.96
Normal
LOWER
• Hydraulic oil {160 ± 20} {160 ± 20}

temperature:
At machine 27.95 ± 1.96 27.95 ± 1.96
Within operat-
push-up {285 ± 20} {285 ± 20}
ing range
• Engine at high 29.42 +1.47
–0.98 29.42 +1.47
–0.98
idle Normal
{300 +15
–10 } {300 +15
–10 }
Hydraulic pressure
Arm relief pressure • Working

mode: P
• Pump outlet At power max. — —
MPa
pressure {kg/cm2}
when mea- 29.42 +1.47
–0.98 29.42 +1.47
–0.98
Normal
sured circuit is {300 +15
–10 } {300 +15
–10 }
Bucket relief pressure relieved
• Relieve either
At power max. — —
travel circuit.
28.42 +1.47 28.42 +1.47
Open
–0.98 –0.98
Normal
{290 +15
–10 } {290 +15
–10 }
Bottom dump relief
pressure +1.47
24.52 –0.98 24.52 +1.47
Close
–0.98
Normal
{250 +15
–10 } {250 +15
–10 }
29.91 ± 0.98 29.91 ± 0.98
Swing relief pressure
{305 ± 10} {305 ± 10}
35.3 ± 1.47 35.3 ± 1.47
Travel relief pressure
{360 ± 15} {360 ± 15}
• Hydraulic oil temperature: +0.39 +0.39
3.14 0 3.14 0
Control pressure Within operating range
• Engine at high idle {32 +4
0} {32 +4
0}
14 PC600-8
Cate-
gory
• Hydraulic oil All control
2.25 ± 0.2 Min. 1.76
temperature: levers at
{23 ± 2} {Min. 18}
Within operat- neutral
TVC valve output ing range
pressure • Engine at high +0.20 +0.20
Boom RAISE 1.10 –0.53 1.05 –0.53
idle
• Working relief (Normal) +2.0 +2.0
{11.2 –5.4 } {10.7 –5.4 }
mode: P
• Hydraulic oil
All control
temperature: Max. 0.4 Max. 0.55
levers at
Within operat- {Max. 4} {Max. 5.5}
neutral
ing range
• Engine at high
idle +0.20 +0.20
CO-NC valve output Boom RAISE 1.10 –0.53 1.05 –0.53
• Working +2.0 +2.0
pressure relief (Normal) {11.2 –5.4 } {10.7 –5.4 }
mode: P
Hydraulic pressure
• When track
runs idle,
Travel under no
measure oil Min. 1.7 Min. 1.7
load (Lever at MPa
pressure on {Min. 17} {Min. 17}
stroke end) {kg/cm2}
idle side.
• Hydraulic oil
All control 1.76 ± 0.2 Min. 1.5
temperature:
levers at neutral {18 ± 2} {Min. 15}
Within operat-
Jet sensor output ing range
differential pressure • Engine at high Travel under no
idle Max. 0.2 Max. 0.2
load (Lever at
• Working {Max. 2} {Max. 2}
stroke end)
mode: P
• Hydraulic oil temperature: +0.54 +0.54
PPC valve output Within operating range 2.9 –0.15 2.9 –0.15
pressure • Engine at high idle +5.5 +5.5
{30 –1.5 } {30 –1.5 }
• Control lever at stroke end
Max. 2.0 Max. 2.9
Oil pressure drop • Difference between relief pres-
{Max. 20} {Max. 30}
sure at high idle and that at low
idle
Swing
Overrun when stopping • Hydraulic oil temperature: deg. Max. 45 Max. 60

swing Within operating range (mm) (Max. 775) (Max. 1,040)
• Bucket: No load
• Working mode: P
• Stop after swinging one turn
and measure distance that
swing circle moves
PC600-8 15
Cate-
gory
90° 4.0 ± 0.5 Max. 4.9

Time taken to start ture: Within operating sec.
swing range
• Bucket: No load
180° 5.8 ± 0.7 Max. 7.2
• Working mode: P
• Time taken to swing 90°
and 180° from starting
position
Time taken to swing • Hydraulic oil temperature: sec. 34 – 38 Max. 40

• Bucket: No load
• Working mode: P
Swing
• Swing one turn, then measure

time taken to swing next 5 turns

Hydraulic drift of swing Within operating range mm 0 0
• 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 min-
utes.
Leakage from swing • Engine at high idle
motor • Swing lock switch: ON
• Leakage in 1 minute during
swing relief
16 PC600-8
Cate-
gory
STD: 54 – 66 STD: 54 – 66
Lo
LC: 57 – 70 LC: 57 – 70

ture: Within operating
Travel speed
range sec.
(Free rotation)
• Working mode: P
• Raise track on one side
at a time, rotate one turn, STD: 35 – 43 STD: 35 – 43
Hi
then measure time taken LC: 37 – 46 LC: 37 – 46
for next 5 turns with no
load.
Lo 23 – 31 23 – 31
Travel speed • Hydraulic oil temperature: sec.

(Actual travel) Within operating range
Travel
• Working mode: P
• On flat place
Hi 15 – 19 15 – 19
• Run up for at least 10 m,
and measure time taken
to travel next 20 m on flat
ground.

Travel deviation • Working mode: P mm Max. 200 Max. 220
• Travel speed: Lo
• On hard and flat place
• Measure travel deviation (x) in
travel of 20 m after running up
10 m.
PC600-8 17
Cate-
gory
Hydraulic drift of travel mm 0 0

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

sprocket at uphill end of
machine.
• Measure the distance the
machine moves in 5 minutes.
Leakage of travel • Engine at high idle
motor • Travel: Lock sprocket.
• Measure leakage in 1 minute
during travel relief.
Total work equip-

ment
Max. 1,500 Max. 1,800
(hydraulic drift at
tip of bucket teeth)
Hydraulic drift of work equipment
Boom cylinder • Hydraulic oil temperature:

(amout of retrac- Within operating range Max. 150 Max. 230
Work equipment
tion of cylinder) • On level and flat place

• Work equipment: In above mea-
suring posture with rated load mm
70 kN {7,200 kg}
Arm cylinder
• Engine: Stopped
(amount of exten- Max. 30 Max. 45
• Work equipment control lever:
sion of cylinder)
Neutral
• Start measuring just after set-
ting machine and measure
Bucket cylinder every 5 minutes for 15 minutes.
(amount of retrac- Max. 8 Max. 12
tion of cylinder)
18 PC600-8
Cate-
gory
RAISE
5.5 ± 0.6 Max. 6.8

Boom speed • Engine: High idle
• Working mode: P
LOWER
move bucket between
RAISE stroke end and 4.0 ± 0.4 Max. 5.2
ground touch point of
bucket (including operating
IN
4.5 ± 0.5 Max. 5.9

Arm speed Within operating range
Work equipment speed
• Working mode: P
Work equipment

OUT
move arm between OUT 2.7 ± 0.3 Max. 3.6

stroke end and IN stroke sec.
end (including operating
OPEN
2.2 ± 0.2 Max. 2.8
Bottom speed
CLOSE

CURL
4.0 ± 0.4 Max. 5.0

Bucket speed Within operating range
• Working mode: P
DUMP
move bucket between

DUMP stroke end and 4.0 ± 0.4 Max. 2.8
CURL stroke end (including
operating time of cylinder
cushion).
PC600-8 19
Cate-
gory
Boom time lag Max. 3 Max. 3

• Working mode: P
• Lower boom from RAISE stroke
lift up front side of machine after
bucket touches ground.
Work equipment
Time lag
Arm time lag • Hydraulic oil temperature: sec. Max. 3 Max. 3

• Working mode: P
• Move in arm from OUT stroke
start moving arm again after it is
stopped.
Bucket time lag Max. 3 Max. 3

• Working mode: P
• Curl bucket from DUMP stroke
start moving bucket again after
it is stopped.
20 PC600-8
Cate-
gory
Time lag
Bottom time lag sec. Max. 3 Max. 3

Work equipment

• Close bottom in full open state
and measure time taken to start
moving bottom again after it is
stopped.
Oil leakage
Cylinder Within operating range Max. 5 Max. 20

cc/min
• Relieve cylinder to be mea-
Center swivel joint sured or travel circuit and mea- Max. 10 Max. 100
sure leakage in 1 minute.
performance
Pump
Hydraulic pump
• See following page. l/min See following page.
discharge amount

55°C
Fan speed rpm 1,450 ± 50 1,450 ± 50
55°C MPa 13.2 – 18.1 13.2 – 18.1
Fan
Fan circuit oil pressure

• Engine: High idle {kg/cm2} {135 – 185} {135 – 185}
55°C
Fan pump EPC current mA 490 ± 50 490 ± 50
PC600-8 21

Cate-
gory
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 Standard value Judgement

Average
discharge pressure of for discharge standard lower
Check point pressure
pressure other pump amount Q limit Q
(MPa {kg/cm2})
(MPa {kg/cm2} (MPa {kg/cm2}) (l/min) (l/min)
P1 + P2
As desired P1 P2 P= See graph See graph
2
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 speci-
fied speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of mea-
surement, and use them as a base for calculating the pump discharge amount at the specified speed.
22 PC600-8
PC600-8 23
©2009 KOMATSU
All Rights Reserved
24
SEN00444-04
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up


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 1
SEN00444-04 30 Testing and adjusting
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
2 PC600-8
PC600-8 3
Tools for testing, adjusting and troubleshooting

Sym-
Test, measurement item Part No. Part name Q’ty Remarks
bol
Measuring intake air 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
pressure (boost A
pressure) 799-201-2220 Hose
Measuring exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299 °C
temperature
1 799-201-9001 Handy smoke checker 1
Measuring exhaust gas
C Commercially Bosch index: 0 – 9
color 2 Smoke meter 1
available
Adjusting valve Commercially
D Clearance gauge 1 (Intake: 0.35 mm, Exhaust: 0.57 mm)
clearance available
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Measuring compression
E 795-471-1330 Adapter 1 For 140E-5 engine
pressure 2
6261-71-615A Gasket 1 For 140E-5 engine
Measuring blow-by
F 799-201-1504 Blow-by checker 1
pressure
Measuring engine oil Pressure gauge: 2.5, 6, 40, 60 MPa

799-101-5002 Hydraulic tester 1
pressure 1 {25, 60, 400, 600 kg/cm2}
Testing EGR valve and G
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
bypass valve drive oil
pressure 2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring fuel pressure H
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter 1 8 × 1.25 o R1/8
3
07005-00812 Seal washer 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 ∅5mm × 2 – 3 m
available
Testing leakage from
pressure limiter and J 4 Commercially
Hose 1 ∅15mm × 2 – 3 m
return rate from injector available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Measuring clearance of Commercially
K Dial gauge 1 With magnet
swing circle bearing available
Testing and adjusting in Pressure gauge: 2.5, 6, 40, 60 MPa
work equipment, swing, 799-101-5002 Hydraulic tester 1
L {25, 60, 400, 600 kg/cm2}
and travel circuit oil
pressures 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Testing and adjusting 799-101-5002 Hydraulic tester 1
M {25, 60, 400, 600 kg/cm2}
control circuit oil pressure
4 PC600-8
Sym-
bol

1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting Differential pressure
piston pump control oil N 2 799-401-2701
gauge
1
pressure
799-101-5220 Nipple 2
3 Size: 10 × 1.25 mm
07002-11023 O-ring 2
4 799-401-3200 Adapter 2 Size: 03
708-25-14140 Cap 1
Testing servo piston 1 For HPV95 + 95 pump
P 07000-B2065 O-ring 1
stroke
2 566-98-41120 Disc gauge 1
1 {25, 60, 400, 600 kg/cm2}
Measuring PPC valve
Q
output pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-3200 Adapter 1 Size: 03
Measuring outlet 799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
pressure of solenoid
R
valve and PPC shuttle 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
valve
2 799-401-3200 Adapter 1 Size: 03
Measuring fan speed S 799-205-1100 Multiple tachometer 1
Measuring fan circuit oil 799-101-5002 Hydraulic tester 1
T {25, 60, 400, 600 kg/cm2}
pressure
Commercially
Measuring oil leakage U Measuring cylinder 1
available
Measuring wear of
— 796-627-1140 Wear gauge 1 Same as PC600, 600LC-7
sprocket
Measuring water
temperature and oil — 799-101-1502 Digital thermometer 1 –99.9 – 1,299 ºC
temperature
Measuring operating 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}

—
effort and pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Scale 1
hydraulic drift available
Measuring work Commercially
— Stopwatch 1
equipment speed available
Measuring voltage and Commercially
— Multimeter 1
resistance available
PC600-8 5
Sym-
bol
799-601-4101
— or T-adapter 1
799-601-4201
— 799-601-4211 T-adapter 1 Engine controller
— 799-601-4220 T-adapter 1 Engine controller
— 799-601-9020 T-adapter 1 Ambient pressure sensor
— 799-601-4240 Socket 1 For 16 A
Troubleshooting for Deep socket (21mm)
engine controller /
sensors / actuators (MITOLOY 4ML-21 or
Commercially equivalent)
— 1
available Applicable engine serial
No.:
530001-534132 For coolant temperature sensor
Deep socket (19mm)
(MITOLOY 4ML-19 or
— 795T-981-1010 equivalent) 1
Applicable engine serial
No.: 534133 and up
799-601-4101
or
799-601-4201
or
— 799-601-9000 T-adapter assembly 1
or
799-601-9100
or
799-601-9200
For DT2P
— 799-601-9020 • Adapter for DT 1
(Does not include 799-601-9100)
For DT3P (Does not include 799-601-
— 799-601-9030 • Adapter for DT 1
4101, 799-601-4201 and 799-601-9100)
For DT6P (Does not include 799-601-
— 799-601-9050 • Adapter for DT 1
4101, 799-601-4201 and 799-601-9100)
For DT12GRP
Troubleshooting for
— 799-601-9110 • Adapter for DT (GR) 1 (Does not include 799-601-4101,
chassis / sensors / wiring
799-601-4201 and 799-601-9100)
harnesses
For DT12BP
— 799-601-9120 • Adapter for DT (B) 1 (Does not include 799-601-4101,
799-601-4201 and 799-601-9100)
For DT12GP
— 799-601-9130 • Adapter for DT (G) 1 (Does not include 799-601-4101,
799-601-4201 and 799-601-9100)
For HD30 (Does not include 799-601-
— 799-601-9240 • T-adapter for HD30 1 4101,
799-601-4201 and 799-601-9200)
799-601-7000
or
799-601-7100
— or T-adapter assembly 1
799-601-7400
or
799-601-8000
6 PC600-8
Sym-
bol
For X1P (Does not include 799-601-7000

— 799-601-7010 • Adapter for X 1
and 799-601-7100)
— 799-601-7020 • Adapter for X 1 For X2P
— 799-601-7040 • Adapter for X 1 For X4P
For SW8P
— 799-601-7060 • Adapter for SWP 1
(Does not include 799-601-8000)
— 799-601-7210 • Adapter for 040 1 For A16P
For M1P (Does not include 799-601-7000
— 799-601-7080 • Adapter for M 1
and 799-601-7100)
Troubleshooting for — 799-601-7090 • Adapter for M 1 For M2P
chassis / sensors / wiring
harnesses — 799-601-7110 • Adapter for M 1 For M3P
— 799-601-7120 • Adapter for M 1 For M4P
— 799-601-7130 • Adapter for M 1 For M6P
— 799-601-7140 • Adapter for S 1 For S8P
For S12P (Does not include 799-601-
— 799-601-7160 • Adapter for S 1
8000)
— 799-601-7170 • Adapter for S 1 For S16P
— 799-601-7520 T-adapter assembly 1
— 799-601-8000 • Adapter for 070 1 For 070-12P
PC600-8 7
Socket
8 PC600-8
Measuring engine speed 4. Measuring all-pump relief speed

1) Start the engine and set the fuel control dial
a Measure the engine speed under the following in the high idle position (MAX).
condition. 2) Set the working mode switch in the P mode
• Engine coolant temperature: Within operat- position.
ing range 3) Relieve the boom circuit by raising the boom
• Hydraulic oil temperature: Within operating and measure the engine speed.
range
5. Measuring power max. ON + all-pump relief
1. Preparation work speed
Turn the starting switch ON and set the machine 1) Start the engine and set the fuel control dial
monitor to “Monitoring”. in the high idle position (MAX).
a For the operating method, see “Special func- 2) Set the working mode switch in the P mode
tion of machine monitor”. position.
a Monitoring code: 01002 Engine speed 3) While relieving the boom circuit by raising
01006 Engine speed the boom and holding the power max.
a Code 01002 is information of the engine con- switch, measure the engine speed.
troller and code 01006 is information of the a The power max. function is reset automati-
pump controller. The engine speed can be cally in about 8.5 seconds even if the switch
measured with either of those codes. is kept held. Accordingly, measure the en-
a The engine speed is displayed in rpm. gine 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 con-
trol, and travel levers in neutral and meas-
ure 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 idle-
cut ON speed.
7. Measuring auto-deceleration ON speed

2. Measuring low idle speed 1) Start the engine and set the fuel control dial
1) Start the engine and set the fuel control dial in the high idle position (MAX).
in the low idle position (MIN). 2) Turn the auto-deceleration switch ON.
2) Set the work equipment control, swing con- 3) Set the work equipment control, swing con-
trol, and travel levers in neutral and meas- trol, and travel levers in neutral. When the
ure the engine speed. auto-deceleration operates, measure the
engine speed.
3. Measuring high idle speed a The engine speed lowers to a certain level
1) Start the engine and set the fuel control dial about 6 seconds after all the levers are set in
in the high idle position (MAX). neutral. This level is the auto-deceleration
2) Set the working mode switch to the P mode speed.
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 de-
gree that the PPC oil pressure switch is
turned ON. Do not relieve the swing.
PC600-8 9
Measuring intake air pressure 4. Run the engine at a medium or higher speed
and drain the oil from the hose.
(boost pressure) a Insert the connecting parts of the gauge and
hose about a half and open the self-seal on
a Tools for measuring intake air pressure (boost the hose side repeatedly, and the oil will be
pressure) drained.
a If Pm kit A is available, the air bleed coupling
Symbol Part No. Part name (790-261-1130) inside the kit can also be
A 799-201-2202 Boost gauge kit used.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
a When installing and removing the measuring
tools, take care not to touch a hot part of the 5. Set the working mode switch to P mode and turn
engine. the power max. switch ON.
a Measure the intake air pressure (boost pres-
sure) under the following condition. 6. Run the engine at high idle and measure the
• Engine coolant temperature: Within operat- intake air pressure (boost pressure) when the
ing range boom RAISE circuit is relieved.
• Hydraulic oil temperature: Within operating
range
1. Open the engine hood.
2. Remove intake air pressure measurement plug

(1) at turbocharger outlet tube.
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 con-

nect gauge [2].
10 PC600-8
Measuring exhaust gas 4. Install sensor [1] of digital thermometer B and

connect them to meter [2].
temperature a Clamp the wiring harness of the digital ther-
mometer so that it does not touch any high
a Tools for measuring exhaust gas temperature temperature part during the measurement.
Symbol Part No. Part name
B 799-101-1502 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 operat-
ing range
range

5. Procedure for measuring maximum exhaust gas
2. Remove heat insulation cover (1). 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 tempera-

ture 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 measure-
ment plug (2).

PC600-8 11
Measuring exhaust gas color

a Tools for measuring exhaust gas color
Symbol Part Number Part name
1 799-201-9001 Handy smoke checker
C Commercially
2 Smoke meter
available
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. 2) Connect the probe hose, the receptacle of
a Measure exhaust gas color under the following the accelerator switch and the air hose to
conditions: the smoke meter C2.
• Engine coolant temperature: Within the op- a The supply air pressure shall be less
erating range. than 1.5 MPa {15 kg/cm2}
3) Connect the power cord to power receptacle.
1. Measurement with C1, Handy Smoke Checker a Before connecting the power cord, make
1) Set a filter paper in the handy smoke sure that the power switch of the smoke
checker C1. meter is turned off.
2) Insert the exhaust gas suction port in the 4) Loosen the cap nut of the suction pump and
exhaust pipe (1). set a filter paper there.
3) Start the engine. a Set the filter paper accurately so that ex-
4) Operate the handle of the smoke checker haust gas does not leak out.
C1, and adhere exhaust gas to the filter 5) Turn on the power switch of the smoke
paper when accelerating the engine quickly meter C2.
or at a high idle.
6) Start the engine.

5) Remove the filter paper and compare the 7) When accelerating the engine quickly or at a
color on the filter paper with the accessory high idle, step down the accelerator pedal of
scale. the smoke meter C2, and collect exhaust
6) After the measurement, remove the meas- gas in the filter paper.
uring tools and return the engine to the orig- 8) Place the filter paper contaminated with
inal state. exhaust gas on new filter papers (more than
10 sheets) in the filter paper holder and read
2. Measurement with Smoke Meter C2 the indicated value.
1) Insert the probe [1] of the smoke meter C2, 9) After completing the measurement, remove
in the outlet of the exhaust pipe (1) and fix it the measuring tools and set to the original
to the exhaust pipe with clip. condition.
12 PC600-8
Adjusting valve clearance 4. Insert clearance gauge D in the clearance

between rocker arm (5) and crosshead (6), and
a Tools for adjusting valve clearance turn adjustment screw (3) to adjust the valve
clearance.
Symbol Part No. Part name a With clearance gauge D inserted, turn the
Commercially adjustment screw and adjust until the clear-
D Clearance gauge ance is a sliding fit.
available
a Valve clearance
Intake valve : 0.35 mm
1. Open the engine hood and remove all the heat
Exhaust valve : 0.57 mm
insulation covers.
3 Locknut:
5. Fix adjustment screw (3) and tighten locknut (4).
2. Remove all the cylinder head covers (1).
45.1 – 51.0 Nm {4.6 – 5.2 kgm}
a After tightening the locknut, check the valve
clearance again.
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 com-
pression top dead center.
a Check the pointer from the alternator side. 6. Rotate the crankshaft 120° each time in the nor-
a Crank the engine with the hexagonal part at mal direction and repeat Steps 2 – 4 to adjust
the water pump drive shaft on the alternator the valve clearance of each cylinder according
side. to the firing order.
a At the compression top dead center, the a Firing order: 1 – 5 – 3 – 6 – 2 – 4
rocker arm of the No. 1 cylinder can be
moved by hand an amount equal to the valve 7. After completing the adjustment, set to the origi-
3 Cylinder head cover mounting bolt:

clearance. If the rocker arm does not move, nal condition.
it is not at the compression top dead center,
so rotate the crankshaft one more turn. 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
PC600-8 13
Measuring compression a Pass a wire, etc. under the fuel path project-
ed sideways and pull up the injector (Do not
pressure pry the injector top up).
a Tools for measuring compression pressure

1 795-502-1590 Compression gauge
E 795-471-1330 Adapter
2
6261-71-615A Gasket
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 – 60°C 5. Install adapter E2 and connect it to compression
gauge E1.
1. Open the engine hood and remove all the heat a Install gasket to the tip of adapter E2.
3 Mounting bolt:
insulation covers. a Secure the adapter with the injector holder.
2. Remove head cover (1) of the cylinder to meas- 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
ure the compression pressure. a Apply a little amount of engine oil to the con-
necting parts of the adapter and gauge so
that air will not leak easily.
6. Install rocker arm assembly (2) and adjust the
3 Mounting bolt:
valve clearance.
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 compres-
sion 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 in-
jector wiring harness (Loosen the terminal
nuts alternately).
14 PC600-8
5) Tighten sleeve nut (15) of the fuel high-pres-
3 Sleeve nut:
sure tube securely.
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
3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}

top alternately.
7. Operate the machine monitor to set it to the no-

injection 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 After installing the rocker arm assembly, ad-
a Read the pressure gauge pointer when it is just the valve clearance. For details, see
3 Rocker arm assembly mounting bolt:

stabilized. “Adjusting valve clearance”.
a When measuring the compression pressure,
measure the engine speed, too, and check 93 – 103 Nm {9.5 – 10.5 kgm}
3 Cylinder head cover mounting bolt:

that it is in the measurement condition range.
10. After completing the measurement, remove the 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
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 posi-
tion of the cylinder head.
a When setting the injector, pull the fuel
high-pressure tube to outside of the cyl-
inder head so that the threads of the in-
jector 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-pres-
sure tube to injector (11) lightly.
a Use a high-pressure pipe ring wrench
(on the market) to disconnect and con-
nect the fuel high-pressure tube.
a Tighten the sleeve nut lightly until it is
stopped by the injector.
3 Mounting bolt:
4) Tighten mounting bolt (13) securely.
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
PC600-8 15
Measuring blow-by pressure Measuring engine oil pressure

a Tools for measuring blow-by pressure a Tools for measuring engine oil pressure
Symbol Part No. Part name Symbol Part No. Part name
F 799-201-1504 Blow-by checker 799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
a Measure the blow-by pressure under the follow-
2 799-401-2320 Gauge
ing conditions.
• Engine coolant temperature: Within operat-
ing range a Measure the engine oil pressure under the fol-
• Hydraulic oil temperature: Within operating lowing conditions.
range • Engine coolant temperature: Within operat-
ing range
1. Remover the engine under cover (front side).
1. Remove the engine room cover (control valve
2. Install the nozzle [1] of blow-by checker F to side) or under cover (front side).
blow-by hose (1).
2. Install hose [1] of hydraulic tester G1 and con-
3. Connect the hose [2] and gauge [3]. nect them to gauge G2.
4. Start the engine and set the working mode 3. Start the engine and measure the oil pressure
switch to the P mode position. with the engine at low idle and high idle.
5. Run the engine at high idle and measure the

blow-by pressure when arm IN circuit is relieved.
3 Oil pressure switch:

6. After finishing measurement, remove the meas- 2.9 – 5.9 Nm {0.3 – 0.6 kgm}
uring tools and set to the original condition.
16 PC600-8
Testing EGR valve and bypass 3. Connect hydraulic testers [2] and [3] (Compo-
nent part of tool G1) to the nipple [1].
valve drive oil pressure
4. Start the engine and measure the oil pressure at
a Testing instrument for EGR valve and bypass low idle and high idle.
valve drive oil pressure
799-101-5002 Hydraulic tester
G 1
790-261-1204 Digital 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 meas-

uring 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
2 Plug: LT2 or LG-5

sealant to the plug before installing.
3 Plug: 9.8 – 19.6 Nm {1.0 – 2.0 kgm}
PC600-8 17
Handling equipment in fuel Releasing remaining pressure

circuit in fuel system
a Precautions in inspection and maintenance of a While the engine is rotating, pressures occur in
fuel system equipment the low pressure circuit and the high pressure
The common rail type fuel injection system circuit of the fuel system.
(CRI) is composed of more precise components Low pressure circuit : feed pump – fuel filter –
than the usual fuel injection pump and nozzle fuel supply pump
and will probably get out of order when foreign High pressure circuit : fuel supply pump – com-
matters enter the system. mon rail – fuel injector
During inspection and maintenance of the fuel a When 30 seconds elapse after the engine
system, pay more attention to foreign matters stopped, pressures in both the low pressure cir-
than in case of usual fuel injection pumps and cuit and the high pressure circuit drop to the
wash the system carefully with clean fuel if dusts safe level automatically.
enter the system. a Since pressure remaining in the fuel system
should be released certainly before inspection of
a Precautions in replacement of fuel filter cartridge the fuel system and mounting and removing of
Be sure to use genuine fuel filter cartridge of equipment, be sure to observe the following pre-
k Inspect the fuel system or mount or remove

Komatsu. cautions:
The common rail type fuel injection system
(CRI) is composed of more precise components equipment more than 30 seconds after the en-
than the usual fuel injection pump and nozzle gine stopped and after pressure remaining in the
and is equipped with special filter with highly fuel system is released. (Pressure remains in the
efficient filtration performance to prevent foreign fuel system right after the engine stopped, so do
matters from entering the system. not start any work until 30 seconds elapse.)
Therefore, be sure to use genuine filters only.
Otherwise, the fuel system will possibly get out
of order.
18 PC600-8
Measuring fuel pressure 3. Run the engine at high idle and measure the
fuel pressure.
a Tools for measuring fuel pressure a If the fuel pressure is in the following range,
it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
{1.5 – 3 kg/cm2}
2 799-401-2320 Gauge
H
Adapter
795-471-1450
3 (8 × 1.25 o R1/8)
07005-00812 Seal washer
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
k Since the pressure in the high-pressure circuit

pump.
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.
PC600-8 19
Reduced cylinder mode operation No-injection cranking

a Reduced cylinder mode operation means to run a No-injection cranking means to crank the engine
the engine with the fuel injectors of 1 or more with the starting motor while all the injections are
cylinders disabled electrically to reduce the stopped electrically. The purpose and effect of
number of effective cylinders. The purposes and this operation are as follows.
effects of this operation are as follows. • Before the engine is started after it or the ma-
1. This operation is used to find out a cylinder chine has been stored for a long period, the no-
which does not output power normally (or, com- injection cranking is performed to lubricate the
bustion in it is abnormal). engine parts and protect them from seizure.
a See “Special functions of machine monitor, no-
2. When a cylinder is selected for the reduced cyl- injection cranking”.
inder 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 fol-
lows.
• 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 con-

trols 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”.
20 PC600-8
Testing leakage from pressure limiter and return rate from injector
a Testing tools for measuring leakage and return 1. Preparation work

rate of fuel 1) Remove tube (3) between common rail (1)
and supply pump (2).
2) Insert spacer J1 on supply pump (2) side
1 6151-51-8490 Spacer and tighten the removed joint bolt again.
2 6206-71-1770 Joint a Connect the return pipe to the fuel tank
Commercially again, too.
3
available
Hose a Be sure to fit the gaskets to both ends of
the spacer.
J Commercially
4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
PC600-8 21
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
2. Testing leakage from pressure limiter with a wire, etc. to prevent it from coming
1) Lay test hose J3 so that it will not slacken off.
and put its end in the oil pan. 2) Lay test hose J4 so that it will not slacken
2) Operate machine monitor to set it so that it and put its end in the oil pan.
can check the engine speed.
3) Start the engine and keep its speed equiva-
lent 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 Leakage
(rpm) (cc/min)
Operation with
Max. 10
rated outout 3) Operate machine monitor to set it so that it
can check the engine speed.
4) Start the engine and keep its speed equiva-
lent to the rated load.
22 PC600-8
5) After the engine speed is stabilized, test the Bleeding air from fuel circuit
return rate in 1 minute with measuring cylin-
der J5. a If fuel is used up or if a fuel circuit part is
a You may test for 20 seconds and judge removed and installed, bleed air from the fuel
by multiplying the result by 3. circuit according to the following procedure.
a If the supply pump is not supplying fuel,
the engine speed may not rise. In this 1. Remove fuel prefilter (1) and fill it with fuel.
case, record the engine speed, too, dur- a Fill the fuel prefilter with clean fuel and take
ing the test. care that dirt will not enter it.
a If the return rate (spill) from the injector a Check that the cap is fitted to part (a) (central
is in the following range, it is normal. hole) of the fuel prefilter, and then add fuel
Rated output Limit of return rate through part (b) (holes around the central
speed (rpm) (spill) (cc/min) hole).
a After filling the fuel prefilter with fuel, remove
1,600 960
the cap from part (a).
1,700 1,020 a If clean fuel is not available, do not remove
1,800 1,080 the prefilter but fill it with the fuel by operating
priming pump (4).
1,900 1,140 a Do not add fuel to fuel main filter (2) from out-
2,000 1,200 side.
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.
PC600-8 23
2. Install fuel prefilter (1) to the filter head. 6. Start the engine with the starting motor.
a Thinly apply engine oil to the packing surface a The air in the high-pressure circuit is bled au-
on the fuel prefilter. tomatically if the engine is rotated.
a After the packing surface on the fuel prefilter a If the engine does not start, there may be still
side touches the seal surface of the filter air in the low-pressure circuit. In this case,
head, tighten the fuel prefilter by 3/4 turns. repeat the above procedure from step 3.
3. Remove air bleeding plug (3) of the main fuel fil-

ter and operate priming pump (4).
a Operate the priming pump until fuel flows out
of the plug hole. After fuel starts flowing out,
3 Air bleeding plug:

install plug (3).
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4. Loosen air bleeding plug (5) of the main fuel fil-

ter and operate priming pump (4).
of the plug hole. After fuel starts flowing out,
3 Air bleeding plug:

install plug (5).
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
5. Loosen air bleeder (6) of the fuel supply pump

and operate priming pump (4) 90 – 100 times.
of the bleeder. After fuel starts flowing out,
tighten the bleeder and operate the priming
3 Air bleeder:
pump several times until it becomes heavy.
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
24 PC600-8
Testing fuel system for leakage 9. Inspect the fuel piping and devices for fuel leak-
k Very high pressure is generated in the high-pres-

age.
a Inspect mainly around the high-pressure cir-
sure circuit of the fuel system. If fuel leaks while cuit parts coated with the color checker for
the engine is running, it is dangerous since it can fuel leakage.
catch fire. a If any fuel leakage is detected, repair it and
After testing the fuel system or removing its inspect again from step 1.
parts, test it for fuel leakage according to the fol- a If no fuel leakage is detected, inspection is
lowing procedure. completed.
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 leak-

age.
cuit 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.

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

age.
fuel leakage.
8. Run the engine at high idle and load it, and

relieve the oil from the hydraulic pump.
PC600-8 25
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.
26 PC600-8
Testing and adjusting air 3. Tighten nuts and bolts (4), (3), (2) and (1) in this
order.
conditioner compressor belt a When the belt was replaced, readjust it after
tension 1 hour operation.
Testing
1. Open the engine hood and remove the insula-
tion cover on the air conditioner compressor
side.
2. Measure the belt deflection (a) when pushing a

point midway between the air conditioner com-
pressor 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 nor-
mal.
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 loos-
ened.
• 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 ten-
sion cannot be adjusted any more or they
have a cut or a crack, replace them.
PC600-8 27
Testing clearance of swing 3. Set the dial gauge K to the zero point.
circle bearing 4. Arrange the arm almost at right angles to the

ground and lower the boom until the front leg of
a Tools for testing clearance of swing circle bear- the machine body rises.
ing a At the time, the front of the upper structure
Symbol Part No. Part name rises and its rear lowers.
Commercially Dial gauge
K
available (with magnet)
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 Para-

graph 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 revolv-
ing frame lower face.
a At the time, the front of the upper structure
lowers and its rear rises.
28 PC600-8
Testing and adjusting track Adjusting

a If the track shoe tension is not proper, adjust it in
shoe tension the following manner.
Testing 1. When the tension is too strong

1. Travel the machine forward by the length of Discharge grease by loosening valve (3).
track on ground, keeping the engine at low idle,
and stop the machine slowly. k Do not loosen valve (3) more than one turn,
because grease will spurt due to its internal
2. Place steel bar [1] on the track shoe between high pressure.
second carrier roller (1) and third carrier roller
(2). 2. When the tension is too weak
a L beam is recommended for bar [1], because Add grease through grease fitting (4).
of its deflection-free nature. a If the normal track shoe tension is not re-
stored even after greasing, move the ma-
3. Measure max. clearance (a) between bar [1] chine slowly back and forth.
and the track shoe.
• Max. standard clearance (a): 10 – 30 mm
PC600-8 29
Testing and adjusting work a Use quick coupler (2) to measure the
rear pump (No. 1 R + No. 2 R) circuit oil
equipment, swing, and travel pressure.
circuit oil pressures a Use quick coupler (1) to measure the
front pump (No.1F + No.2F) circuit oil
a Tools for testing and adjusting work equipment, pressure.
swing, and travel circuit oil pressures a The relief pressure of the boom LOWER
circuit can be measured only in the front
Symbol Part No. Part name pump circuit.
799-101-5002 Hydraulic tester a The relief pressure of the bucket DUMP
L circuit can be measured only in the rear
pump circuit.
a The relief pressure of the swing circuit
Measuring can be measured only in the front pump
a Measure the work equipment, swing and travel circuit.
circuit oil pressures under the following condi- a Use the oil pressure gauges of 60 MPa
tions: {600 kg/cm2}.
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).
2. Measuring work equipment circuit oil pres-

sure
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 low-
pressure setting side.
1. Preparation work a If the boom cylinder is relieved at the
k Lower the work equipment to the ground and

LOWER stroke end, the safety-suction
valve on the boom head side of the right
stop the engine. Operate the control levers side 4-spool control valve relieves on the
several times to release the remaining pres- low-pressure setting side (The set pres-
sure in the piping, and then loosen the oil fill- sure of the safety-suction valve is lower
er cap of the hydraulic tank slowly to release than that of the main relief valve).
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.
30 PC600-8
2) Measuring relief pressure during L mode 3. Measuring swing circuit oil pressure
i) Start the engine and set the working 1) Start the engine and set the working mode
mode switch in the L mode position. switch in the P mode position.
ii) Run the engine at high idle, relieve the 2) Turn the swing lock switch ON.
boom cylinder singly at the RAISE stroke 3) Run the engine at high idle, relieve the
end, and measure the oil pressure. swing motor, and measure the oil pressure.
a The main relief valves of the control a The safety valves of the front and rear swing
valve (left and right) relieve on the high- motors relieve. (The set pressure of the
pressure setting side. safety valves is lower than that of the main
3) Measuring relief pressure during machine relief valve.)
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 pres-
sure.
a Since the set pressure of the safety-suc-
tion 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 low-
pressure setting side.
4) Measuring relief pressure during one-touch
power max. operation 4. Measuring travel circuit oil pressure
i) Start the engine and set the working 1) Start the engine and lock the travel mecha-
mode switch in the P mode position. nism.
k Put pin [2] between the sprocket and

ii) Run the engine at high idle, relieve each
work equipment cylinder singly at the fol-
lowing stroke end, press the one-touch track frame to lock the travel mecha-
power max. switch, and measure the oil nism securely.
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, meas-
ure the engine speed in that period.
PC600-8 31
2) Run the engine at high idle, relieve the 4) Turn holder (7) to adjust the pressure.
travel motor, and measure the oil pressure. a If the holder is:
a The main relief valves of the control valve • Turned to the right, the pressure rises.
(left and right) relieve on the high-pressure • Turned to the left, the pressure lowers.
setting side. a Pressure changed by 1 turn of holder:
12.5 MPa {128 kg/cm2}
3 Locknut:
5) Fix holder (7) and tighten locknut (8).
93.2 – 122.6 Nm {9.5 – 12.5 kgm}

a If the high-pressure setting side is ad-
justed, the low-pressure setting side
changes. Accordingly, adjust the low-
pressure 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.
6) Fix elbow (6) and tighten locknut (5).
1. Adjusting main relief valve (high-pressure 7) Connect hose (4).
setting) of right side 5-spool control valve 8) After completing the adjustment, check the
a If the work equipment oil pressure in the front oil pressure again according to the above
pump circuit (during L mode) and the L.H. described measurement procedure.
travel oil pressure are abnormal, adjust the
high-pressure setting side of main relief 2. Adjusting main relief valve (low-pressure set-
valve (3) of the right side 5-spool control ting) of right side 5-spool control valve
valve according to the following procedure. • 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 set-
ting 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 max-
imizing oil pressure are abnormal, adjust the
low-pressure setting of main relief valve (3)
of the right side 5-spool control valve accord-
ing 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.
a The high pressure setting is the state in 1) Disconnect hose (4).
which the 2-stage relief solenoid valve is 2) Loosen locknut (5) and set elbow (6) free.
turned ON and the pilot pressure is applied 3) Fix union (9) and loosen locknut (10).
to the changeover port. 4) Turn union (9) to adjust the pressure.
1) Disconnect hose (4). a If the union is:
2) Loosen locknut (5) and set elbow (6) free. • Turned to the right, the pressure rises.
3) Fix holder (7) and loosen locknut (8). • Turned to the left, the pressure lowers.
32 PC600-8
a Pressure changed by 1 turn of union: 4. Adjusting main relief valve (low-pressure set-
12.5 MPa {128 kg/cm2} ting) of left side 4-spool control valve
1) If the work equipment oil pressure in the
3 Locknut:
5) Fix union (9) and tighten locknut (10). rear pump circuit (during normal relief oper-
ation) is abnormal or the high-pressure set-
39.2 – 49.0 Nm {4.0 – 5.0 kgm} ting side was adjusted, adjust the low-
pressure setting side of main relief valve
(11) of the left 4-spool control valve accord-
a Adjust the left side 4-spool control valve sim-
ilarly 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.
6) Fix elbow (6) and tighten locknut (5). 5. Adjusting swing motor safety valve
7) Connect hose (4). a If the relief pressure of the swing motor is ab-
8) After completing the adjustment, check the normal, adjust safety valves (12) and (13) of
oil pressure again according to the above the swing motor according to the following
described measurement procedure. procedure.
• (12): Safety valve of left swing motor
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 follow-
ing procedure.
• (13): Safety valve of right swing motor
a Adjust the left side 4-spool control valve sim-

ilarly to the right side 5-spool control valve.
PC600-8 33
1) Fix adjustment screw (14) and loosen lock-

nut (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 adjust-
ment screw: 3.87 MPa {39.5 kg/cm2}
3) Fix adjustment nut (14) and tighten locknut
3 Locknut:
(15).
118 –147 Nm {12 – 15 kgm}
4) After completing the adjustment, check the

oil pressure again according to the above
described measurement procedure.
34 PC600-8
Testing and adjusting control 3. Run the engine at high idle, set the work
equipment • swing lever and travel lever in neu-
circuit oil pressure tral, and measure the oil pressure.
a Tools for testing and adjusting control circuit oil

pressure
M
Measuring
a Measure the control circuit oil pressure under
the following condition.

range
stop the engine. Operate the control levers sev- Adjusting

eral times to release the remaining pressure in a If the control circuit oil pressure is abnormal,
the piping, and then loosen the oil filler cap of adjust control relief valve (2) according to the
the hydraulic tank slowly to release the internal following procedure.
pressure of the hydraulic tank.
1. Open the pump compartment cover (front side)
and remove oil pressure measurement plug (1).
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]. 3. Turn adjustment screw (4) to adjust the pres-
a Use the oil pressure gauges of 6 MPa{60 kg/ sure.
cm2} a If the adjustment screw is:
• Turned to the right, the pressure rises.
• Turned to the left, the pressure lowers.
3 Locknut: 9.8 Nm {1 kgm}

4. Fix adjustment screw (4) and tighten locknut (5).
PC600-8 35
5. After completing the adjustment, repeat the pro-

cedure in above to check the set pressure
again.
36 PC600-8
Testing and adjusting piston 3) Install nipple N3 and connect oil pressure
gauge [1] of hydraulic tester N1.
pump control oil pressure a Use the oil pressure gauges of 6 MPa
{60 kg/cm2}.
a Tools for testing and adjusting piston pump con- a Fig. shows the view from the pump room
trol oil pressure under cover side.
1
Differential pressure
2 799-401-2701
N gauge
799-101-5220 Nipple (10 × 1.5 mm)
3
07002-11023 O-ring
4 799-401-3200 Adapter (Size: 03)
Measuring
a Measure the piston pump control oil pressure
under the following conditions: 4) Start the engine and set the working mode
• Hydraulic oil temperature: Within the operat- switch in the P mode position.

ing range 5) Set all the control levers in neutral and
measure the TVC valve output pressure
stop the engine. Operate the control levers sev- under the following condition.
eral times to release the remaining pressure in i) Set all the control levers in neutral.
the piping, and then loosen the oil filler cap of ii) Run the engine at high idle and measure
the hydraulic tank slowly to release the internal the output pressure.
6) Relieve the boom circuit by raising the boom
(normally), and measure the TVC valve out-
put pressure under the following condition.
1. Measuring TVC valve output pressure
• Run the engine at high idle, relieve the
a Since the TVC valve output pressure varies
boom circuit by raising the boom, and
with the discharge pressure of each pump,
measure the output pressure.
check that the work equipment, swing, and
7) Set the working mode switch in the L mode
travel circuit oil pressure is normal before position, relieve the boom circuit by raising
starting measurement. the boom, and measure the TVC valve out-
a Since the basic pressure of the TVC valve put pressure under the following condition.
output pressure is the control circuit pres- i) Select L mode.
sure, check that the control circuit oil pres- ii) Run the engine at high idle, relieve the
sure is normal before starting measurement. boom circuit by raising the boom, and
1) Open the pump compartment cover (front measure the output pressure.
side)
2) Remove oil pressure measurement plug (1)
of the No. 1 front pump.
8) After completing the measurement, remove

the measuring tools and set to the original
condition.
PC600-8 37
2. Measuring CO • NC valve output pressure 7) Drive the travel motor under no load and
1) Open the undercover of the No. 2 pump. measure the CO • NC valve output pressure
2) Remove oil pressure measurement plugs under the following condition.
(2) and (3) of the No. 2 pump. i) Raise the track shoe to be measured by
• (2): For front pump circuit using the boom and arm.
• (3): For rear pump circuit ii) Run the engine at high idle, drive the
travel motor under no load (with the lever
at the stroke end), and measure the out-
put 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
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 9) After completing the measurement, remove
the output pressure. the measuring tools and set to the original
6) Relieve the boom circuit by raising the boom condition.
(P mode) and measure the CO • NC valve
output pressure under the following condi-
tion.
i) Run the engine at high idle, relieve the
38 PC600-8
3. Measuring jet sensor output differential pres-

sure 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 con-
trol 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) 3) Start the engine and set the working mode
a The jet sensor output differential pres- switch in the P mode position.
sure may be measured at the inlet hose 4) Set all the control levers in neutral and
of the No. 1 pump by using adapter N4 measure the jet sensor output differential
and nipple N3. 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 dif-
ferential pressure gauge and connect
the low pressure (Pd) to the low pres-
sure side (lower side). Since the differ-
ential 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).
PC600-8 39
3) Fix adjustment screw (9) and tighten locknut
3 Locknut:
(10).
5.9 – 9.8 Nm {0.6 – 1.0 kgm}

condition.
Adjusting 4) After completing the adjustment, check the

1. Adjusting TVC valve oil pressure again according to the above
a When adjusting the TVC valve, open the described measurement procedure.
pump compartment cover.
a If the TVC valve output pressure is abnor- 2. Adjusting CO • NC valve
mal, adjust TVC valve (8) of the No. 1 pump a When adjusting the CO valve side of the
according to the following procedure. CO • NC valve, remove the No. 1 pump un-
dercover. When adjusting the NC valve
side, open the pump compartment cover.
a If the CO • NC valve output pressure is ab-
normal, 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).
pressure.
• Turned to the right, the pressure ris-
es.
• Turned to the left, the pressure low-
ers.
40 PC600-8
• (13): Front NC valve of No. 1 pump a If the adjustment screw is:

• (14): Rear NC valve of No. 1 pump • Turned to the right, the pressure ris-
es.
ers.
ment screw: 0.39 MPa {4.0 kg/cm2} (at
J/S difference pressure)
iii) Fix adjustment screw (17) and tighten
3 Locknut:
locknut (18).
5.9 – 9.8 Nm {0.6 – 1.0 kgm}
1) Adjusting CO valve side

i) Fix adjustment screw (15) and loosen
locknut (16).
ii) Turn adjustment screw (15) to adjust the
pressure.
es.
ers.
a Pressure changed by 1 turn of adjust- iv) After completing the adjustment, check
ment screw: 4.05 MPa {41.25 kg/cm2} (at the oil pressure again according to the
pump pressure) above described measurement proce-
iii) Fix adjustment screw (15) and tighten dure.
3 Locknut:
locknut (16).
3. Adjusting jet sensors of right side 5-spool
5.9 – 9.8 Nm {0.6 – 1.0 kgm} 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, ad-
just jet sensor relief valves (19) and (20) ac-
cording to the following procedure.
• (19): Jet sensor relief valve of right side 5-
spool control valve
• (20): Jet sensor relief valve of left side 4-
spool control valve
iv) After finishing adjustment, check the oil

pressure again according to the above
2) Adjusting NC valve side
i) Fix adjustment screw (17) and loosen
locknut (18).
ii) Turn adjustment screw (17) to adjust the
pressure.
PC600-8 41
1) Fix adjustment screw (21) and loosen lock-

nut (22).
pressure.
es.
ers.
3) Fix adjustment screw (21) and tighten lock-
3 Locknut: 59 – 78 Nm {6 – 8 kgm}
nut (22).
4) After completing the adjustment, check the

oil pressure again according to the above
42 PC600-8
Testing servo piston stroke a After checking that the rod moves
smoothly, keep it at the position where it
is most protruded.
a Tools for testing servo piston stroke
5) Stop the engine and measure the size of the
Symbol Part No. Part name rod protrusion (a2).
6) Calculate the servo piston stroke (b) from
708-25-14140 Cap
1 the measured size.
P 07000-B2065 O-ring a Servo piston stroke (b) = (a2) – (a1)
2 566-98-41120 Disc gauge a Standard stroke (b): 9.37 mm
a When the NC valve output pressure is normal

but the pump performance is considered inap-
propriate, inspect the acceptability of the servo
valve and piston according to the following pro-
cedures:
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 condi-
tion.
3. Judgment of servo valve

a If the servo piston stroke is abnormal, re-
move the servo valve, servo piston cap, and
spring, and check that you can move the ser-
vo piston smoothly before judging the condi-
tion of the servo valve.
1) When servo piston stroke is normal:
Servo valve is normal.
2) When servo piston stroke is abnormal:
2. Measurement of stroke
• Servo piston moves smoothly;
1) Remove the cap and the shim of the servo
Servo valve is abnormal.
valve on the measuring side.
• Servo piston does not move smoothly;
a Since the cap is pressed with the spring,
Servo valve is normal.
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 con-
trol lever changes the stroke.
PC600-8 43
Measuring PPC valve output • (3) : For boom LOWER circuit

• (4) : For arm IN circuit
pressure
a Tools for measuring PPC valve output pressure
1
Q 790-261-1204 Digital hydraulic tester
2 799-401-3200 Adapter (Size: 03)
a Measure the PPC valve output pressure under

the following conditions:

range
stop the engine. Operate the control levers sev- • (5) : For arm OUT circuit
eral times to release the remaining pressure in • (6) : For bucket CURL circuit
the piping, and then loosen the oil filler cap of
the hydraulic tank slowly to release the internal
1. Remove the control valve top cover or opera-

tor'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
• (7) : For swing circuit (left and right)
44 PC600-8
• (8) : For travel circuit (left and right, forward,

and reverse)
3. Install nipple [1] of hydraulic tester Q1 and con-

nect 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.

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 con-

trol 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.
PC600-8 45
Connection diagram of pilot piping (PPC, Solenoid, OLSS circuit)
46 PC600-8
a The colors in ( ) in the figure are the colors of the tapes wound onto the hoses.
PC600-8 47
Measuring outlet pressures of

solenoid valve and PPC shuttle
valve
a Tools for measuring outlet pressures of solenoid
valve and PPC shuttle valve
1
R 790-261-1204 Digital hydraulic tester
2 799-401-3200 Adapter (Size: 03)
a Measure the outlet pressures of solenoid valve

and PPC shuttle valve under the following con- • (7): Bucket CURL Hi cancel solenoid
dition. valve

range
stop the engine. Operate the control levers sev-

eral 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
1. Measuring outlet pressure of solenoid valve

1) Remove operator’s cab under cover (rear
side) or control valve upper cover.
2) Disconnect outlet hoses (1) – (7) of the sole-

noid valves to be measured, and install
3) Install nipple [1] of hydraulic tester R1 and
adapter R2 and connect the hoses again.
connect it to oil pressure gauge [2].
• (1): PPC lock solenoid valve
a Use a pressure gauge of 6 MPa {60 kg/
cm2}.
a The following figure shows the measur-
ing 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
48 PC600-8
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 equipment-
swing or travel control lever, operate it
finely to a degree that the PPC oil pres-
sure switch is turned ON.
a If the solenoid valve outlet pressure is as
shown in the table, the solenoid valve is
normal.

condition.
PC600-8 49
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.
Operation
Oil pressure
No. Solenoid valve Measurement condition Operation of machine of
(MPa {kg/cm2})
solenoid
• Set lock lever in LOCK Basic pressure circuit to
OFF 0 {0}
position. PPC valve is closed.
1 PPC lock
• Set lock lever in FREE Basic pressure circuit to Min. 2.74
ON
position. PPC valve is opened. {Min. 28}
• Set working mode switch in L Pump CO function is turned
OFF 0 {0}
mode. ON.
• Power max. switch ON (only
2 CO cancel 8.5 sec.).
• Turn heavy lift switch ON and Pump CO function is turned Min. 2.74
ON
raise boom singly. OFF. {Min. 28}
• Swing lock switch ON
• Operate travel lever.
• Set working mode switch in L Main relief valve is set to Min. 2.74
3 2-stage relief ON
mode. high pressure. {Min. 28}
• Turn machine push-up switch Boom LOWER safety valve
OFF 0 {0}
ON. is set to high pressure.
4 Machine push-up
• Turn machine push-up switch Boom LOWER safety valve Min. 2.74
ON
OFF. is set to low pressure. {Min. 28}
• Set travel speed switch in Lo Swash plate angle of travel
OFF 0 {0}
position. motor is set to maximum.
5 Travel speed select
• Set travel speed switch in Hi Swash plate angle of travel Min. 2.74
ON
position. motor is set to minimum. {Min. 28}
• Turn swing lock switch ON.
• About 10 seconds after work Swing holding brake is
OFF 0 {0}
equipment • swing control lever applied.
6 Swing holding brake is set in NEUTRAL position.
• Turn swing lock switch OFF
Swing holding brake is Min. 2.74
and operate work equipment ON
released. {Min. 28}
• swing control lever.
Min. 2.35
• Bucket CURL operated singly. Bucket Hi spool is operated OFF
Bucket CURL Hi can- {Min. 24}
7
cel (see Note) • Bucket CURL operated other
Bucket Hi spool is stopped. ON 0 {0}
than above.
Note: The inlet pressure of the bucket CURL Hi cancel solenoid valve is the boom RAISE PPC circuit pres-
sure. 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).
50 PC600-8
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.

condition.
3. Measuring outlet pressures of arm • swing

PPC shuttle valves (arm side)
3) Install nipple [1] of hydraulic tester Q1 and 1) Remove the control valve top cover.
connect it to oil pressure gauge [2]. 2) Disconnect control valve inlet hose (9),
a Use an oil pressure gauge of 6 MPa {60 install adapter R2, and connect the hose
kg/cm2}. again.
4) Run the engine at high idle, set the condition 3) Install nipple [1] of hydraulic tester R1 and
as shown in the following table, and meas- connect it to oil pressure gauge [2].
ure the output pressure. a Use an oil pressure gauge of 6 MPa {60
a If the outlet pressures of the boom and kg/cm2}.
bucket PPC shuttle valve are as shown
in the following table, the boom • bucket
PPC shuttle valve are normal.
Oil pressure
Measurement condition
(MPa {kg/cm2})
Neutral 0 {0}
Operated to Min. 2.35
boom RAISE {Min. 24}
Right work Operated to Min. 2.35
equipment boom LOWER {Min. 24}
control lever Operated to Min. 2.35
bucket CURL {Min. 24}
bucket DUMP {Min. 24}
PC600-8 51
4) Run the engine at high idle, set the condition 4. Measuring outlet pressures of arm and swing
as shown in the following table, and meas- PPC shuttle valves (swing side)
ure the output pressure. 1) Remove the control valve top cover.
a If the outlet pressures of the arm • swing 2) Remove swing PPC oil pressure switch
PPC shuttle valve are as shown in the (10).
following table, the arm • swing PPC
shuttle valve (arm side) are normal.
Oil pressure
(MPa {kg/cm2})
Neutral 0 {0}
equipment arm IN {Min. 24}
control lever
arm OUT {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}.

condition.
4) Run the engine at high idle, set the condition

as shown in the following table, and meas-
ure 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.
Oil pressure
(MPa {kg/cm2})
Neutral 0 {0}
equipment swing LEFT {Min. 24}
control lever
swing RIGHT {Min. 24}
52 PC600-8

condition.
PC600-8 53
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
3 Lock nut: 98 – 127 Nm {10 – 13kgm}

the specified tightening torque.
5. Install boot (1).
6. Install work equipment, swing PPC valve

assembly.
54 PC600-8
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 posi-
tion, extend the bucket and arm cylinders ful-
ly 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 condi-
tion 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).
PC600-8 55
Adjusting • No. 1 pump

a If the travel deviation is abnormal, adjust the
thickness of the shim at the servo piston accord-
1. Determine where to add a shim from the direc-

tion of the travel deviation.
a Adjustment method
When machine When machine
deviates to left deviates to right
Add shim on rear pump Add shim on front pump
side (c). side (b).
• 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
3 Bolt: 59 – 74 Nm {6.0 – 7.5 kgm}

mm for each pump.
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, loos-
en 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.
56 PC600-8
Measuring fan speed Measuring fan circuit oil pressure

a Tools for measuring fan speed a Tools for measuring fan circuit oil pressure
Symbol Part No. Part name Symbol Part No. Part name
S 799-203-8001 Multitachometer 799-101-5002 Hydraulic tester
T
1. Remove the covers until the fan blade end is seen.

a Measure the fan circuit oil pressure under the
following condition.
2. Stick a reflection tape to the fan.
• Hydraulic oil temperature: Within operating range
3. Set probe [1] of multitachometer S with stand
stop the engine. Operate the control levers sev-
[2], match it to the reflection tape, and connect it
eral times to release the residual pressure in the
to meter [3].
piping, and then loosen the oil filler cap of the hy-
a Take care that the probe will not interfere
draulic tank slowly to release the internal pres-
with the fan.
sure of the hydraulic tank.
1. Connect gauge [2] of hydraulic tester T to oil pres-

sure 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 pres-
sure.


PC600-8 57
Inspection of locations of 2. Inspection of arm cylinder

1) Operate the arm cylinder to move the arm to
hydraulic drift of work equipment the position 100 mm before the digging
stroke end, and stop the engine.
a If there is any hydraulic drift in the work equip-
ment (cylinders), check in the following manner
to determine if the cause is in the cylinder pack-
ing 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 rat-
ed load to the bucket.
2) Operate the control lever to the CURL posi-

tion.
• If the lowering speed increases, the cyl-
inder 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 RAISE posi- [Reference]If the cause of the hydraulic drift is in the
tion or the bucket control lever to the CURL defective packing, and the above opera-
position. tion is carried out, downward movement
• If the lowering speed increases, the cyl- is accelerated for the following reasons.
inder packing is defective. 1) If the work equipment is set to the above pos-
• If there is no change, the control valve is ture (holding pressure applied to the bottom
defective. end), the oil at the bottom end leaks to the head
a Operate the control lever with the engine end. However, the volume at the head end is
starting switch in the ON position. smaller than the volume at the bottom end by
a If pressure in the accumulator has the volume of the rod end, so the internal pres-
dropped, run the engine for approx. 10 sure at the head end increases because of the
seconds to charge the accumulator oil flowing in from the bottom end.
again. 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 main-
tained at a certain pressure (this differs accord-
ing 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.
58 PC600-8
Measuring oil leakage 2. Measuring leakage from arm cylinder

1) Run the engine and move in the arm to the
stroke end.
a Tools for measuring oil leakage
Symbol Part No. Part name k Referring to “Releasing remaining pres-
sure in hydraulic circuit”, release the re-
Commercially
U Measuring cylinder maining pressure from the piping on the
available
arm cylinder head side (Operate the le-
ver only in the CURL direction, howev-
a Measure the oil leakage under the following
er).
condition.
2) Disconnect hose (2) on the cylinder head
side and block it with a flange.
range
k Take care not to disconnect the hose on
1. Measuring leakage from boom cylinder
the cylinder bottom side.
1) Run the engine and raise the boom to the
a Use the following part to block the hose.
stroke end.
07379-01044 (Flange #10)
k Referring to “Releasing remaining pres-
maining pressure from the piping on the
boom cylinder head side (Operate the
lever only in the RAISE direction, how-
ever).
2) Disconnect hoses (1) on the cylinder head

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 con-

trol lever in the DUMP direction.
4) Start measuring the oil leakage 30 seconds
after the arm cylinder is relieved and meas-
ure for 1 minute.
5) After completing the measurement, set to
the original condition.

boom cylinder by operating the boom con-
trol lever in the RAISE direction.
k Take care not to operate the boom con-

trol lever in the LOWER direction.
after the boom cylinder is relieved and
measure for 1 minute.
PC600-8 59
3. Measuring leakage from bucket cylinder 4. Measuring leakage from swing motor
1) Run the engine and curl the bucket to the 1) Disconnect drain hoses (4) and plug them.
stroke end. a Use the following parts to block the hos-
k Referring to “Releasing remaining pres-

es.
07376-70522 (Plug #05)
maining pressure from the piping on the
bucket cylinder head side (Operate the
lever only in the CURL direction, how-
ever).
2) Disconnect hose (3) on the cylinder head

07379-01044 (Flange #10)
2) Turn the swing lock switch ON.

swing circuit and measure the oil leakage.
a Start measuring the oil leakage 30 sec-
onds after the swing motor circuit is re-
lieved and measure for 1 minute.
a After measuring 1 time, swing the upper
structure 180° and measure again.

bucket cylinder by operating the bucket con-
trol lever in the CURL direction.
k Take care not to operate the bucket

control lever in the DUMP direction.
after the bucket cylinder is relieved and
measure for 1 minute.
60 PC600-8
5. Measuring leakage from travel motor 6. Measuring leakage from center swivel joint
1) Remove the travel motor cover. 1) Put pin [1] between the sprocket and track
4 Travel motor cover: 35 kg

frame to lock the travel motor of the port to
be inspected, and then stop the engine.
k Loosen the oil filler cap of the hydraulic

2) Start the engine and lock the travel mecha-
nism.
k Set pin [1] between the sprocket and

tank slowly to release the internal pres-
sure of the tank.
track frame to lock the travel mecha- a Inspection ports, travel directions, and
nism securely. measurement ports (See figure on fol-
lowing parts)
Inspection Travel Measurement
port direction ports
A R.H. reverse T and B
B L.H. reverse A and C
C R.H. forward B and D
D L.H. forward C and E
E Speed select D and T
T Drain —
3) Disconnect drain hose (5) of the travel

motor and plug it.
07376-70628 (Plug #06)

travel circuit and measure the oil leakage.
k Since wrong operation of the levers can

cause an accident, make signs and
confirmation securely.
a Start measuring the oil leakage 30 sec-
onds after the travel motor circuit is re-
lieved 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 cylin-
der and those of the cylinder and piston).
PC600-8 61
2) Disconnect the hoses of the upper and 3) Run the engine at high idle and measure the
lower measurement ports of the inspection oil leakage through the measurement ports.
port from the top of the swivel joint and a When measuring ports A, B, C, and D,
block them. relieve the travel motor slowly in the re-
a For combination of the inspection port volving direction (See the table on the
and measurement ports, see the above last page).
table. a When measuring port E, set the travel
a Use the following parts to block the hos- speed select switch in the Hi position.
es. 4) Start measuring the oil leakage 1 minute
• Ports A, B, C, D: after the center swivel joint is relieved and
07379-01044 (Flange #10) measure for 1 minute.
• Port E: 07376-70315 (Plug #03)
• Port T: 07376-70522 (Plug #05)
62 PC600-8
Releasing remaining pressure 3. Release of remaining pressure from swing

motor circuit
in hydraulic circuit a Release the remaining pressure from the
swing motor circuit by performing the proce-
1. Release of remaining pressure from hydrau- dure for 2. Release of remaining pressure
lic tank from hydraulic cylinder circuit.
The hydraulic tank is enclosed and pressurized. 4. Release of remaining pressure from travel
When removing a hose or a plug connected motor circuit
to the hydraulic tank, release the remaining a Since the control valve spool of the travel
pressure from the hydraulic tank according motor is open, release the remaining pres-
to the following procedure. sure from the travel motor circuit by perform-
1) Lower the work equipment to the ground in ing the procedure for 1. Release of
a stable posture and stop the engine. remaining pressure from hydraulic tank.
2) Slowly loosen oil filler cap (1) of the hydrau-
lic tank to release the air from the tank.
2. Release of remaining pressure from hydrau-

lic cylinder circuit
k When disconnecting the piping between a

hydraulic cylinder and the control valve, re-
lease the remaining pressure from the piping
1) Referring to 1. Release of remaining pres-
sure 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 con-
trol levers on both sides forward, backward,
to the right, and to the left.
a The control valve is driven with the pres-
sure 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.
PC600-8 63
Bleeding air from each part
Air bleeding procedure

Air bleeding item 1 2 3 4 5 6
Bleeding Bleeding Bleeding Checking
Bleeding
air from Starting air from air from oil level
Contents of work air from
hydraulic engine swing travel and start-
cylinder
pump motor motor ing work
• Replacement of hydraulic oil q q
q q q q
• Cleaning of strainer (see Note) (see Note)
• Replacement of return filter ele-
q q
ment
• Replacement or repair of
hydraulic pump q q q q
• Removal of suction piping
• Replacement or repair of control
valve q q q
• Removal of control valve piping
• Replacement or repair of cylin-
der q q q
• Removal of cylinder piping
• Replacement or repair of swing
motor q q q
• Removal of swing motor piping
• Replacement or repair of travel
motor q q q
• Removal of travel motor piping
• Replacement or repair of swivel
joint q q
• Removal of swivel joint piping
Note: Bleed air from the swing motor and travel motor only when the oil was drained from the motor cases.
1. Bleeding air from hydraulic pump 3) After clear oil flows out of bleeders (1) and
3 Bleeder:
1) Loosen air bleeders (1) and (2) by 4 turns (2), tighten the bleeders.
and remove the oil filler cap of the hydraulic
tank. 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
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.
64 PC600-8
2. Starting engine 5. Bleeding air from travel motor

When running the engine after performing step 1) Remove the travel motor cover.
4 Travel motor cover: 35 kg

1, keep its speed at low idle for 10 minutes.
3. Bleeding air from cylinder 2) Loosen bleeder (4) by 1 turn and start the
a If a cylinder was replaced, bleed air from it engine.
before connecting the work equipment. In a Do not loosen the bleeder more than 1
particular, the boom cylinder does not move turn.
to the lowering stroke end, if it is installed to 3) Run the engine at low idle and repeat the
the work equipment. forward and reverse travel operations 4 - 5
1) Run the engine at low idle for about 5 min- times. After clear oil flows out, tighten the
utes. bleeder.
2) Running the engine at low idle, raise and a Limit the operation of the lever to a de-
3 Bleeder:
lower the boom 4 – 5 times. gree that the machine starts traveling.
a Stop the piston rod about 100 mm before
each stroke end. Do not relieve the oil. 27.4 – 35.3 Nm {2.8 – 3.6 kgm}
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 dur-
ing swinging operation, however, bleed
air from the parking brake circuit accord-
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.
PC600-8 65
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.
©2009 KOMATSU
All Rights Reserved
66
Inspection procedures for diode 3) Determine if a specific diode is good or no

good with the indicated value.
a Check an assembled-type diode (8 pins) and • No change in the indicated value: No
single diode (2 pins) in the following manner. continuity (defective).
a The continuity direction of an assembled-type • Change in the indicated value: Continui-
diode is as shown in the diagram below. ty established (normal) (Note)
Note: A silicon diode shows a value between
400 and 600.
a The continuity direction of a single diode is

shown on the diode surface.
2. When using analog type circuit tester
1) Switch the testing mode to resistance range.
2) Check the needle swing in case of the fol-
lowing 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)
1. When using digital type circuit tester will differ depending on a circuit tester
1) Switch the testing mode to diode range and type or a selected measurement range)
confirm the indicated value. • If the needle swings in either case of i)
a Voltage of the battery inside is displayed and ii): Defective (short-circuited inter-
with conventional circuit testers. nally)
2) Put the red probe (+) of the test lead to the • If the needle does not swing in any case
anode (P) and the black probe (–) to the of i) and ii): Defective (short-circuited in-
cathode (N) of diode, and confirm the dis- ternally)
played value.
PC600-8 67
©2009 KOMATSU
All Rights Reserved
68
SEN00445-03
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up


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
PC600-8 1
Special function of machine monitor
[1] Figure input switch 1 [6] Figure input switch 6 [ ] Return switch
[2] Figure input switch 2 [7] Figure input switch 7 [ ] Upward move switch
[3] Figure input switch 3 [8] Figure input switch 8 [ ] Downward move switch
[4] Figure input switch 4 [9] Figure input switch 9 [ ] Input confirmation switch
[5] Figure input switch 5 [0] Figure input switch 0
2 PC600-8
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 Service Menu

1 Function of inputting and setting password 16 Function of Monitoring [01]
2 Function for showing KOMATSU logo Function for Abnormality Electrical system
17
3 Function for check before starting Record [02] Mechanical system
4 Function for machine maintenance 18 Function for Maintenance Record [03]
5 Function for showing caution items 19 Function for Maintenance Mode Change [04]
Function for confirming working mode and travel 20 Function for Phone Number Entry [05]
6
speed
Key-ON mode
7 Function for display of ordinary items
Function for AAAA/ Language
Function for adjusting display luminance and 21
8 Default [06] Unit
contrast
Setting of wiper
9 Function for confirming maintenance information
22 Function for Adjustment [07]
10 Function for showing service meter reading
23 Function of Cylinder Cut Out [08]
11 Function for checking display LCD
24 Function of no injection [09]
12 Function for showing occurrence of caution item
13 Function for showing action code No.
14 Function for showing failure code No.
Function of reversing fan rotation and adjusting
15
economy mode value
PC600-8 3
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 mainte-
nance 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 main-
tenance time is approaching or has just passed.
a This display appears only when the mainte-
nance 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 abnor-
mality, a corresponding symbol mark is shown
after the display of machine check before start-
ing 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.
4 PC600-8
6. Function for confirming working mode and 8. Function for adjusting display luminance and
travel speed contrast
After the display of machine check before start- Luminance as well as contrast of the display can
ing day's work, amplified symbol marks for work- be adjusted by operating the display adjusting
ing mode and travel speed are shown for 2 switch.
seconds to urge an operator to confirm the set-
ting.
9. Function for confirming maintenance infor-

mation
7. Function for display of ordinary items Detailed information on maintenance items (set
The display of confirming working mode and time and elapse of time) can be confirmed and
travel speed is switched to this display of ordi- resetting after the confirmation is feasible by
nary items. operating the maintenance switch.
a If the working mode setting or travel speed a Use service menu for setting or releasing
setting is changed, or auto-deceleration or maintenance items and setting maintenance
windshield wiper setting is activated while time.
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.
PC600-8 5
10. Function for showing service meter reading 12. Function for showing occurrence of caution
Only the service meter reading can be shown by item
the following switching operation, when the If any of the caution items occurs, the magnified
engine starting switch is turned OFF. corresponding symbol mark is shown for 2 sec-
• Switching operation: onds and thereafter stays on the display as a
[ ] + [ ] (synchronized switching opera- small symbol mark until it is dissolved.
tion)
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 dis-
play is normal.
a This display returns to the immediately pre-
ceding one, if making any other switching
operation.
6 PC600-8
13. Function for showing action code No.

When a trouble occurs on the machine, the
action code is automatically displayed depend-
ing on the magnitude of the trouble to call atten-
tion 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
Failure mode Instructions given to operator
code
If the emergency pump drive switch is set to the upper (emergency) position,
E02 Error in pump control system the machine can operate normally. Have the machine inspected immedi-
ately, however.
E03 Error in swing brake system Have the machine inspected immediately.
Error in engine controller power
supply system
E10 Have the machine inspected immediately.
Abnormality in engine controller
drive system circuit (engine stop)
Error in engine controller system Set the machine in a safe position and have the machine inspected immedi-
E11
(Engine protection output down) ately.
Set the machine in a safe position and have the machine inspected immedi-
E14 Error in throttle system
ately.
Error in engine sensor
Ordinary operation is possible. Have the machine inspected immediately,
E15 (water temperature, fuel tempera-
however.
ture and oil pressure)
Set the machine in a safe position and have the machine inspected immedi-
E0E Error in network
ately.
PC600-8 7
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 regis-
tered), failure code No. is shown in turn.
• Switching operation: [ ]
a The following display is repeated in order ac-
cording 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.
8 PC600-8
Failure code table
Action Failure Alarm Component Category of

Trouble (Displayed on screen)
code code buzzer in charge record
Mechanical
— A000N1 Eng. Hi Out of Std MON
system
Mechanical
— AA10NX Aircleaner Clogging MON
system
Mechanical
— AB00KE Charge Voltage Low MON
system
Mechanical
— B@BAZG Eng. Oil Press. Low MON
system
Mechanical
— B@BAZK Eng. Oil Level Low MON
system
Mechanical
— B@BCNS Eng. Water Overheat MON
system
Mechanical
— B@BCZK Eng. Water Lvl Low MON
system
Mechanical
— B@HANS Hydr. Oil Overheat MON
system
Electrical
E10 CA111 ECM Critical Internal Failure ENG
system
Electrical
E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG
system
Electrical
E11 CA122 Chg Air Press Sensor High Error q ENG
system
Electrical
E11 CA123 Chg Air Press Sensor Low Error q ENG
system
Electrical
E14 CA131 Throttle Sensor High Error q ENG
system
Electrical
E14 CA132 Throttle Sensor Low Error q ENG
system
Electrical
E15 CA135 Eng Oil Press Sensor High Error q ENG
system
Electrical
E15 CA141 Eng Oil Press Sensor Low Error q ENG
system
Electrical
E15 CA144 Coolant Temp Sens High Error q ENG
system
Electrical
E15 CA145 Coolant Temp Sens Low Error q ENG
system
Electrical
E15 CA153 Chg Air Temp Sensor High Error q ENG
system
Electrical
E15 CA154 Chg Air Temp Sensor Low Error q ENG
system
Electrical
E15 CA187 Sens Supply 2 Volt Low Error q ENG
system
Electrical
E15 CA221 Ambient Press Sens High Error q ENG
system
Electrical
E15 CA222 Ambient Press Sens Low Error q ENG
system
Electrical
E15 CA227 Sens Supply 2 Volt High Error q ENG
system
Electrical
— CA234 Eng Overspeed ENG
system
Electrical
E03 CA238 Ne Speed Sens Supply Volt Error q ENG
system
Electrical
E15 CA263 Fuel Temp Sensor High Error q ENG
system
Electrical
E15 CA265 Fuel Temp Sensor Low Error q ENG
system
Electrical
E11 CA271 IMV/PCV1 Short Error q ENG
system
PC600-8 9

Electrical
E11 CA272 IMV/PCV1 Open Error q ENG
system
Electrical
E11 CA273 PCV2 Short Error q ENG
system
Electrical
E11 CA274 PCV2 Open Error q ENG
system
Electrical
E11 CA322 Inj #1(L#1) Open/Short Error q ENG
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
E10 CA342 Calibration Code Incompatibility ENG
system
Electrical
E10 CA351 Injectors Drive Circuit Error q ENG
system
Electrical
system
Electrical
system
Electrical
E10 CA441 Battery Voltage low error q ENG
system
Mechanical
E10 CA442 Battery Voltage high error q ENG
system
Electrical
E11 CA449 Rail Press Very High Error q ENG
system
Electrical
E11 CA451 Rail Press Sensor High Error q ENG
system
Electrical
E11 CA452 Rail Press Sensor Low Error q ENG
system
Electrical
E15 CA553 Rail Press High Error q ENG
system
Electrical
— CA554 Rail Press Sensor In Range Error ENG
system
Electrical
E15 CA559 Rail Press Low Error q ENG
system
Electrical
E11 CA689 Eng Ne Speed Sensor Error q ENG
system
Electrical
E11 CA731 Eng Bkup Speed Sens Phase Error q ENG
system
Electrical
E10 CA757 All Persistent Data Lost Error q ENG
system
Electrical
E11 CA778 Eng Bkup Speed Sensor Error q ENG
system
Electrical
E15 CA1228 EGR Valve Servo Error 1 q ENG
system
Electrical
system
Electrical
E11 CA1626 BP Valve Sol Current High Error q ENG
system
Electrical
E11 CA1627 BP Valve Sol Current Low Error q ENG
system
Electrical
E15 CA1628 Bypass Valve Servo Error 1 q ENG
system
10 PC600-8

Electrical
system
Electrical
E11 CA1631 BP Valve Pos Sens High Error q ENG
system
Electrical
E11 CA1632 BP Valve Pos Sens Low Error q ENG
system
Electrical
E0E CA1633 KOMNET Datalink Timeout Error q ENG
system
Electrical
E11 CA1642 EGR Inlet Press Sens Low Error q ENG
system
Electrical
E11 CA1653 EGR Inlet Press Sens High Error q ENG
system
Electrical
E14 CA2185 Throt Sens Sup Volt High Error q ENG
system
Electrical
E14 CA2186 Throt Sens Sup Volt Low Error q ENG
system
Electrical
E11 CA2249 Rail Press Very Low Error q ENG
system
Electrical
E11 CA2271 EGR Valve Pos Sens High Error q ENG
system
Electrical
E11 CA2272 EGR Valve Pos Sens Low Error q ENG
system
Electrical
E11 CA2351 EGR Valve Sol Current High Error q ENG
system
Electrical
E11 CA2352 EGR Valve Sol Current Low Error q ENG
system
Electrical
E15 CA2555 Grid Htr relay Volt Low Error q ENG
system
Electrical
E15 CA2556 Grid Htr relay Volt High Error q ENG
system
Electrical
— D110KB Battery Relay Drive S/C PUMP
system
Electrical
— D163KB Flash Light Relay S/C PUMP
system
Electrical
— D195KB Step Light Relay S/C PUMP
system
Electrical
— DA25KP Press. Sensor Power Abnormality PUMP
system
Electrical
— DA2SKQ Model selection Abnormality PUMP
system
Mechanical
— DA80MA Auto. Lub. Abnormal PUMP
system
Electrical
E0E DA2RMC Pump Comm. Abnormality q PUMP
system
Electrical
E0E DAFRMC Monitor Comm. Abnormality q PUMP
system
Electrical
— DGE5KY Ambi. Temp. Sensor S/C PUMP
system
Electrical
— DGH2KB Hydr. Oil Temp. Sensor S/C PUMP
system
Electrical
— DHPAMA F Pump P.Sensor Abnormality PUMP
system
Electrical
— DHPBMA R Pump P.Sensor Abnormality PUMP
system
Electrical
— DV20KB Travel Alarm S/C PUMP
system
Electrical
— DW43KA Travel Speed Sol. Disc. PUMP
system
Electrical
— DW43KB Travel Speed Sol. S/C PUMP
system
PC600-8 11

Electrical
E03 DW45KA Swing Brake Sol. Disc. q PUMP
system
Electrical
E03 DW45KB Swing Brake Sol. S/C q PUMP
system
Electrical
— DW48KA CO Cancel Sol. Disc. PUMP
system
Electrical
— DW48KB CO Cancel Sol. S/C PUMP
system
Electrical
— DW7BKA Fan Reverse Sol. Disc. PUMP
system
Electrical
— DW7BKB Fan Reverse Sol. S/C PUMP
system
Electrical
— DW4XKA Bucket Curl Hi Cancel Sol. Disc. PUMP
system
Electrical
— DW4XKB Bucket Curl Hi Cancel Sol. S/C PUMP
system
Electrical
— DWK0KA 2-stage Relief Sol. Disc. PUMP
system
Electrical
— DWK0KB 2-stage Relief Sol. S/C PUMP
system
Electrical
E11 DX16KA Fan Pump EPC Sol. Disc. q PUMP
system
Electrical
E11 DX16KB Fan Pump EPC Sol. S/C q PUMP
system
Electrical
E02 DXA0KA TVC Sol. Disc. q PUMP
system
Electrical
E02 DXA0KB TVC Sol. S/C q PUMP
system
Electrical
— DY20KA Wiper Working Abnormality PUMP
system
Electrical
— DY20MA Wiper Parking Abnormality PUMP
system
Electrical
— DY2CKB Washer Drive S/C PUMP
system
Electrical
— DY2DKB Wiper Drive (For) S/C PUMP
system
Electrical
— DY2EKB Wiper Drive (Rev) S/C PUMP
system
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 ser-
vice 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.
12 PC600-8
15. Function of reversing fan rotation and adjust- 4] If the [ ] switch is pressed, the screen
ing economy mode value to wait for change of the fan rotation
1) Reversing fan rotation direction appears and the engine speed
1] Press switch [5] of the monitor, and the is lowered to low idle automatically.
following screen appears. After about 15 seconds, the fan rotation
• "01": Fan rotation reversing menu is reversed. After 4 seconds, the engine
• "02": Economy mode value adjust- speed returns to the level before the
ing menu [ ] switch was pressed.
a The fan speed is in proportion to the en-

gine 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 start-
ed. When stopping reversing the fan ro-
tation, turn the starting switch to the OFF
position.)
2] Select "1" Fan rotation reversing and 5] If the fan rotation is reversed, the follow-
press the [ ] switch, and the following ing screen appears automatically and is
screen appears. maintained as long as the fan rotation is
a The fan mark is green. in reverse.
3] When reversing the fan rotation, press a The fan mark is yellow.
the [ ] switch.
a When not reversing the fan rotation,
press the return switch [ ], and the
previous screen appears.
PC600-8 13
6] If any trouble occurs while the fan is 3] If the [ ] switch is pressed, the screen to
rotating in reverse, the following warn- wait for change of the fan rotation direc-
ing monitor is displayed. In this case, tion appears and the engine speed is low-
see the page of explanation of the mon- ered to low idle automatically. After about
itoring items and take necessary rem- 15 seconds, the fan rotation is returned to
edy. 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 nor-
mal 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 pre- Remarks
vious screen appears. 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.
14 PC600-8
2) This state shows that reversing of the 3) Adjusting economy mode value
fan rotation is prohibited to protect the 1] In the screen of 2)-1], select "2" E mode
components under some conditions of and press the [ ] switch, and the fol-
coolant temperature and hydraulic oil lowing screen appears.
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 hy-
draulic oil temperature gauges are in
the range shown below, the fan rota-
tion 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 lev-
els 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
Production
consumption
E0 Initial value
E1 Economy adjustment 1
Good Little
a As the value is increased to [E3

side], the fuel consumption is re-
duced and the production is also re-
duced.
PC600-8 15
Operation and display of service menu 3) Showing Service Menu display

The display is changed to the initial display of
Way of switching to Service Menu service menu program. Select an appropriate
a When using Service Menu, change the display item from among the menu.
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.
No. Service Menu

00 Return (Termination of Service Menu)
01 Monitoring
02 Abnormality Record
03 Maintenance Record
2) Switch operation
04 Maintenance Mode Change
Operate the switch as instructed below.
• Switch operation: [ ] + [1] o [2] o [3] 05 Phone Number Entry
(Enter a figure, depressing [ ]) 06 AAAA / Default
07 Adjustment
08 Cylinder cut out
09 No-injection
4) Termination of Service Menu function

When terminating the initial display or any sub-
sequent 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.
16 PC600-8
16. Function of Monitoring [01] any of the following switch operations, after
The machine monitor monitors signals from an the registration work has been completed.
assortment of switches, sensors and actuators • Keep [ ] switch depressed. (For about
installed in various parts of the machine. Moni- 3 seconds)
tored information can be put in display or con- • Select Menu 99999 and depress [ ]
firmed on a real time basis through the following switch.
operations. a The display automatically moves to the dis-
play of monitored information, when all of the
1) Selection of menu registrable items have been duly registered.
Select "01 Monitoring" in the initial display of a Monitored information are transmitted via
Service Menu and depress [ ] switch. communication circuits. Thus the number of
selected items can impact the communica-
tion speed. If truly real time monitoring is re-
quired, 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.
2) Setting of monitoring item

i) Select or register an item to be moni-
tored through the following switch oper-
ation.
• [ ] 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. (De-
pending 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
PC600-8 17
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 con-
dition, information holding is released.
5) Machine setting mode switching function

If it becomes necessary to change settings
of working mode, travel speed and auto-
deceleration while monitoring, depress the
corresponding switch, then the mode confir-
mation display is shown.
a When a specific setting is confirmed, de-
press [ ] switch, then the display re-
turns to that of monitoring.
a In case a specific setting has been
changed while monitoring, the new set-
ting is still maintained when returning
from Service Menu to Operator's Menu
after the monitoring is finished.
18 PC600-8
Monitoring items list

Code Unit (Default: ISO)
Monitoring item Remarks
No. ISO meter inch
00000 Return (Not displayed) Ending menu
99999 To Display Screen (Not displayed) Display execution menu
00200 Controller Model Select Numeral
00201 Machine ID Numeral
01002 Engine Speed r/min rpm rpm
01601 2nd Eng Speed Command r/min rpm rpm
01100 F Pump Pressure MPa kg/cm2 Psi
01101 R Pump Pressure MPa kg/cm2 Psi
04107 Coolant Temperature °C °C °F
14200 Fuel Temperature °C °C °F
04401 Hydr. Oil Temperature °C °C °F
37502 Ambient Temperature °C °C °F
01300 TVC Sol. Curr mA mA mA
31623 Fan Pump EPC Sol. Curr mA mA mA
03200 Battery Voltage V V V
03203 Battery Power Supply V V V
04300 Battery Charge Vol. V V V
01006 Engine Speed r/min rpm rpm
37200 Engine Oil Pressure MPa kg/cm2 Psi
36400 Rail Pressure MPa kg/cm2 Psi
37400 Ambient Pressure kPa kg/cm 2
Psi
18400 Intake Temperature °C °C °F
18500 Charge Temperature °C °C °F
36500 Boost Pressure kPa kg/cm2 Psi
18000 EGR Inlet Pressure kPa kg/cm 2
Psi
18100 EGR Valve Position mm mm in
18200 BPS Valve Position mm mm in
36700 Engine Torque Ratio % % %
18700 Engine Output Torque Nm Nm kgfm
01112 F Pump Pres. Sensor Vol. V V V
01113 R Pump Pres. Sensor Vol. V V V
03000 Fuel Dial Pos Sens Volt V V V
04200 Fuel Level Sensor Vol. V V V
04105 Coolant Temp Sens Volt V V V
14201 Fuel Temp. Sensor Vol. V V V
04402 Hydr. Temp. Sensor Vol. V V V
37503 Ambi. Temp. Sensor Vol. V V V
37201 Eng Oil Press Sens Volt V V V
PC600-8 19

No. ISO meter inch
37401 Ambient Press Sens Volt V V V
18401 Intake Temp Sens Volt V V V
18501 Charge Temp Sens Volt V V V
36501 Charge Press Sens Volt V V V
36401 Rail Pressure Sens Volt V V V
18001 EGR In Press Sens Volt V V V
18101 EGR Valve Pos Sens Volt V V V
18201 BPS Valve Pos Sens Volt V V V
17201 PCV Close Timing CA CA CA
17500 Engine Power Mode — — —
31701 Throttle Position % % %
31706 Final Throttle Position % % %
18600 Inject Fueling Command mg/st mg/st mg/st
36200 Rail Press Command MPa kg/cm 2
PSi
36300 Injection Timing Command CA CA CA
37300 Fuel Rate (Note 1) L/h L/h L/h
01602 2nd Eng. Speed Command % % %
13113 Main Pump Absorb Torque Nm kgm Ibft
13114 Fan Pump Absorb Torque Nm kgm Ibft
13112 Total Pump Absorb Torque Nm kgm Ibft
Swing Display of ON/OFF
Travel Display of ON/OFF
Boom Lower Display of ON/OFF
01900 Pressure Switch 1
Boom Raise Display of ON/OFF
Arm Curl Display of ON/OFF
Arm Dump Display of ON/OFF
Bucket Curl Display of ON/OFF
Bucket Dump Display of ON/OFF
01901 Pressure Switch 2
Service Display of ON/OFF
Travel Steering Display of ON/OFF
Bucket Hi Cancel Display of ON/OFF
Swing Brake Display of ON/OFF
2-Stage Relief Display of ON/OFF
02300 Solenoid 1
Travel Speed Display of ON/OFF
Fan Reverse Display of ON/OFF
CO Cancel Display of ON/OFF
Lever SW Display of ON/OFF
02200 Switch Input 1 Swing Release SW Display of ON/OFF
Swing Brake S Display of ON/OFF
20 PC600-8

No. ISO meter inch
Model Select 1 Display of ON/OFF
02201 Switch Input 2 Model Select 3 Display of ON/OFF
02202 Switch Input 3 Key Switch (AAC) Display of ON/OFF
Step Light SW Display of ON/OFF
02203 Switch Input 4
Horn SW Display of ON/OFF
Over Load Sensor Display of ON/OFF
05500 Sensor Input 1
Auto Greasing Display of ON/OFF
03700 Controller Output 1 Batt. Relay Dr. Display of ON/OFF
Step L. Relay Display of ON/OFF
03701 Controller Output 2 Flush L. Relay Display of ON/OFF
Travel Alarm Display of ON/OFF
Key Switch Display of ON/OFF
Start Display of ON/OFF
04500 Monitor Input 1 Preheat Display of ON/OFF
Light Display of ON/OFF
Rad. Level Display of ON/OFF
Aircleaner Display of ON/OFF
04501 Monitor Input 2 Eng. Oil Level Display of ON/OFF
Battery Charge Display of ON/OFF
Swing Brake SW. Display of ON/OFF
Bzzr Cancel SW. Display of ON/OFF
Window Limit SW. Display of ON/OFF
04502 Monitor Input 3
W Limit SW. Display of ON/OFF
Upper P Limit SW. Display of ON/OFF
Lower P Limit SW. Display of ON/OFF
20216 ECM Build Version — — —
20217 ECM CAL Data Ver. — — —
18900 ECM Internal Temp °C °C °F
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).
PC600-8 21
17. Function for Abnormality Record [02] 3) Information shown in display of Abnormality
The machine monitor records failures that Record in the electrical system
occurred on the machines in the past after clas- [1]: The numerator expresses sequence of
sifying them into failures in the electric system failure occurrence, counting from the
and those in the mechanical system. Information latest one. The denominator expresses
on them can be displayed through the following the total number of a specific failure
operation. recorded.
[2]: "E" is displayed as long as the failure is
1) Selection of menu not repaired.
Select “02 Abnormality Record” in the initial Failure Code (section in 4 digits and
display of Service Menu and depress [ ] phenomenon in 2 digits)
switch. [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.
4) Information shown in display of Abnormality
No. Abnormality Record Submenu Record in the mechanical systems
Return [1]: Record No.
00
(termination of Abnormality Record) [2]: Contents of Abnormality
01 Electrical Systems
[3]: Failure Code (section in 4 digits and
phenomenon in 2 digits)
02 Mechanical Systems [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.
22 PC600-8
5) Resetting Electrical Systems

a Resetting the Abnormality Record (dele-
tion) is possible only with the electrical
system. The Abnormality Record in the
mechanical system cannot be reset.
a For resetting any specific or all informa-
tion in the Electrical Systems, follow the
operation explained below.
i) 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.
ii) Operate the switch, following the instruc-
tions 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.
PC600-8 23
18. Function for Maintenance Record [03] 19. Function for Maintenance Mode Change [04]
The machine monitor panel records information Conditions set for controlling maintenance dis-
on the maintenance of filters and oils. The play function can be changed in the following
stored information can be displayed through the manner.
following switch operation. • Turn the function effectual or ineffectual.
• Change the set interval for replacement.
1) Selection of menu
Select “03 Maintenance Record” in Service 1) Selection of menu
Menu and depress [ ] switch. 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 2) Selection of item to be changed
[3]: Service meter reading at the latest Select an item to be changed in the display
replacement of Maintenance Mode Change menu.
24 PC600-8
4) Set contents of individual items

No. Maintenance mode change item [1]: Default: The maintenance time set in
the monitor (recommended by the man-
Return (Termination of maintenance
00 ufacturer and cannot be changed).
mode change)
[2]: Set: Maintenance time that can be
01 Maintenance Mode On/Off freely set. The maintenance mode pro-
02 Engine Oil Exch. Int. gram functions based on this mainte-
nance time. (The maintenance time can
03 Engine Oil Filter Exch. Int. be increased or decreased by 50 hours
04 Main Fuel Filter Exch. Int. with [ ] or [ ] switch)
[3]: On: Maintenance display function with
41 Pre Fuel Filter Exch. Int.
this instruction becomes effectual.
05 Hydr. Oil Filter Exch. Int. [4]: Off: Maintenance display with this
06 H/Tank Breather Exch. Int. instruction becomes ineffectual.
a The lowest maintenance time is 50 h.
07 Corro. Resis. Exch. Int.
08 PTO Oil Service Int.
09 Final Drive Oil Exch. Int.
10 S/Machinery Oil Exch. Int.
11 Hydraulic Oil Exch. Int.
12 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
5) Set contents of "Use Default Values"
all oil and filter related items are turned
When selecting this menu and depressing
effectual. (Irrespective of whether "On"
or "Off" set for individual items, this set- the switch [ ], all individual time settings
ting prevails) are reduced to the initial settings.
• 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 set-
ting prevails)
PC600-8 25
20. Function for Phone Number Entry [05] 3) Entry and setting phone number
In the display of Action Code, a telephone num- Following the method explained below,
ber and Failure Code are shown alternately. entry a phone number in the Phone Number
Phone number can be inputted or modified in Entry display (Entry automatically begins
the following manner. with a cursor at the left end).
a If there is no Phone number registered, the i) Enter a number into a cursor at the left
display for Phone numbers does not appear. end with a ten-key.
ii) Depress [ ] switch when all the num-
1) Selection of menu bers have been entered.
Select “05 Phone Number Entry” menu in a Numbers can be entered up to the max.
the display of Service Menu, and depress 12 digits, but omit unnecessary digits.
[ ] switch. a When entering a wrong number, de-
press [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 input-
ted, it is deleted, upon switching to the
Phone Number Entry display.
26 PC600-8
21. Function for AAAA/Default [06] 3) Function for Key-on Mode

It is possible to change the following settings for When the engine starting switch is turned
the machine monitor as well as the machine. ON, a working mode can be set that is
Make a change as is required. shown in the machine monitor.
• Working mode when the engine starting • P Mode, E Mode, L Mode, B Mode: If
switch is in the ON position. any of them is set, the machine always
• Display language in Service Menu ramps up with that working mode, when
• Display unit in the monitoring function turning the engine starting switch ON.
• Setting of double wiper or single wiper • Mode at Previous Key-off: If this mode is
set, the machine ramps up with the
1) Selection of menu working mode that was last used in the
Select 06 "AAAA/Default menu" in the ini- previous machine operation.
tial display of Service Menu, and depress • Default Value: If this mode is set, the
[ ] switch. machine ramps up with the default mode
(P mode only) that was originally set at
the time of delivery from the factory.
2) Selection of submenu
Select an item to change from the submenu,
and depress [ ] switch.
No. AAAA/Default submenu
00 Return
01 Key-on Mode
02 Language
03 Unit
04 Wiper Select
05 All Default Value
PC600-8 27
4) Function for AA/Language 6) Function for wiper select

In Service Menu, the language in use can The wiper specification can be set.
be changed between Japanese and • 1 wiper: Machine with standard cab or
English. fixed-front window cab
a English is used as the language for de- (Only upper wiper)
fault setting in the machine monitor. • 2 wipers: Machine with fixed-front win-
a If the machine monitor for spare parts is dow cab (if equipped)
to be used in a Japanese-speaking re- (Upper wiper and lower wiper)
gion or organization, change the lan- a If this setting is not matched to the spec-
guage from English to Japanese, using ification of the actually installed wiper,
this function. 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 ma-
chine monitor is SI, i.e. International sys-
tem of units.
28 PC600-8
22. Function for Adjustment [07] 3) Function of pump absorption torque

The machine can be adjusted with the machine The pump absorption torque can be
monitor. adjusted in the following ranges.
a Basically, this setting does not need to
1) Selection of menu be changed.
Select "07 Adjustment" on the service menu
Adjustment
Pump absorption torque
value
2) Selection of sub menu 220 +98.1 Nm {+10.0 kgm}

Select the sub menu to check the setting 221 +73.5 Nm {+7.5 kgm}
222 +49.0 Nm {+5.0 kgm}
223 +24.5 Nm {+2.5 kgm}
224 0.0 Nm {0.0 kgm}
225 –24.5 Nm {–2.5 kgm}
226 –49.0 Nm {–5.0 kgm}
227 –73.5 Nm {–7.5 kgm}
228 –98.1 Nm {–10.0 kgm}
No. Sub menu of adjustment

00 Return (Finish adjustment)
01 Pump Absorption Torque
02 Fan Speed Mode Select
03 Fan 100% Speed Adjust
04 Fan 70% Speed Adjust
PC600-8 29
4) Fan speed mode selection function a The set value is kept even after the start-
To adjust the fan speed, it must be fixed ing switch is turned OFF.
temporarily. Select one of the following
modes as necessary. Adjustment
Fan 100% Speed
value
560 + 140 rpm
561 + 120 rpm
562 + 100 rpm
563 + 80 rpm
564 + 60 rpm
565 + 40 rpm
566 + 20 rpm
567 0
568 – 20 rpm
Adjustment 569 – 40 rpm
Fan speed mode selection
value
56A – 60 rpm
Normal mode: For normal opera-
550 56B – 80 rpm
tion
56C – 100 rpm
70% speed mode: For check of
551
meeting of regulations 56D – 120 rpm
100% speed mode: For fan speed 56E – 140 rpm
552
adjustment
a If the starting switch is turned OFF, the 6) Fan 70% speed adjustment function
fan speed mode returns to "550: Normal After "70% speed" is set in 4) above, the fan
mode". speed can be adjusted within the following
Keep the starting switch ON while ad- range.
justing 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 follow-
ing range.
a Adjust the fan speed within the standard
range (1,050 ± 50 rpm).
30 PC600-8
a The set value is kept even after the start-

ing switch is turned OFF (only when the
fan is set in the 70% speed mode).
Adjustment
Fan 70% Speed
value
570 + 140 rpm
571 + 120 rpm
572 + 100 rpm
573 + 80 rpm
574 + 60 rpm
575 + 40 rpm
576 + 20 rpm
577 0
578 – 20 rpm
579 – 40 rpm
57A – 60 rpm
57B – 80 rpm
57C – 100 rpm
57D – 120 rpm
57E – 140 rpm
PC600-8 31
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 cyl-
inders. This operation is used to find out a cylin-
der 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 cylin-
der Nos. to cancel disabling of those cylin-
ders.
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 disa-
bled for the reduced cylinder mode oper-
ation.
32 PC600-8
4) Function of holding engine speed [Reference]: How to use holding function effec-
If the [ ] switch is pressed while the Cylin- tively
der Cut Out operation screen is used, the The engine speed displayed by the holding
engine speed is held and displayed on the function is held on the screen until the holding
lower line. function is cancelled, regardless of setting and
If the [ ] switch is pressed while the engine cancellation of the Cylinder Cut Out operation.
speed is held, holding of the engine speed is Accordingly, a defective cylinder can be found
cancelled and the engine speed displayed out effectively according to the following proce-
on the lower line goes off. dure.
a If the holding function is used, the held (1) Run the engine normally (without disabling
engine speed is displayed in ( ) on the any cylinder) and hold the engine speed.
lower line and the current engine speed (2) Disable a cylinder to be checked.
is displayed on the upper line. (3) Run the engine under the same condition as
a The holding function can be used both in the normal operation in step (1) and com-
and out of the Cylinder Cut Out opera- pare the engine speed at this time with the
tion. held engine speed.
(4) Check the cylinder once, regardless of
change of the engine speed.
(5) Repeat steps (2) - (4) to check the other cyl-
inders.
a If the engine speed does not lower at all
or lower less when a cylinder is selected
for the Cylinder Cut Out operation, com-
bustion in that cylinder must be abnor-
mal.
PC600-8 33
24. Function of no injection [09]

The operator can perform no-injection with the
machine monitor.
No-injection cranking is the function of prevent-
ing fuel injection through the injector when the
engine is rotated with the starting motor for mea-
suring compression pressure, etc.
a Be sure to set the no-injection while the en-
gine 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 Prepara-
tion" 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 sec-
onds to protect the starting motor.
3) After communication is checked, the letters

disappear and the following screen appears.
34 PC600-8
7) After finishing no injection, press the [ ]

switch on the previous screen, and the let-
ters 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 run-
ning, 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.
PC600-8 35
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.
36 PC600-8
Procedure for turning on

KOMTRAX terminal
When the machine is delivered, KOMTRAX ter-
minal is installed:
a When the machine is delivered, KOMTRAX ter-
minal 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 oper-
ation of KOMTRAX.
3) Disconnect the inspecting connector 1 and
maintain that state for 5 seconds.
2. Registration of KOMTRAX terminal
4) Turn ON the starting switch and maintain
The person responsible to operation of
that state for 5 seconds.
KOMTRAX shall register the subject terminal
5) Disconnect the inspecting connector 2 and
using the KOMTRAX client PC.
maintain that state for 5 seconds.
a See “KOMTRAX administrator manual” for
6) Connect the inspecting connector 1 again
the procedure.
and maintain that state for 5 seconds.
a Above completes the necessary operations.
7) Connect the inspecting connector 2 again
When installing KOMTRAX terminal after the
8) Make sure that the KOMTRAX terminal 7-
machine is delivered:
segment indicator lamps are normally
a When installing KOMTRAX terminal after the
turned on.
machine is delivered (machine with the retro-
a After step 7), if display is normal, the 7-
spective equipment), implement the following
segment indicator lamp displays for 30
procedure.
seconds (“d”, “0”, and “–” are displayed
repeatedly).
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, pro-
ceed to the next step.
2) Make sure visually that the inspecting con-
nectors 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)
PC600-8 37
a As [Normal] is indicated, proceed to the

next step.
a If [Abnormal] is indicated, repeat the pro-
cedure 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 proce-
dure from step 1).
10) Return the starting switch to ON position
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 7-
segment 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). 13) Turn the starting switch OFF.
a If [Receiving error] were displayed, 14) Make sure that the 7-segment indicator
check the communication antenna and lamp (a) comes on normally in 5 seconds.
cable for external troubles. If any, repair a As [Normal] is displayed, the station
the trouble and repeat the procedure opening inspection is complete.
from step 1). a If [Abnormal] is displayed, the inspection
a If [GPS position data sensing error and is incomplete and must be repeated from
receiving error] were displayed, check step 1).
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 re-
peat the procedure from step 1)).
38 PC600-8
2. Application for start of use

a The application for start of use is allowed
only after the terminal station opening in-
spection has been successfully ended.
1) Concerning the machine body for which the
station opening inspection has been com-
pleted, report the following information to
the person responsible to operation of KOM-
TRAX.
(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 opera-
tions.
PC600-8 39
KOMTRAX terminal lamp indications
LED for CPU 7-segment and dot for CPU

1. LED-C1 (R signal and ACC signal) 7. 7-segment (Number of mails which are not trans-
2. LED-C2 (Initial output state) mitted yet and condition of satellite link)
3. LED-C3 (S-NET and C signal state) 8. Dot (GPS positioning state)
4. LED-C4 (CAN state)
5. LED-C5 (Download writing state)
6. LED-C6 (Download writing state)
40 PC600-8
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) Contents of display
ON Starting switch ACC signal: ON, Alternator R signal: ON
Quick
State of starting switch Starting switch ACC signal: OFF, Alternator R signal: ON
flashing
1 LED-C1 ACC signal, alternator R
signal Slow
Starting switch ACC signal: ON, Alternator R signal: OFF
flashing
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
State of engine control ON Engine control signal: ON

2 LED-C2
signal OFF Engine control signal: OFF
ON S-NET: Connected, starting switch C signal: OFF
Quick
State of S-NET connec- Starting switch C signal: ON
flashing
3 LED-C3 tion and starting switch C
signal Slow
(Not used)
flashing
OFF S-NET: Disconnected, Starting switch C signal: OFF
ON CAN: Present (Fuel sensor: Absent)
Quick
CAN: Present (Fuel sensor: Present)
flashing
4 LED-C4 State of CAN connection
Slow
CAN: Absent (Fuel sensor: Present)
flashing
OFF CAN: Absent (Fuel sensor: Absent)
Single side Download writing mode (Special function for system adminis-
5 LED-C5
ON trator)
Download writing state
Both sides
6 LED-C6 Normal working mode
OFF
*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
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 Display (*2) Contents of display
Figure indicates number of mails which are not sent yet
Lighting of
Number of mails which (When 10 or more mails are not sent yet, 9 is indicated).
0–9
are not sent yet and sat- Lighting indicates that satellite is captured.
7 7-segment
ellite capturing condi- Quick Figure indicates number of mails which are not sent yet
tion) blinking of (When 10 or more mails are not sent yet, 9 is indicated).
0–9 Quick blinking indicates that satellite is not captured.
ON Positioning with GPS complete (Position is recognized, *3)
State of positioning with
8 Dot Positioning with GPS incomplete (Position is not recog-
GPS OFF
nized, *3)
*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
Preparation work for 2. Engine controller

1) Remove controller cover (1).
troubleshooting electrical
system
a When troubleshooting an electric circuit related
to the machine monitor, engine controller, or
pump controller, expose the related connectors
1. Machine monitor
1) Remove cover (1).
a The cover is secured with 2 clips at the
top and bottom. Those clips can be re-
moved 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 trouble-
shooting to connectors ENG, CE02, and
CE03 of the engine controller.
a Since the connectors are secured with
screws, loosen those screws before dis-
connecting them.
a After returning the connectors, tighten
3 Screw: 2.82 Nm {0.288 kgm}

the screws to the specified torque.
2) Remove the 3 mounting screws and discon-

nect 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 trouble-
shooting to connectors CM01, CM02, and
CM03 of the machine monitor.
PC600-8 43
3. Pump controller
a The pump controller is installed in the cover
at the rear of the operator's seat.
2) Insert or connect T-adapters for trouble-

shooting to connectors CP01, CP02, and
CP03 of the pump controller (6).
a Since the connectors are secured with
screws, loosen those screws before dis-
connecting them.
a After returning the connectors, tighten
3 Screw: 2.82 Nm {0.288 kgm}

the screws to the specified torque.
44 PC600-8
Adjusting mirrors 3. Adjusting mirror (b)

Adjust mirror (b) so that the operator can see
1. Mirrors installed positions 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.
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 3.14 - 3.53
{32 - 36} {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 Boom Revolving frame

1. Arm cylinder bracket 4. Boom top bracket 9. Boom bracket
T Left T Right T Left T Right T Left T Right
2. Arm foot 5. Boom cylinder bracket
T Left T Right T End plate T Left T Right Track frame
3. Arm top boss 6. Arm cylinder bracket 10. Circle bracket
T Left T Right T Left T Right T Front T Rear
7. Boom lower plate T Left T Right
T Left T Right 11. Track frame mounting section
8. Boom foot T Front T Rear
T Left T Right T Left T Right
PC600-8 51
Undercarriage inspection
(Program form No.: SELA195001)
52 PC600-8
SEN00445-03
PC600-8 53
SEN00445-03
©2009 KOMATSU
All Rights Reserved
54
SEN03960-04
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC600-8
PC600LC-8

PC600-8 30001 and up
40 Troubleshooting
Failure code table and fuse locations
Failure codes table............................................................................................................................................... 2

Fuse locations...................................................................................................................................................... 6
PC600-8 1
SEN03960-04 40 Troubleshooting
Failure codes table
Action Failure Alarm Component Category of Reference

code code buzzer in charge record document No.
Mechanical
— A000N1 Eng. Hi Out of Std MON
system
Mechanical
— AA10NX Aircleaner Clogging MON
system
Mechanical
— AB00KE Charge Voltage Low MON
system
Mechanical
— B@BAZG Eng. Oil Press. Low MON
system
Mechanical
— B@BAZK Eng. Oil Level Low MON
system
Mechanical
— B@BCNS Eng. Water Overheat MON
system
Mechanical
— B@BCZK Eng. Water Lvl Low MON
system
Mechanical
— B@HANS Hydr. Oil Overheat MON
system
Electrical
E10 CA111 ECM Critical Internal Failure ENG
system
Electrical
E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG
system
Electrical
E11 CA122 Chg Air Press Sensor High Error q ENG
system
Electrical
E11 CA123 Chg Air Press Sensor Low Error q ENG
system
Electrical
E14 CA131 Throttle Sensor High Error q ENG
system
Electrical
E14 CA132 Throttle Sensor Low Error q ENG
system Troubleshooting
Electrical by failure code,
E15 CA135 Eng Oil Press Sensor High Error q ENG
system Part 1
Electrical SEN00448-02
E15 CA141 Eng Oil Press Sensor Low Error q ENG
system
Electrical
E15 CA144 Coolant Temp Sens High Error q ENG
system
Electrical
E15 CA145 Coolant Temp Sens Low Error q ENG
system
Electrical
E15 CA153 Chg Air Temp Sensor High Error q ENG
system
Electrical
E15 CA154 Chg Air Temp Sensor Low Error q ENG
system
Electrical
system
Electrical
E15 CA221 Ambient Press Sens High Error q ENG
system
Electrical
E15 CA222 Ambient Press Sens Low Error q ENG
system
Electrical
system
Mechanical
— CA234 Eng Overspeed ENG
system
Electrical
E03 CA238 Ne Speed Sens Supply Volt Error q ENG
system
Electrical
E15 CA263 Fuel Temp Sensor High Error q ENG
system
Electrical
E15 CA265 Fuel Temp Sensor Low Error q ENG
system
Electrical
E11 CA271 IMV/PCV1 Short Error q ENG
system
2 PC600-8

Electrical
E11 CA272 IMV/PCV1 Open Error q ENG
E11 CA273 PCV2 Short Error q ENG
system Part 1
E11 CA274 PCV2 Open Error q ENG
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
E10 CA342 Calibration Code Incompatibility ENG
system
Electrical
E10 CA351 Injectors Drive Circuit Error q ENG
system
Electrical
system
Electrical
system
Electrical
E10 CA441 Battery Voltage low error q ENG
system
Mechanical
E10 CA442 Battery Voltage high error q ENG
system
Electrical
E11 CA449 Rail Press Very High Error q ENG
E11 CA451 Rail Press Sensor High Error q ENG
system Part 2
E11 CA452 Rail Press Sensor Low Error q ENG
system
Electrical
E15 CA553 Rail Press High Error q ENG
system
Electrical
— CA554 Rail Press Sensor In Range Error ENG
system
Electrical
E15 CA559 Rail Press Low Error q ENG
system
Electrical
E11 CA689 Eng Ne Speed Sensor Error q ENG
system
Electrical
E11 CA731 Eng Bkup Speed Sens Phase Error q ENG
system
Electrical
E10 CA757 All Persistent Data Lost Error q ENG
system
Electrical
E11 CA778 Eng Bkup Speed Sensor Error q ENG
system
Electrical
system
Electrical
system
Electrical
E11 CA1626 BP Valve Sol Current High Error q ENG
system
Electrical
E11 CA1627 BP Valve Sol Current Low Error q ENG
system
Electrical
system
PC600-8 3

Electrical
system
Electrical
E11 CA1631 BP Valve Pos Sens High Error q ENG
system
Electrical
E11 CA1632 BP Valve Pos Sens Low Error q ENG
system
Electrical
E0E CA1633 KOMNET Datalink Timeout Error q ENG
system
Electrical
E11 CA1642 EGR Inlet Press Sens Low Error q ENG
system
Electrical
E11 CA1653 EGR Inlet Press Sens High Error q ENG
system
Electrical
E14 CA2185 Throt Sens Sup Volt High Error q ENG
E14 CA2186 Throt Sens Sup Volt Low Error q ENG
system Part 2
E11 CA2249 Rail Press Very Low Error q ENG
system
Electrical
E11 CA2271 EGR Valve Pos Sens High Error q ENG
system
Electrical
E11 CA2272 EGR Valve Pos Sens Low Error q ENG
system
Electrical
E11 CA2351 EGR Valve Sol Current High Error q ENG
system
Electrical
E11 CA2352 EGR Valve Sol Current Low Error q ENG
system
Electrical
E15 CA2555 Grid Htr relay Volt Low Error q ENG
system
Electrical
E15 CA2556 Grid Htr relay Volt High Error q ENG
system
Electrical
— D110KB Battery Relay Drive S/C PUMP
system
Electrical
— D163KB Flash Light Relay S/C PUMP
system
Electrical
— D195KB Step Light Relay S/C PUMP
system
Electrical
E0E DA22KK Pump Solenoid Power Low Error PUMP
system
Electrical
— DA25KP Press. Sensor Power Abnormality PUMP
system
— DA2SKQ Model selection Abnormality PUMP Electrical
system
Mechanical
— DA80MA Auto. Lub. Abnormal PUMP
system
Electrical Troubleshooting
E0E DA2RMC Pump Comm. Abnormality q PUMP
system by failure code,
Electrical Part 3
E0E DAFRMC Monitor Comm. Abnormality q PUMP SEN00450-02
system
Electrical
— DGE5KY Ambi. Temp. Sensor S/C PUMP
system
Electrical
— DGH2KB Hydr. Oil Temp. Sensor S/C PUMP
system
Electrical
— DHPAMA F Pump P.Sensor Abnormality PUMP
system
Electrical
— DHPBMA R Pump P.Sensor Abnormality PUMP
system
Electrical
— DV20KB Travel Alarm S/C PUMP
system
Electrical
— DW43KA Travel Speed Sol. Disc. PUMP
system
Electrical
— DW43KB Travel Speed Sol. S/C PUMP
system
4 PC600-8

Electrical
E03 DW45KA Swing Brake Sol. Disc. q PUMP
system
Electrical
E03 DW45KB Swing Brake Sol. S/C q PUMP
system
Electrical
— DW48KA CO Cancel Sol. Disc. PUMP
system
Electrical
— DW48KB CO Cancel Sol. S/C PUMP
system
Electrical
— DW7BKA Fan Reverse Sol. Disc. PUMP
system
Electrical
— DW7BKB Fan Reverse Sol. S/C PUMP
system
Electrical
— DW4XKA Bucket Curl Hi Cancel Sol. Disc. PUMP
system
Electrical
— DW4XKB Bucket Curl Hi Cancel Sol. S/C PUMP
system
Electrical
— DWK0KA 2-stage Relief Sol. Disc. PUMP
— DWK0KB 2-stage Relief Sol. S/C PUMP
system Part 3
E11 DX16KA Fan Pump EPC Sol. Disc. q PUMP
system
Electrical
E11 DX16KB Fan Pump EPC Sol. S/C q PUMP
system
Electrical
E02 DXA0KA TVC Sol. Disc. q PUMP
system
Electrical
E02 DXA0KB TVC Sol. S/C q PUMP
system
Electrical
— DY20KA Wiper Working Abnormality PUMP
system
Electrical
— DY20MA Wiper Parking Abnormality PUMP
system
Electrical
— DY2CKB Washer Drive S/C PUMP
system
Electrical
— DY2DKB Wiper Drive (For) S/C PUMP
system
Electrical
— DY2EKB Wiper Drive (Rev) S/C PUMP
system
PC600-8 5
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 Circuit breaker Circuit breaker

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

a This connection table shows the devices to which each power supply of the fuse boxes supplies power (A
switch power supply is a device which supplies power while the starting switch is at the ON position and a
constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting for a displayed code, you should check the fuse boxes to see if the
power is supplied normally.
Type of power
Fuse No. Fuse capacity Destination of power
supply
TVC solenoid (for emergency pump drive)
1 10A
Swing holding brake solenoid (for swing brake release)
Boom stabilizer solenoid
2 10A
Machine push up solenoid
Switch power PPC lock solenoid
3 10A
supply Starting motor cut-out relay
(Circuit breaker 1) Cigarette lighter
4 20A
Windshield washer motor
Horn
5 10A Flash light
Bottom dump open solenoid (for loading shovel)
6 10A Intake air heater
7 10A Rotary lamp
Switch power
8 10A (Spare)
supply
(Circuit breaker 1) Radio
9 10A
Bottom dump close solenoid (for loading shovel)
10 20A Machine monitor, Buzzer
11 25A Air conditioner unit
12 20A (Spare)
Switch power
13 20A (Spare)
supply
(Circuit breaker 1) 14 10A OPT power supply (1)
OPT power supply (2)
15 10A
12 V power supply
Radio backup
16 10A
Room lamp
Constant power 17 10A Step light
supply
18 10A (Spare)
(Circuit breaker 9)
19 10A (Spare)
20 5A ACC (Engine controller)
PC600-8 7
SEN03960-04

© 2010 KOMATSU
All Rights Reserved
8
SEN00447-04
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up

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 1
Points to remember when troubleshooting

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

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

coolant
5. Check swing machinery oil level — Add oil

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

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

2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30V Replace
2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment
3. Check for discolored, burnt, exposed wiring — Replace

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

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

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to
the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, press the [ ] switch of the panel switch section in
the current condition to display the failure code.
Carry out troubleshooting in [Display of code] according to the displayed failure code of electrical system.
2. Procedure for troubleshooting to be taken when electrical system failure code or mechanical system
failure code is recorded in abnormality record:
If an action code is not displayed on the machine monitor, check for an electrical system failure code or
mechanical system failure code with the abnormality record function of the machine monitor.
If a code is recorded, carry out troubleshooting in [Display of code] according to that code.
a If failure codes of electrical system are recorded, delete all of them and reproduce them, and then see if
the trouble is still detected.
a A mechanical system failure code cannot be deleted.
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is not
recorded:
If an action code is not displayed and a abnormality record is not recorded in the machine monitor, a trouble
that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and
mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the
table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting
related to that phenomenon in the "E mode" or "H mode".
PC600-8 5
Information contained in troubleshooting table

a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-
tents fully before proceeding to actual troubleshooting work.
Action Code Failure Code

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

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

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

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

troubleshooting.
• Connector No.: Indicates (Model – Number of pins) and
(Color).
• "Connector No. and pin No." from each branching/merging
point: Shows the ends of branch or source of merging within
the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the machine.
PC600-8 7
Failure-looking phenomenon and troubleshooting No.

Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Action to be taken concerning User Code, Error Code and Failure Code
1 Display User Code in monitor panel Accord-
ing to
Display Failure Code in mechanical system after checking Abnormality displayed
2
Record code
Engine related failure
3 Starting performance is poor (starting always takes time) S-1
4 Engine does not turn E-1 S-2 a)
Engine turns but no exhaust smoke
5 S-2 b)
Engine does not start comes out
Exhaust smoke comes out but engine
6 S-2 c)
does not start (Fuel is being injected)
7 Engine does not pick up smoothly (follow-up is poor) S-3
8 Engine stops during operations S-4
9 Engine does not rotate smoothly (hunting) S-5
10 Engine lacks output (or lacks power) S-6
11 Exhaust smoke is black (incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Oil becomes contaminated quickly S-9
14 Fuel consumption is excessive S-10
15 Oil is in cooling water (or water spurts back, or water level goes down) S-11
16 Oil pressure caution lamp lights up (drop in oil pressure) S-12
17 Oil level rises (water, fuel in oil) S-13
18 Water temperature becomes too high (overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
21 Preheater does not operate E-2
22 Auto engine warm-up device does not work E-3
23 Auto-decelerator does not operate E-4 H-5
Failure related to work equipment, swing and travel
24 Speed or power of all work equipment, travel, and swing is low H-1
25 Engine speed lowers remarkably or engine stalls H-2
26 All work equipment, travel, and swing systems do not work E-5 H-3
27 Abnormal sound is heard from around pump H-4
Work equipment-related failure
28 Boom speed or power is low H-6
29 Arm speed or power is low H-7
30 Bucket speed or power is low H-8
31 Boom does not move H-9
8 PC600-8
Troubleshooting
display
32 Arm does not move H-10
33 Bucket does not move H-11
34 Bottom dump does not move E-31 H-12
35 Hydraulic drift of work equipment is large H-13
36 Time lag of work equipment is large H-14
37 Power max. function does not operate E-6 H-15
38 Machine push-up function does not operate or stop E-7 H-16
When arm and boom • bucket are operated simultaneously,
39 H-17
boom • bucket speeds are low
When bucket and boom • arm • swing • travel are operated simulta-
40 H-18
neously, boom • arm • swing • travel speeds are low
41 When arm and swing are operated simultaneously, swing speed is low H-19
Travel related failure
42 Machine deviates in one direction H-20
43 Machine deviates largely at start H-21
44 Machine deviates largely during compound operation H-22
45 Travel speed or power is low H-23
46 Machine does not travel (only one track) H-24
47 Travel speed does not change H-25
48 Travel alarm does not sound or does not stop sounding E-29
Swing related falure
49 Upper structure does not swing H-26
50 Swing speed or acceleration is low H-27
51 Upper structure overruns excessively when it stops swinging H-28
52 Large shock is made when upper structure stops swinging H-29
53 Large abnormal sound is made when upper structure stops swinging H-30
54 Hydraulic drift of swing is large H-31
Machine monitor related failure (Operator’s Menu: Ordinary Display)
55 Any item is not displayed on machine monitor E-8
56 Part of display on machine monitor is missing E-9
57 Machine monitor displays contents irrelevant to the model E-10
58 Fuel level monitor red lamp lights up while engine is running E-11
59 Engine water thermometer does not display normally E-12
60 Hydraulic oil temperature gauge does not display correctly E-13
61 Fuel gauge does not display correctly E-14
62 Swing lock monitor does not display correctly E-15
63 When monitor switch is operated, nothing is displayed E-16
64 Windshield wiper and window washer do not work E-17
PC600-8 9
Troubleshooting
display
Machine monitor related failure (Service Menu: Special Function Display)
65 "Boom RAISE" is not correctly displayed in monitoring function E-18
66 "Boom LOWER" is not correctly displayed in monitoring function E-19
67 "Arm IN" is not correctly displayed in monitoring function E-20
68 "Arm OUT" is not correctly displayed in monitoring function E-21
69 "Bucket CURL" is not correctly displayed in monitoring function E-22
70 "Bucket DUMP" is not correctly displayed in monitoring function E-23
71 "Swing" is not correctly displayed in monitoring function E-24
72 "Travel" is not correctly displayed in monitoring function E-25
Other failure
73 Air conditioner does not work E-26
74 Step light does not light up or go off E-27
75 Electric grease gun does not operate E-28
76 Horn does not sound E-30
10 PC600-8
PC600-8 11
Connection table for connector pin numbers (Rev. 2009.04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer to
the mating portion of the housing.
12 PC600-8
PC600-8 13
14 PC600-8
PC600-8 15
16 PC600-8
PC600-8 17
18 PC600-8
PC600-8 19
20 PC600-8
PC600-8 21
22 PC600-8
PC600-8 23
24 PC600-8
PC600-8 25
26 PC600-8
PC600-8 27
28 PC600-8
PC600-8 29
30 PC600-8
PC600-8 31
32 PC600-8
PC600-8 33
34 PC600-8
PC600-8 35
36 PC600-8
PC600-8 37
38 PC600-8
PC600-8 39
40 PC600-8
PC600-8 41
42 PC600-8
PC600-8 43
44 PC600-8
PC600-8 45
46 PC600-8
PC600-8 47
T- branch box and T- branch adapter table (Rev. 2009.03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal col-
umn indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
48 PC600-8
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
PC600-8 49
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
50 PC600-8
PC600-8 51
©2009 KOMATSU
All Rights Reserved
52
SEN00448-03
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up

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 1
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
2 PC600-8
Failure code [A000N1] Eng. Hi Out of Std
Action code Failure code Failure Eng. Hi Out of Std

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

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

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

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

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

Presumed cause and
Between (1) and (2)

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

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

a Turn the engine starting switch OFF for the preparations, and keep the engine
Alternator defective Alternator Engine Voltage
1
(Internal defect) Between terminal R
Above low idle 27.5 – 29.5 V
and grounding
If the voltage is abnormal, check the belt tension too.
Disconnection of wiring
harness position during the troubleshooting.
Presumed cause and
2 (Disconnection or defec-
Wiring harness between CM02 (female) (11) and alter- Resistance
tive contact with connec- Max. 1 z
tor) nator terminal R value
position during the troubleshooting.
Grounding fault of wiring
harness Between wiring harness between CM02 (female) (11)
3 and alternator terminal R, or between CM02 (female)
(Contact with grounding Resistance
circuit) (11), D01, J01, and starting switch terminal BR, or Min. 1 Mz
value
between CM02 (female) (11), battery relay terminal BR
and grounding
4 Machine monitor defective CM02 Engine Voltage
Between (11) and
Above low idle 27.5 – 29.5 V
grounding
6 PC600-8
Electrical circuit diagram related to engine preheating, starting, charging
PC600-8 7
Failure code [B@BAZG] Eng. Oil Press. Low
Action code Failure code Failure Eng. Oil Press. Low

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

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

or defective contact in Resistance Max. 1 z
connector) (female) (1)
Resistance Max. 1 z
(female) (2)
Ground fault in wiring starting switch ON.
4 harness
(Contact with GND circuit) Wiring harness between ENG (female) (13) – POIL
Resistance Min. 1 Mz
(female) (3)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Hot short (Short circuit
5 with 24V circuit) in wiring Voltage Max. 1 V
(female) (3)
harness
Voltage Max. 1 V
(female) (1)
a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
ENG CE01 Voltage
6 Defective engine controller
Between (37) – (47) 4.5 – 5.5 V
Between (13) – (47) 0.5 – 4.5 V
8 PC600-8
Electrical circuit diagram related to Eng. Oil Press. Low
PC600-8 9
Failure code [B@BAZK] Eng. Oil Level Low
Action code Failure code Failure Eng. Oil Level Low

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

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

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

Below normal level Min. 1 Mz
Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
tor) (female) (1) value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
4 Machine monitor defective CM02 Engine oil level Voltage
Normal level Max. 1 V
Below normal level 20 – 30 V
Electrical circuit diagram related to engine oil level switch
10 PC600-8
Failure code [B@BCNS] Eng. Water Overheat
Action code Failure code Failure Eng. Water Overheat

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

Engine overheated Check the engine for overheating. If it has been overheated, find out the cause and
1
Presumed cause and
(While system is normal) check the engine for damage, then repair.
Engine coolant
Carry out troubleshooting for "E-12 Display of engine coolant temperature gauge on
2 temperature sensor
machine monitor is abnormal" in E-mode.
system defective
Engine controller position during the troubleshooting.
3
defective ENG (female) Engine water temperature Resistance value
Between (15) and (38) 105°C 3.28 kz
Electrical circuit diagram related to engine coolant temperature sensor
PC600-8 11
Failure code [B@BCZK] Eng. Water Lvl Low
Action code Failure code Failure Eng. Water Lvl Low

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

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

Presumed cause and
Between (1) and (2)

Below LOW level Min. 1 Mz
harness
(female) (1) value
tor) Resistance
value
4 Machine monitor defective CM02 Sub-tank coolant level Voltage
Within normal level Max. 1 V
Below LOW level 20 – 30 V
12 PC600-8
Electrical circuit diagram related to radiator coolant level switch
PC600-8 13
Failure code [B@HANS] Hydr. Oil Overheat
Action code Failure code Failure Hydr. Oil Overheat

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

Hydraulic oil overheated Check the hydraulic oil for overheating. If it has been overheated, find out the cause
1
(While system is normal) and check the hydraulic equipment for damage, then repair.
Hydraulic oil temperature
2 sensor defective P22 (male) Hydraulic oil temperature Resistance value

Presumed cause and
(Internal short-circuiting) Between (1) and (2) 90 – 3.5 kz

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

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

Check circuit breaker No.7 directly for defect.
1 Defective circuit breaker No.7
(If circuit breaker is turned OFF, circuit probably has ground fault.)
a Prepare with starting switch OFF, then carry out trouble-
Disconnection in wiring har- shooting without turning starting switch ON.
ness (Disconnection in wir- Wiring harness between CE03
2 Resistance Max. 1 z
ing or defective contact in (female) (3) – battery (B)
connector) Wiring harness between CE03
Possible causes and Resistance Max. 1 z
(female) (1) – chassis ground
standard value in nor-
mal state a Prepare with starting switch OFF, then carry out trouble-
Ground fault in wiring har- shooting without turning starting switch ON.
3 ness (Short circuit with GND 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 Voltage
Between (3) – (1) 20 – 30 V
Circuit diagram related to controller power supply
PC600-8 15
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Action code Failure code Eng Ne and Bkup Speed Sens Error
Trouble
Contents of trouble • Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
Problem that appears • Engine cannot be started (if engine has been stopped).
on machine • Engine stops (if engine has been running).
Related information

Defective Ne speed sensor
1 Carry out troubleshooting for Failure code [CA689].
system
Defective Bkup speed sen-
2 Carry out troubleshooting for Failure code [CA778].
sor system
Defective mount of Ne Check mount of Ne speed sensor directly for defect (defective
Possible causes and 3
speed sensor installation of sensor, internal trouble of flywheel, etc.)
mal state Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defec-
4
speed sensor tive installation of sensor, internal trouble of supply pump, etc.)
Defective connection Check Ne speed sensor and Bkup speed sensor directly for
5
(Wrong connection) defective connection (wrong connection).
If causes 1 – 5 are not detected, engine controller may be
6 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
16 PC600-8
PC600-8 17
Failure code [CA122] Chg Air Press Sensor High Error
Action code Failure code Chg Air Press Sensor High Error
Trouble
Contents of trouble • Signal voltage in charge pressure sensor circuit is abnormally high.
Action of controller • Fixes charge pressure (400 kPa {4.1 kg/cm2}) and continues operation.
• Acceleration performance of engine drops.
on machine
• Signal voltage of boost pressure sensor can be checked with monitoring function.
Related information
(Code: 36501 Boost pressure sensor voltage)

Defective sensor power If failure code [CA187] or [CA227] is indicated, carry out trouble-
1
supply system shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
Defective charge pres- PIM Voltage
2 sure sensor (Internal Between (1) – (2) Power supply 4.75 – 5.25 V
trouble) Pressure sensor voltage is measured with wiring harness con-
nected. Accordingly, if voltage is abnormal, check wiring harness
and controller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Wiring harness between ENG (female)
(37) – PIM (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (47) – PIM (female) (2)
3 ness (with another wiring Wiring harness between ENG (female)
harness) (37) – PIM (female) (1) and between Resistance Min. 1 Mz
Possible causes and
ENG (female) (44) – PIM (female) (3)
mal state Wiring harness between ENG (female)
(47) – PIM (female) (3) and between Resistance Min. 1 Mz
ENG (female) (44) – PIM (female) (3)
(37) – PIM (female) (1) and chassis Voltage Max. 1 V
Hot short (Short circuit ground
4 with 24V circuit) in wiring Wiring harness between ENG (female)
harness (47) – PIM (female) (2) and chassis Voltage Max. 1 V
ground
(44) – PIM (female) (3) and chassis Voltage Max. 1 V
ground
Defective engine control- or start engine and carry out troubleshooting.
5
ler ENG Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
18 PC600-8
Circuit diagram related to charge pressure sensor
PC600-8 19
Failure code [CA123] Chg Air Press Sensor Low Error
Action code Failure code Chg Air Press Sensor Low Error
Trouble
Contents of trouble • Signal voltage in charge pressure sensor circuit is abnormally low.
Action of controller • Fixes charge pressure (400 kPa {4.1 kg/cm2}) and continues operation.
• Acceleration performance of engine drops.
on machine
• Signal voltage of boost pressure sensor can be checked with monitoring function.
Related information
(Code: 36501 Boost pressure sensor voltage)
Possible causes and Cause Standard value in normal state/Remarks on troubleshooting

mal state Carry out troubleshooting for failure Code [CA122].
20 PC600-8
PC600-8 21
Failure code [CA131] Throttle Sensor High Error
Action code Failure code Throttle Sensor High Error

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

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

2
(Internal defect) Between (1) – (3) 4.0 – 6.0 kz
Between (2) – (1) 0.25 – 5.0 kz
Between (2) – (3) 0.25 – 5.0 kz
Wiring harness between CE02
(female) (22) – P20 (female) (1) and
between CE02 (female) (9) – P20
(female) (2)
Short circuit in wiring har-
3 ness (with another wiring Wiring harness between CE02
harness) (female) (22) – P20 (female) (1) and
Possible causes and Resistance Min. 1 Mz
(female) (3)
mal state
(female) (23) – P20 (female) (3) and
(female) (2)
Hot short (short circuit with Voltage Max. 1 V
(female) (22) – P20 (female) (1)
4 24V circuit) in wiring har-
ness Wiring harness between CE02
Voltage Max. 1 V
Voltage Max. 1 V
5 Defective engine controller CE02 Voltage
Between (9) – (23) Signal 0.5 – 4.5 V
22 PC600-8
Circuit diagram related to throttle sensor of fuel control dial type
PC600-8 23
Failure code [CA132] Throttle Sensor Low Error
Action code Failure code Throttle Sensor Low Error

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

mal state Carry out troubleshooting for failure Code [CA131].
24 PC600-8
PC600-8 25
Failure code [CA135] Eng Oil Press Sensor High Error

Action code Failure code Eng Oil Press Sensor High Error
Trouble
Contents of trouble • Signal voltage in oil pressure sensor circuit is abnormally high.
Action of controller • Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
—
on machine
• Signal voltage of oil pressure sensor can be checked with monitoring function.
Related information
(Code: 37201 Oil pressure sensor voltage)

1
POIL Voltage
Defective oil pressure
2 Between (1) – (2) Power supply 4.75 – 5.25 V
sensor (Internal trouble)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
(37) – POIL (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring ENG (female) (47) – POIL (female) (2)
Possible causes and 3 harness (with another Wiring harness between ENG (female)
standard value in wiring harness) (37) – POIL (female) (1) and between Resistance Min. 1 Mz
normal state ENG (female) (13) – POIL (female) (3)
(47) – POIL (female) (2) and between Resistance Min. 1 Mz
ENG (female) (13) – POIL (female) (3)
Hot short (Short circuit Voltage Max. 1 V
(37) – POIL (female) (1)
4 with 24V circuit) in wir-
ing harness Wiring harness between ENG (female)
Voltage Max. 1 V
Voltage Max. 1 V
5
ler ENG Voltage
26 PC600-8
Circuit diagram related to oil pressure sensor
PC600-8 27
Failure code [CA141] Eng Oil Press Sensor Low Error
Action code Failure code Eng Oil Press Sensor Low Error
Trouble
Contents of trouble • Signal voltage in oil pressure sensor circuit is abnormally low.
Action of controller • Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
—
on machine
• Signal voltage of oil pressure sensor can be checked with monitoring function.
Related information
(Code: 37201 Oil pressure sensor voltage)

mal state Carry out troubleshooting for failure code [CA135].
28 PC600-8
PC600-8 29
Failure code [CA144] Coolant Temp Sens High Error
Action code Failure code Coolant Temp Sens High Error

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

Defective coolant tempera- shooting without turning starting switch ON.
1 ture sensor (Internal trou- Coolant
TWTR (male) Resistance
ble) temperature
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
ness (Disconnection in wir- Wiring harness between ENG
ing or defective contact in (female) (15) – TWTR (female) (A)
Possible causes and connector) Wiring harness between ENG
standard value in nor- Resistance Max. 1 z
mal state (female) (38) – TWTR (female) (B)
3 ness (Short circuit with GND Wiring harness between ENG
circuit) (female) (15) – TWTR (female) (A) Resistance Min. 1 Mz
and chassis ground
4 Defective engine controller Coolant
ENG (female) Resistance
temperature
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
30 PC600-8
Circuit diagram related to coolant temperature sensor
PC600-8 31
Failure code [CA145] Coolant Temp Sens Low Error
Action code Failure code Coolant Temp Sens Low Error

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

32 PC600-8
PC600-8 33
Failure code [CA153] Chg Air Temp Sensor High Error
Action code Failure code Chg Air Temp Sensor High Error
Trouble
Contents of trouble • Signal voltage in charge temperature sensor circuit is abnormally high.
Action of controller • Fixes charge temperature (intake air temperature) (70°C) and continues operation.
—
on machine
• Signal voltage of boost temperature sensor can be checked with monitoring function.
Related information
(Code: 18501 Boost temperature sensor voltage)

Intake air
TIM (male) Resistance
temperature
Defective charge tempera- 0°C 29 – 36 kz
1 ture sensor
25°C 9 – 11 kz
(Internal trouble) Between (A) – (B)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
Between (A) –
All range Min. 1 Mz
chassis ground
Possible causes and 2 Resistance Max. 1 z
ing or defective contact in (female) (23) – TIM (female) (A)
connector) Wiring harness between ENG
mal state Resistance Max. 1 z
(female) (47) – TIM (female) (B)
circuit) (female) (23) – TIM (female) (A) and Resistance Min. 1 Mz
chassis ground
Intake air
temperature
4 Defective engine controller 0°C 29 – 36 kz
25°C 9 – 11 kz
Between (23) – (47)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
34 PC600-8
Circuit diagram related to charge temperature sensor
PC600-8 35
Failure code [CA154] Chg Air Temp Sensor Low Error
Action code Failure code Chg Air Temp Sensor Low Error
Trouble
Contents of trouble • Signal voltage in charge temperature sensor circuit is abnormally low.
Action of controller • Fixes charge temperature (intake air temperature) (70°C) and continues operation.
—
on machine
• Signal voltage of boost temperature sensor can be checked with monitoring function.
Related information
(Code: 18501 Boost temperature sensor voltage)

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

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

36 PC600-8
PC600-8 37
Failure code [CA221] Ambient Press Sens High Error
Action code Failure code Ambient Press Sens High Error

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

1
and carry out troubleshooting.
PAMB Voltage
Defective atmospheric
2 pressure sensor (Internal
trouble) Between (3) – (2) Signal 0.5 – 4.5 V
(33) – PAMB (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (38) – PAMB (female) (2)
harness) (33) – PAMB (female) (1) and between Resistance Min. 1 Mz
Possible causes and
ENG (female) (3) – PAMB (female) (3)
mal state Wiring harness between ENG (female)
(38) – PAMB (female) (2) and between Resistance Min. 1 Mz
ENG (female) (3) – PAMB (female) (3)
(33) – PAMB (female) (1) and chassis Voltage Max. 1 V
Hot short (Short circuit ground
4 with 24V circuit) in wiring Wiring harness between ENG (female)
harness (38) – PAMB (female) (2) and chassis Voltage Max. 1 V
ground
(3) – PAMB (female) (3) and chassis Voltage Max. 1 V
ground
Defective engine control- ENG Voltage
5
ler
Between (33) – (38) 4.75 – 5.25 V
Between (3) – (38) 0.5 – 4.5 V
38 PC600-8
Circuit diagram related to atmospheric pressure sensor
PC600-8 39
Failure code [CA222] Ambient Press Sens Low Error
Action code Failure code Ambient Press Sens Low Error

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

40 PC600-8
PC600-8 41
Failure code [CA227] Sens Supply 2 Volt High Error
Action code Failure code Sens Supply 2 Volt High Error

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

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Bkup speed
G connector
sensor
Oil pressure
POIL connector
sensor
Disconnect devices at Atmospheric
PAMB
2
Defective sensor right in order. If error pressure sensor
(Internal trouble) code disappears when Charge pres-
PIM connector
a device is discon- sure sensor
nected, that device EGR inlet pres-
has a defect in it. PEVA connector
sure sensor
EGR valve lift
SEGR connector
sensor
Possible causes and
standard value in nor- Common rail
PFUEL connector
mal state pressure sensor
Short circuit in wiring har- ing without turning starting switch ON.
ness Wiring harness between ENG (female)
3
(with another wiring har- (37) – each sensor (female) and between
ness) Resistance Min. 1 Mz
ENG (female) (47) – each sensor
(female)
Wiring harness between ENG (female) (37)
– each sensor (female) and chassis ground
harness
Voltage Max. 1 V
– each sensor (female) and chassis ground
Defective engine control- and carry out troubleshooting.
5
ler ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
42 PC600-8
Circuit diagram related to sensor power supply 2 (5 V)
PC600-8 43
Failure code [CA234] Eng Overspeed
Action code Failure code Eng Overspeed

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

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

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

Defective Ne speed sen- Disconnect devices at right

1 in order. If error code disap-
sor (Internal trouble) Ne speed
pears when a device is dis- NE connector
sensor
connected, that device has
a defect in it.
Disconnection in wiring ing without turning starting switch ON.
harness (Disconnection Wiring harness between ENG (female)
in wiring or defective con- (16) – NE (female) (1)
tact in connector) Wiring harness between ENG (female)
Resistance Max. 1 z
(48) – NE (female) (2)
Possible causes and
standard value in nor- a Prepare with starting switch OFF, then carry out troubleshoot-
mal state ing without turning starting switch ON.
Ground fault in wiring
3 harness (Short circuit Resistance Min. 1 Mz
(16) – NE (female) (1) and chassis ground
with GND circuit)
(48) – NE (female) (2) and chassis ground
Short circuit in wiring har- ing without turning starting switch ON.
harness) (16) – NE (female) (1) and between ENG Resistance Min. 1 Mz
(female) (48) – NE (female) (2)
5
ler ENG Voltage
Between (16) – (48) 4.75 – 5.25 V
Circuit diagram related to Ne speed sensor power supply
PC600-8 45
Failure code [CA263] Fuel Temp Sensor High Error
Action code Failure code Fuel Temp Sensor High Error

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

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

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

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

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

Defective supply pump PCV1 (male) Resistance
1
PCV1 (Internal trouble) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
Wiring harness between ENG
Ground fault in wiring har-
(female) (4) – PCV1 (female) (1) and Resistance Min. 1 Mz
2 ness (Short circuit with GND
chassis ground
circuit)
Possible causes and Wiring harness between ENG
standard value in nor- (female) (5) – PCV1 (female) (2) and Resistance Min. 1 Mz
mal state chassis ground
Hot short (Short circuit with
3 24V circuit) in wiring har- Voltage Max. 1 V
(female) (4) – PCV1 (female) (1)
ness
Voltage Max. 1 V
Between (4) – (5) 2.3 – 5.3 z
Between (4), (5) –
Min. 1 Mz
chassis ground
Circuit diagram related to supply pump PCV1
PC600-8 49
Failure code [CA272] IMV/PCV1 Open Error
Action code Failure code IMV/PCV1 Open Error

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

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

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

1
PCV2 (Internal trouble) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
chassis ground
circuit)
Possible causes and (female) (10) – PCV2 (female) (2) and Resistance Min. 1 Mz
standard value in nor- chassis ground
mal state a Prepare with starting switch OFF, then turn starting switch
Hot short (Short circuit with
(female) (9) – PCV2 (female) (1) and Voltage Max. 1 V
3 24V circuit) in wiring har-
chassis ground
ness
(female) (10) – PCV2 (female) (2) and Voltage Max. 1 V
chassis ground
Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
PC600-8 51
Failure code [CA274] PCV2 Open Error
Action code Failure code PCV2 Open Error

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

Defective supply pump shooting without turning starting switch ON.
1 PCV2 (Internal disconnec-
PCV2 (male) Resistance
tion)
Between (1) – (2) 2.3 – 5.3 z
ing or defective contact in (female) (9) – PCV2 (female) (1)
Resistance Max. 1 z
Possible causes and a Prepare with starting switch OFF, then carry out trouble-
standard value in nor- shooting without turning starting switch ON.
mal state
chassis ground
circuit)
chassis ground
Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
52 PC600-8
PC600-8 53
©2010 KOMATSU
All Rights Reserved
54
SEN00449-02
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up

40 Troubleshooting
Failure code [CA322] Inj #1 (L#1) Open/Short Error............................................................................................ 4

Failure code [CA325] Inj #6 (L#6) Open/Short Error.......................................................................................... 10
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 1
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
2 PC600-8
PC600-8 3
Failure code [CA322] Inj #1 (L#1) Open/Short Error
Action code Failure code Inj #1 (L#1) Open/Short Error

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

Defective injector #1 (Inter- CN1 (male) Resistance
1
nal trouble) Between (1) – (2) 0.4 – 1.1 z
Between (1), (2) –
Min. 1M z
chassis ground
ing or defective contact in (female) (45) – CN1 (female) (1)
Resistance Max. 1 z
(female) (53) – CN1 (female) (2)
mal state
(female) (45) – CN1 (female) (1) and Resistance Min. 1 Mz
chassis ground
circuit)
chassis ground
Defective another cylinder If multiple failure codes are displayed for injector malfunction,
4
injector or wiring harness carry out troubleshooting for them, too.
Between (45) – (53) 0.4 – 1.1 z
Between (45), (53) –
Min. 1 Mz
chassis ground
4 PC600-8
Circuit diagram related to injector #1
PC600-8 5

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

1
Between (1), (2) –
Min. 1 Mz
chassis ground
Resistance Max. 1 z
mal state
chassis ground
circuit)
chassis ground
4
Between (46) – (60) 0.4 – 1.1 z
Between (46), (60) –
Min. 1 Mz
chassis ground
6 PC600-8
PC600-8 7

Trouble
• Output drops.
on machine

1
Between (1), (2) – chassis
Min. 1M z
ground
Resistance Max. 1 z
mal state
chassis ground
circuit)
chassis ground
4
Between (55) – (52) 0.4 – 1.1 z
Between (55), (52) –
Min. 1M z
chassis ground
8 PC600-8
PC600-8 9

Trouble
• Output drops.
on machine

1
Between (1), (2) –
Min. 1 Mz
chassis ground
Resistance Max. 1 z
mal state
chassis ground
circuit)
chassis ground
4
Between (57) – (59) 0.4 – 1.1 z
Between (57), (59) –
Min. 1 Mz
chassis ground
10 PC600-8
PC600-8 11

Trouble
• Output drops.
on machine

1
Between (1), (2) –
Min. 1 Mz
chassis ground
Resistance Max. 1 z
mal state
chassis ground
circuit)
chassis ground
4
Between (54) – (51) 0.4 – 1.1 z
Between (54), (51) –
Min. 1 Mz
chassis ground
12 PC600-8
PC600-8 13

Trouble
• Output drops.
on machine

1
Between (1), (2) –
Min. 1 Mz
chassis ground
Resistance Max. 1 z
mal state
chassis ground
circuit)
chassis ground
4
Between (56) – (58) 0.4 – 1.1 z
Between (56), (58) –
Min. 1 Mz
chassis ground
14 PC600-8
PC600-8 15
Failure code [CA342] Calibration Code Incompatibility
Action code Failure code Calibration Code Incompatibility

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

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

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

If another failure code (code of abnormality in injector system)
1 Defective related system
is indicated, carry out troubleshooting for it.
Check circuit breaker No.7 directly for defect.
Defective circuit breaker
2 (If circuit breaker is turned OFF, circuit probably has ground
No.7
fault.)
ness (Disconnection in wir- Wiring harness between CE03
ing or defective contact in (female) (3) – battery (+)
connector) Wiring harness between CE03
mal state a Prepare with starting switch OFF, then carry out trouble-
(female) (3) – battery (+) and chassis Resistance Min. 1 Mz
ground
circuit)
(female) (1) – chassis ground and Resistance Min. 1 Mz
chassis ground
CE03 Voltage
Between (3) – (1) 20 – 30 V
PC600-8 17
Circuit diagram related to controller power supply
18 PC600-8
Failure code [CA352] Sens Supply 1 Volt Low Error
Action code Failure code Sens Supply 1 Volt Low Error

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

PC600-8 19
Failure code [CA386] Sens Supply 1 Volt High Error
Action code Failure code Sens Supply 1 Volt High Error

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

Disconnect devices at Atmospheric
Defective sensor (Inter- PAMB connector
2 right in order. If error pressure sensor
nal trouble) code disappears when a
device is disconnected, Bypass valve lift
that device has a defect SBP connector
sensor
in it.
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
in wiring or defective (33) – each sensor (female) (5 V circuit)
contact in connector) Wiring harness between ENG (female)
(38) – each sensor (female) (ENG circuit)
mal state
without turning starting switch ON.
4 harness (Short circuit Resistance Min. 1 Mz
(33) – each sensor (female) (5 V circuit)
with GND circuit)
(38) – each sensor (female) (ENG circuit)
Short circuit in wiring
5 harness (with another Wiring harness between ENG (female)
wiring harness) (33) – each sensor (female) (5 V circuit)
and between ENG (female) (38) – each
sensor (female) (ENG circuit)
6
ler ENG Voltage
Between (33) – (38) 4.75 – 5.25 V
20 PC600-8
Circuit diagram related to sensor power supply 1 (5 V)
PC600-8 21
Failure code [CA441] Battery Voltage Low Error
Action code Failure code Battery Voltage Low Error

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

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

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

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

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

PC600-8 23
Failure code [CA451] Rail Press Sensor High Error
Action code Failure code Rail Press Sensor High Error

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

1
supply shooting for it first.
PFUEL Voltage
Defective common rail
2 pressure sensor (Internal
trouble) Between (2) – (3) Signal 0.25 – 4.6 V
Disconnection in wiring Wiring harness between ENG (female)
Resistance Max. 1 z
harness (Disconnection (37) – PFUEL (female) (1)
3
in wiring or defective con- Wiring harness between ENG (female)
tact in connector) Resistance Max. 1 z
Possible causes and (25) – PFUEL (female) (2)
standard value in nor- Wiring harness between ENG (female)
mal state Resistance Max. 1 z
(47) – PFUEL (female) (3)
(37) – PFUEL (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (25) – PFUEL (female) (2)
harness) (37) – PFUEL (female) (1) and between Resistance Min. 1 Mz
ENG (female) (47) – PFUEL (female) (3)
(25) – PFUEL (female) (2) and between Resistance Min. 1 Mz
ENG (female) (47) – PFUEL (female) (3)
Defective engine control- ENG Voltage
5
ler
Between (37) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
24 PC600-8
Circuit diagram related to common rail pressure sensor
PC600-8 25
Failure code [CA452] Rail Press Sensor Low Error
Action code Failure code Rail Press Sensor Low Error

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

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

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

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

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

PC600-8 27
Failure code [CA559] Rail Press Low Error
Action code Failure code Rail Press Low Error

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

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

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

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-pres-
sure feed”.
28 PC600-8
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
• Overflow valve (1): Spring is seen through both holes.
• Bypass valve (2): Spring is seen through hole on nut side.
• Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
PC600-8 29
Check sheet for no-pressure feed

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

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

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

Checking condition Unit Measured value Good NG
return rate (Reference value)
Leakage through pressure lim-
11 At rated output (pump relief) cc/min Max. 10
iter
Equivalent to rating 1,600 rpm cc/min 960 Speed:
Equivalent to rating 1,700 rpm cc/min 1,020
12 Return rate from injector Equivalent to rating 1,800 rpm cc/min 1,080
Equivalent to rating 1,900 rpm cc/min 1,140 Return rate:
Equivalent to rating 2,000 rpm cc/min 1,200
30 PC600-8
*1 – *10:
When inspecting with the monitoring function, see the monitoring codes list.
Equivalent to rating:
Relieve the oil under the following condition.
1) Run engine at full throttle.
2) Select P mode.
3) Raise boom.
PC600-8 31
Failure code [CA689] Eng Ne Speed Sensor Error
Action code Failure code Eng Ne Speed Sensor Error

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

Defective sensor power If failure code [CA238] is indicated, carry out troubleshooting for
1
supply system it first.
Resistance Max. 1 z
harness (Disconnection (16) – NE (female) (1)
2
(48) – NE (female) (2)
Resistance Max. 1 z
(27) – NE (female) (3)
(16) – NE (female) (1) and chassis Resistance Min. 1 Mz
Ground fault in wiring ground
3 harness (Short circuit Wiring harness between ENG (female)
with GND circuit) (48) – NE (female) (2) and chassis Resistance Min. 1 Mz
Possible causes and ground
mal state
(27) – NE (female) (3) and chassis Resistance Min. 1 Mz
ground
(16) – NE (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (48) – NE (female) (2)
harness) (16) – NE (female) (1) and between Resistance Min. 1 Mz
ENG (female) (27) – NE (female) (3)
(48) – NE (female) (2) and between Resistance Min. 1 Mz
ENG (female) (27) – NE (female) (3)
If causes 1 – 4 are not detected, engine Ne speed sensor may
Defective engine Ne
5 be defective. (Since trouble is in system, troubleshooting cannot
speed sensor
be carried out.)
If causes 1 – 4 are not detected, engine controller may be defec-
Defective engine control-
6 tive. (Since trouble is in system, troubleshooting cannot be car-
ler
ried out.)
32 PC600-8
Circuit diagram related to engine Ne speed sensor
PC600-8 33
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Action code Failure code Eng Bkup Speed Sens Phase Error
Trouble
Contents of trouble • Engine Bkup sensor circuit detected abnormality in phase.
Action of controller • Controls with signals of engine Ne speed sensor.
Problem that appears • Running engine stops (when Ne speed sensor is also abnormal).
on machine • Stopped engine cannot be started (when Ne speed sensor is also abnormal).

Possible causes and Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble-
1
standard value in nor- sensor system shooting for failure code [CA698].
mal state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trou-
2
speed sensor system bleshooting for failure code [CA778].
34 PC600-8
Failure code [CA757] All Persistent Data Lost Error
Action code Failure code All Persistent Data Lost Error

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

PC600-8 35
Failure code [CA778] Engine Bkup Speed Sensor Error
Action code Failure code Engine Bkup Speed Sensor Error

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

1
Resistance Max. 1 z
harness (Disconnection (37) – G (female) (1)
2
(47) – G (female) (2)
Resistance Max. 1 z
(26) – G (female) (3)
(37) – G (female) (1) and chassis Resistance Min. 1 Mz
Ground fault in wiring ground
3 harness (Short circuit Wiring harness between ENG (female)
with GND circuit) (47) – G (female) (2) and chassis Resistance Min. 1 Mz
Possible causes and ground
mal state
(26) – G (female) (3) and chassis Resistance Min. 1 Mz
ground
(37) – G (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring har- (female) (47) – G (female) (2)
harness) (37) – G (female) (1) and between ENG Resistance Min. 1 Mz
(female) (26) – G (female) (3)
(47) – G (female) (2) and between ENG Resistance Min. 1 Mz
(female) (26) – G (female) (3)
If causes 1 – 4 are not detected, engine Bkup speed sensor may
Defective engine Bkup
5 be defective. (Since trouble is in system, troubleshooting cannot
speed sensor
be carried out.)
If causes 1 – 5 are not detected, engine controller may be defec-
6 tive. (Since trouble is in system, troubleshooting cannot be car-
ler
ried out.)
36 PC600-8
Circuit diagram related to engine Bkup speed sensor
PC600-8 37
Failure code [CA1228] EGR Valve Servo Error 1
Action code Failure code EGR Valve Servo Error 1

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

it.
a For measurement of EGR valve drive pressure, see Testing
and adjusting, “Testing EGR valve and bypass valve drive oil
pressure”
Improper EGR valve drive Engine speed EGR valve drive pressure
2
pressure Low idle Min.1.18 MPa {Min.12 kg/cm2}
Min.1.43 MPa
High idle
{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”.
Engine speed Engine oil pressure
Possible causes and
standard value in nor- Min.0.08 MPa
Defective engine oil pres- Low idle
mal state 3 {Min.0.8 kg/cm2}
sure system (main circuit)
Min.0.21 MPa
High idle
{Min.2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting of
engine (S-12 Oil pressure lowers).
Defective oil pump for EGR
4 Check oil pump and relief valve for EGR valve circuit directly.
valve
Defective oil feed piping for
5 Check oil feed piping for EGR valve circuit directly.
EGR valve
Defective oil return piping
6 Check oil return piping for EGR valve circuit directly.
for EGR valve
7 Defective EGR valve Check mechanical section of EGR valve directly.
be carried out.)
38 PC600-8
Failure code [CA1625] EGR Valve Servo Error 2
Action code Failure code EGR Valve Servo Error 2

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

PC600-8 39
Failure code [CA1626] BP Valve Sol Current High Error
Action code Failure code BP Valve Sol Current High Error

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

Defective bypass valve ing without turning starting switch ON.
1
solenoid (Internal trouble) BP (male) Resistance
Between (1) – (2) 10 – 21 z
in wiring or defective con- (31) – BP (female) (1)
Resistance Max. 1 z
(11) – BP (female) (2)
Possible causes and Ground fault in wiring
(31) – BP (female) (1) and chassis Resistance Min. 1 Mz
standard value in nor- 3 harness (Short circuit
ground
mal state with GND circuit)
(11) – BP (female) (2) and chassis Resistance Min. 1 Mz
ground
(31) – BP (female) (1) and chassis Voltage Max. 1 V
4 with 24V circuit) in wiring
ground
harness
(11) – BP (female) (2) and chassis Voltage Max. 1 V
ground
Defective engine control- ing without turning starting switch ON.
5
ler ENG (female) Resistance
Between (31) – (11) 10 – 21 z
40 PC600-8
Circuit diagram related to bypass valve solenoid & lift sensor
PC600-8 41
Failure code [CA1627] BP Valve Sol Current Low Error
Action code Failure code BP Valve Sol Current Low Error

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

42 PC600-8
Failure code [CA1628] Bypass Valve Servo Error 1
Action code Failure code Bypass Valve Servo Error 1

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

If another failure code is indicated, carry out troubleshooting
for it.
a For measurement of bypass valve drive pressure, see Test-
ing and adjusting, “Testing EGR valve and bypass valve
drive oil pressure”
Engine speed Bypass valve drive pressure
Improper bypass valve drive
2 Low idle Min.1.18 MPa {Min.12 kg/cm2}
pressure
Min.1.43 MPa
High idle
{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
Possible causes and ADJUSTING, Testing engine oil pressure.
standard value in nor- Engine Engine oil pressure
mal state Defective engine oil pres-
3 Low idle Min.0.08 MPa {Min.0.8 kg/cm2}
sure system (main circuit)
High idle 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).
Defective oil pump for Check oil pump and relief valve for bypass valve circuit
4
bypass valve directly.
Defective oil feed piping for
5 Check oil feed piping for bypass valve circuit directly.
bypass valve
Defective oil return piping
6 Check oil return piping for bypass valve circuit directly.
for bypass valve
7 Defective bypass valve Check mechanical section of bypass valve directly.
be carried out.)
PC600-8 43
Failure code [CA1629] Bypass Valve Servo Error 2
Action code Failure code Bypass Valve Servo Error 2

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

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

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

1
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective bypass valve SBP Voltage
2 lift sensor (Internal trou- Between (1) – (2) Power supply 4.75 – 5.25 V
ble)
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
Resistance Max. 1 z
harness (Disconnection (33) – SBP (female) (1)
3
in wiring or defective Wiring harness between ENG (female)
contact in connector) Resistance Max. 1 z
(38) – SBP (female) (2)
Resistance Max. 1 z
(29) – SBP (female) (3), (4)
Possible causes and without turning starting switch ON.
standard value in nor- Wiring harness between ENG (female)
mal state Ground fault in wiring Resistance Min. 1 Mz
(33) – SBP (female) (1)
4 harness (Short circuit
with GND circuit) Wiring harness between ENG (female)
(38) – SBP (female) (2)
(29) – SBP (female) (3), (4)
(33) – SBP (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring (female) (38) – SBP (female) (2)
5 harness (with another Wiring harness between ENG (female)
wiring harness) (33) – SBP (female) (1) and between ENG Resistance Min. 1 Mz
(female) (29) – SBP (female) (3), (4)
(38) – SBP (female) (2) and between ENG Resistance Min. 1 Mz
(female) (29) – SBP (female) (3), (4)
Defective engine con- start engine and carry out troubleshooting.
6
troller ENG Voltage
Between (33) – (38) 4.75 – 5.25 V
PC600-8 45
Circuit diagram related to bypass valve solenoid & lift sensor
46 PC600-8
Failure code [CA1632] BP Valve Pos Sens Low Error
Action code Failure code BP Valve Pos Sens Low Error

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

PC600-8 47
Failure code [CA1633] KOMNET Datalink Timeout Error
Action code Failure Code Failure KOMNET Datalink Timeout Error

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

a Prepare with starting switch OFF and hold it in the OFF position during the
troubleshooting.
Wiring harness between CM03 (female) (16) and CE02
harness Resistance
(female) (47) or between CM03 (female) (16) and CP02 Max. 1 z
1 (Disconnection or defec- value
(female) (22)
tor) Wiring harness between CM03 (female) (15) and CE02
Resistance
value
(female) (32)
troubleshooting.
Between wiring harness between CM03 (female) (16)
Ground fault of wiring and CE02 (female) (47) or between CM03 (female) (16) Resistance
Min. 1 Mz
harness and CP02 (female) (22) or between CM03 (female) (16) value
2
(Contact with ground and related circuits and ground
Presumed cause and
circuit) Between wiring harness between CM03 (female) (15)

and CE02 (female) (46) or between CM03 (female) (15) Resistance
Min. 1 Mz
and CP02 (female) (32) or between CM03 (female) (15) value
and related circuits and ground
a Prepare with starting switch OFF and hold it in the ON position during the
troubleshooting.
and CE02 (female) (47) or between CM03 (female) (16)
Short-circuiting of wiring Voltage Max. 1 V
and CP02 (female) (22) or between CM03 (female) (16)
3 harness
(Contact with 24 V circuit)
Voltage Max. 1 V
CAN terminal resistor troubleshooting.
4
defective K02 (male), K03 (male) Voltage
Between (1) and (2) 40 – 80 z
Machine monitor, engine If causes 1 – 4 are not detected, machine monitor, engine controller, or pump control-
5 controller, or pump ler may be defective. (Since trouble is in those devices, troubleshooting cannot be
controller defective carried out.)
48 PC600-8
Electrical circuit diagram related to CAN communication
PC600-8 49
50 PC600-8
Failure code [CA1642] EGR Inlet Press Sens Low Error
Serial numbers : 30001 – 30070
Action code Failure code EGR Inlet Press Sens Low Error
Trouble
Contents of trouble • Signal voltage in EGR inlet pressure sensor circuit is abnormally low.
• Sets EGR inlet pressure to default value (102 kPa {1.0 kg/cm2}) and continues operation.
• Output drops.
on machine
• Signal voltage of EGR inlet pressure sensor can be checked with monitoring function.
Related information
(Code: 18001 EGR inlet sensor voltage)

PC600-8 51
Failure code [CA1653] EGR Inlet Press Sens High Error
Serial numbers : 30001 – 30070
Action code Failure code EGR Inlet Press Sens High Error
Trouble
Contents of trouble • Signal voltage in EGR inlet pressure sensor circuit is abnormally high.
• Sets EGR inlet pressure to default value (102 kPa {1.0 kg/cm2}) and continues operation.
• Output drops.
on machine
• Signal voltage of EGR inlet pressure sensor can be checked with monitoring function.
Related information
(Code: 18001 EGR inlet pressure sensor voltage)

1
Defective EGR inlet pres- PEVA Voltage
2 sure sensor (Internal Between (1) – (2) Power supply 4.75 – 5.25 V
trouble)
Resistance Max. 1 z
harness (Disconnection (37) – PEVA (female) (1)
3
tact in connector) Resistance Max. 1z
(47) – PEVA (female) (2)
Resistance Max. 1 z
(20) – PEVA (female) (3)
Possible causes and ing without turning starting switch ON.
standard value in nor- Wiring harness between ENG (female) (37)
mal state Ground fault in wiring Resistance Min. 1 Mz
– PEVA (female) (1) and chassis ground
with GND circuit) Wiring harness between ENG (female) (47)
(37) – PEVA (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (47) – PEVA (female) (2)
harness) (37) – PEVA (female) (1) and between Resistance Min. 1 Mz
ENG (female) (20) – PEVA (female) (3)
(47) – PEVA (female) (2) and between Resistance Min. 1 Mz
ENG (female) (20) – PEVA (female) (3)
6
ler ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
52 PC600-8
Circuit diagram related to EGR inlet pressure sensor
PC600-8 53
Failure code [CA2185] Throt Sens Sup Volt High Error
Action code Failure code Throt Sens Sup Volt High Error
Trouble
Contents of trouble • Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
Action of controller • Sets throttle angle with signal other than throttle sensor signal and continues operation.
—
on machine

Defective accelerator Disconnect devices at right

1 in order. If failure code
pedal (Internal trouble) Fuel
disappears when a device P20 connector
control dial
is disconnected, that
device has a defect in it.
Short circuit in wiring Wiring harness between CE02 (female)
Possible causes and 2 harness (with another (22) – P20 (female) (1) and between Resistance Min. 1 Mz
standard value in nor- wiring harness) CE02 (female) (23) – P20 (female) (3)
mal state a Prepare with starting switch OFF, then turn starting switch ON
Wiring harness between CE02 (female)
(22) – P20 (female) (1) and chassis Voltage Max. 1 V
ground
3 with 24V circuit) in wir-
(23) – P20 (female) (3) and chassis Voltage Max. 1 V
ing harness
ground
Defective engine con- CE02 Voltage
4
troller Between (22) – (23) 4.75 – 5.25 V
54 PC600-8
Circuit diagram related to throttle sensor of fuel control dial type
PC600-8 55
Failure code [CA2186] Throt Sens Sup Volt Low Error
Action code Failure code Throt Sens Sup Volt Low Error
Trouble
Contents of trouble • Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low.
Action of controller • Sets throttle angle with signal other than throttle sensor signal and continues operation.
—
on machine

56 PC600-8
Failure code [CA2249] Rail Press Very Low Error
Action code Failure code Rail Press Very Low Error

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

PC600-8 57
Failure code [CA2271] EGR Valve Pos Sens High Error
Action code Failure code EGR Valve Pos Sens High Error
Trouble
Contents of trouble • Signal voltage in EGR valve lift sensor circuit is abnormally high.
• Output drops.
on machine
• Signal voltage of EGR valve lift sensor can be checked with monitoring function.
Related information
(Code: 18101 EGR valve lift sensor voltage)

Defective sensor If failure code [CA187] or [CA227] is indicated, carry out trouble-
1
power supply shooting for it first.
start engine and carry out troubleshooting.
Defective EGR valve SEGR Voltage
2 lift sensor (Internal Between (1) – (2) Power supply 4.75 – 5.25V
trouble)
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
Disconnection in wiring Wiring harness between ENG (female) (37)
harness (Disconnec- Resistance Max. 1 z
– SEGR (female) (1)
3 tion in wiring or defec-
tive contact in Resistance Max. 1 z
connector) – SEGR (female) (2)
Resistance Max. 1 z
– SEGR (female) (3), (4)
Possible causes and
standard value in nor- Wiring harness between ENG (female) (37)
mal state Ground fault in wiring – SEGR (female) (1) and chassis ground
4 harness (Short circuit Wiring harness between ENG (female) (47)
with GND circuit) Resistance Min. 1 Mz
– SEGR (female) (2) and chassis ground
– SEGR (female) (3), (4) and chassis Resistance Min. 1 Mz
ground
– SEGR (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring (female) (47) – SEGR (female) (2)
5 harness (with another Wiring harness between ENG (female) (37)
wiring harness) – SEGR (female) (1) and between ENG Resistance Min. 1 Mz
(female) (19) – SEGR (female) (3), (4)
– SEGR (female) (2) and between ENG Resistance Min. 1 Mz
(female) (19) – SEGR (female) (3), (4)
Defective engine con- start engine and carry out troubleshooting.
6
troller ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
58 PC600-8
Circuit diagram related to EGR valve solenoid & lift sensor
PC600-8 59
Failure code [CA2272] EGR Valve Pos Sens Low Error
Action code Failure code EGR Valve Pos Sens Low Error
Trouble
Contents of trouble • Signal voltage in EGR valve lift sensor circuit is abnormally low.
• Output drops.
on machine
• Signal voltage of EGR valve lift sensor can be checked with monitoring function.
Related information
(Code: 18101 EGR valve lift sensor voltage)

60 PC600-8
PC600-8 61
Failure code [CA2351] EGR Valve Sol Current High Error
Action code Failure code EGR Valve Sol Current High Error
Trouble
Contents of trouble • There is short circuit in drive circuit of EGR valve solenoid.
• Output drops.
on machine

Defective EGR valve ing without turning starting switch ON.
1
solenoid (Internal trouble) EGR (male) Resistance
Between (1) – (2) 10 – 21 z
in wiring or defective con- (22) – EGR (female) (1)
Resistance Max. 1 z
(11) – EGR (female) (2)
Possible causes and Ground fault in wiring
(22) – EGR (female) (1) and chassis Resistance Min. 1 Mz
standard value in nor- 3 harness (Short circuit
ground
mal state with GND circuit)
(11) – EGR (female) (2) and chassis Resistance Min. 1 Mz
ground
(22) – EGR (female) (1) and chassis Voltage Max. 1 V
ground
harness
(11) – EGR (female) (2) and chassis Voltage Max. 1 V
ground
Defective engine control- ing without turning starting switch ON.
5
ler ENG (female) Resistance
Between (22) – (11) 10 – 21 z
62 PC600-8
Circuit diagram related to EGR valve solenoid & lift sensor
PC600-8 63
Failure code [CA2352] EGR Valve Sol Current Low Error
Action code Failure code EGR Valve Sol Current Low Error
Trouble
Contents of trouble • There is disconnection in drive current of EGR valve solenoid.
• Output drops.
on machine

64 PC600-8
Failure code [CA2555] Grid Htr Relay Volt Low Error
Action code Failure code Grid Htr Relay Volt Low Error
Trouble
Contents of trouble • There is low voltage error in intake air heater relay circuit.
• Engine does not start easily at low temperature.
on machine

PC600-8 65
Failure code [CA2556] Grid Htr Relay Volt High Error
Action code Failure code Grid Htr Relay Volt High Error
Trouble
Contents of trouble • There is high voltage error in intake air heater relay circuit.
• Engine does not start easily at low temperature.
on machine

Defective intake air ing without turning starting switch ON.
1 heater relay (Internal
R18 (male) Resistance
trouble)
Between (1) – (2) 200 – 400 z
harness (Disconnection Wiring harness between CE02 (female)
in wiring or defective con- (40) – R18 (female) (1)
tact in connector) Wiring harness between CE02 (female)
Resistance Max. 1 z
(42) – R18 (female) (2)
Possible causes and a Prepare with starting switch OFF, then carry out troubleshoot-
standard value in nor- ing without turning starting switch ON.
mal state Wiring harness between CE02 (female)
(40) – R18 (female) (1) and chassis Resistance Min. 1 Mz
ground
with GND circuit)
(42) – R18 (female) (2) and chassis Resistance Min. 1 Mz
ground
CE02 Heater relay Voltage
4 Under operating
ler Max. 1 V
condition
Between (40) – (42)
Under stopping
20 – 30 V
condition
66 PC600-8
Circuit diagram related to intake air heater
PC600-8 67
©2009 KOMATSU
All Rights Reserved
68
SEN00450-02
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up

40 Troubleshooting
Failure code [D110KB] Battery Relay Drive S/C .................................................................................................. 4

Failure code [D163KB] Flash Light Relay S/C ..................................................................................................... 6
Failure code [D195KB] Step Light Relay S/C....................................................................................................... 8
Failure code [DA22KK] Pump Solenoid Power Low Error ................................................................................. 10
Failure code [DA25KP] Press. Sensor Power Abnormality................................................................................ 12
Failure code [DA2SKQ] Model Selection Abnormality ....................................................................................... 14
Failure code [DA80MA] Auto. Lub Abnormal ..................................................................................................... 16
Failure code [DA2RMC] Pump Comm. Abnormality .......................................................................................... 18
Failure code [DAFRMC] Monitor Comm. Abnormality ....................................................................................... 20
Failure code [DGE5KY] Ambi. Temp. Sensor S/C ............................................................................................. 22
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C ........................................................................................ 23
Failure code [DHPAMA] F pump P. Sensor Abnormality.................................................................................... 24
Failure code [DHPBMA] R pump P. Sensor Abnormality ................................................................................... 26
Failure code [DV20KB] Travel Alarm S/C .......................................................................................................... 28
Failure code [DW43KA] Travel Speed Sol. Disc. ............................................................................................... 30
Failure code [DW43KB] Travel Speed Sol. S/C ................................................................................................. 32
Failure code [DW45KA] Swing Brake Sol. Disc. ................................................................................................ 34
Failure code [DW45KB] Swing Brake Sol. S/C .................................................................................................. 36
Failure code [DW48KA] CO Cancel Sol. Disc.................................................................................................... 38
Failure code [DW48KB] CO Cancel Sol. S/C..................................................................................................... 40
PC600-8 1
Failure code [DW7BKA] Fan Reverse Sol. Disc. ............................................................................................... 42

Failure code [DW7BKB] Fan Reverse Sol. S/C ................................................................................................. 43
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc.................................................................................. 44
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C................................................................................... 46
Failure code [DWK0KA] 2-stage Relief Sol. Disc. .............................................................................................. 48
Failure code [DWK0KB] 2-stage Relief Sol. S/C ................................................................................................ 50
Failure code [DX16KA] Fan Pump EPC Sol. Disc. ............................................................................................ 52
Failure code [DX16KB] Fan Pump EPC Sol. S/C .............................................................................................. 54
Failure code [DXA0KA] TVC Sol. Disc............................................................................................................... 56
Failure code [DXA0KB] TVC Sol. S/C................................................................................................................ 58
Failure code [DY20KA] Wiper Working Abnormality .......................................................................................... 60
Failure code [DY20MA] Wiper Parking Abnormality .......................................................................................... 62
Failure code [DY2CKB] Washer Drive S/C ........................................................................................................ 66
Failure code [DY2DKB] Wiper Drive (For) S/C .................................................................................................. 68
Failure code [DY2EKB] Wiper Drive (Rev) S/C.................................................................................................. 72
2 PC600-8
PC600-8 3
Failure code [D110KB] Battery Relay Drive S/C
Action code Failure code Failure Battery Relay Drive S/C

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

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

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

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

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

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

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

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

Presumed cause and
2
circuit) Min. 1 Mz
and R09 (female) (2) and grounding value
CP02 Step light switch Voltage
3 Pump controller defective
20 – 30 V
Between (19) and ON
(Kept for 60 sec)
grounding
OFF Max. 1 V
8 PC600-8
Electrical circuit diagram related to step light
PC600-8 9
Failure code [DA22KK] Pump Solenoid Power Low Error
Action code Failure code Failure Pump Solenoid Power Low Error
E0E DA22KK phenomenon (Pump controller system)
Failure content • Pump controller solenoid power supply voltage is below 20 V.
Response from
• Limits engine speed to 1,400 rpm.
controller
• If solenoid power supply voltage lowers extremely, work equipment, swing system and travel system do
Phenomenon
not operate.
occurring on
• Engine speed does not rise above 1,400 rpm.
machine
• Hydraulic fan cannot be rotated in reverse.
Relative
• If D110KB is displayed, carry out troubleshooting for it first.
information

Defective circuit breaker If circuit breaker No. 4 is turned OFF, circuit probably has ground fault etc. (See
1
No. 4 cause 3.)
starting switch ON.
Wiring harness between CP03 (female) (2), (12), (22) –
Resistance Max. 1 z
J07 (female) (2), (3), (4)
Disconnection in wiring
harness (Disconnection Wiring harness between J07 (female) (1) – B24 Resistance Max. 1 z
2
in wiring or defective con- Wiring harness between battery relay terminal M – B14 Resistance Max. 1 z
Presumed cause and
tact in connector)
Wiring harness between starting switch terminal BR –
Resistance Max. 1 z
battery relay terminal BR
Wiring harness between CP03 (female) (31), (32), (33)
Resistance Max. 1 z
– J08 – ground
starting switch ON.
Wiring harness between CP03 (female) (2), (12), (22) –
Ground fault in wiring Resistance Min. 1 Mz
J07 (female) (2), (3), (4) – ground
3 harness (Contact with
GND circuit) Wiring harness between J07 (female) (1) – B24 –
ground
Wiring harness between battery relay terminal M – B14
– ground
4 Defective pump controller troubleshooting.
Between CP03 (2), (12), (22) – (31), (32) (33) Voltage 20 – 30 V
10 PC600-8
Electrical circuit diagram related to power supply of pump controller
PC600-8 11
Failure code [DA25KP] Press. Sensor Power Abnormality
Action code Failure code Failure Press. Sensor Power Abnormality

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

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

Connector P25
1 defective shown at right in order. pressure sensor
(Internal short-circuiting) If the error code goes off
when one of those parts is
Rear pump
disconnected, that part is Connector P26
pressure sensor
Presumed cause and
defective.
Grounding fault of wiring Between wiring harness between CP01 (female) (22),
Resistance
harness A06, and P25 (female) (B) and grounding Min. 1 Mz
2 value
(Contact with grounding [Front pump pressure sensor system]
circuit) Between wiring harness between CP01 (female) (22),
Resistance
A06, and P26 (female) (B) and grounding Min. 1 Mz
value
[Rear pump pressure sensor system]
CP01 Voltage
Between (22) and (10) 4.5 – 5.5 V
12 PC600-8
Electrical circuit diagram related to pressure sensor power supply
PC600-8 13
Failure code [DA2SKQ] Model Selection Abnormality
Action code Failure code Failure Model Selection Abnormality

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

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

(male) (1) value
Presumed cause and

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

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

harness Resistance
(female) (22)
Resistance
value
(female) (32)
Grounding fault of wiring and CE02 (female) (47) or between CM03 (female) (16) Resistance
Min. 1 Mz
2
(Contact with grounding and related circuits and grounding
Presumed cause and

Min. 1 Mz
and related circuits and grounding
3 harness
Voltage Max. 1 V
CAN terminal resistor position during the troubleshooting.
4
defective K02 (male), K03 (male) Resistance value
Between (A) and (B) 120 ± 12 z
Monitor panel, If causes 1 – 4 are not detected, machine monitor, engine controller, or pump control-
5 engine controller, or ler may be defective. (Since trouble is in those devices, troubleshooting cannot be
pump controller defective carried out.)
18 PC600-8
PC600-8 19
Failure code [DAFRMC] Monitor Comm. Abnormality
Action code Failure code Failure Monitor Comm. Abnormality

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

harness Resistance
(female) (22)
Resistance
value
(female) (32)
Grounding fault of wiring and CE02 (female) (47) or between CM03 (female) (16) Resistance
Min. 1 Mz
2
(Contact with grounding and related circuits and grounding
Presumed cause and

Min. 1 Mz
3 harness
Voltage Max. 1 V
CAN terminal resistor position during the troubleshooting.
4
defective K02 (male), K03 (male) Voltage
Between (A) and (B) 120 ± 12 z
Machine monitor, engine If causes 1 – 4 are not detected, machine monitor, engine controller, or pump control-
5 controller, or pump ler may be defective. (Since trouble is in those devices, troubleshooting cannot be
controller defective carried out.)
20 PC600-8
PC600-8 21
Failure code [DGE5KY] Ambi. Temp. Sensor S/C
Action code Failure code Failure Ambi. Temp. Sensor S/C

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

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

Presumed cause and
harness (Disconnection Wiring harness between CP01 (female) (9) – P29
in wiring or defective con- (female) (1)
tact in connector) Wiring harness between CP01 (female) (10) – P29
Resistance Max. 1 z
(female) (2)
Hot short (Short circuit troubleshooting.
3 with 24 V circuit) in wiring
harness Wiring harness between CP01 (female) (9) – P29
Voltage Max. 1 V
(female) (1)
starting switch ON.
4 Defective pump controller
P29 (male) Ambient temperature Resistance
Between (1) – (2) 20°C 4 – 6 kz
Circuit diagram related to ambient temperature sensor
22 PC600-8
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C
Action code Failure code Failure Hydr. Oil Temp. Sensor S/C
— DGH2KB phenomenon (Pump controller system)
Failure content • While engine was running, signal of hydraulic oil temperature sensor rose above 102°C.
Response from
machine monitor
Phenomenon
occurring on • If machine is operated as it is, hydraulic components may be damaged.
machine
• If hydraulic oil temperature monitor of monitor panel lights up red while engine is running, this failure
Relative code is recorded.
information • Input (temperature) from hydraulic oil temperature sensor can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature, 04402: Hydraulic oil temperature sensor voltage)

Overheating of hydraulic
Hydraulic oil may have been overheated. Remove cause and repair damaged
1 oil (When system is nor-
hydraulic parts.
mal)
starting switch ON.
Defective hydraulic oil
P22 (male) Hydraulic oil temperature Resistance

2 temperature sensor
Presumed cause and
(Internal defect) Between (1) – (2) 90 – 3.5 kz

Between (1) – 10 – 100°C
Min. 1 Mz
chassis ground
GND circuit) Wiring harness between CM02 (female) (12) – P22
(female) (1) and chassis ground
starting switch ON.
Defective machine moni- CM02 (female) Hydraulic oil temperature Resistance
4
tor Between (12) – (13) 90 – 3.5 kz
Between (12) – 10 – 100°C
Min. 1 Mz
chassis ground
Electric circuit diagram related to hydraulic oil temperature sensor
PC600-8 23
Failure code [DHPAMA] F pump P. Sensor Abnormality
Action code Failure code Failure F pump P. Sensor Abnormality

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

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

Wiring harness between CP01 (female) (10), A06, and Resistance
tor) P25 (female) (A) value
Wiring harness between CP01 (female) (8) and P25 Resistance
Max. 1 z
(female) (C) value
4
(Contact with grounding Between wiring harness between CP01 (female) (8) and Resistance
circuit) Min. 1 Mz
P25 (female) (C) and grounding value
Hot short
Between wiring harness between CP01 (female) (22),
5 (Short circuit with 24 V Voltage Max. 1 V
A06, J25, and P25 (female) (B) and grounding
circuit) in wiring harness
Between wiring harness between C01 (female) (8) and
Voltage Max. 1 V
P25 (female) (C) and grounding
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
Between (22) and (10) 4.5 – 5.5 V
Between (8) and (10) 0.5 – 4.5 V
24 PC600-8
Electrical circuit diagram related to front pump pressure sensor
PC600-8 25
Failure code [DHPBMA] R pump P. Sensor Abnormality
Action code Failure code Failure R pump P. Sensor Abnormality

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

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

3
or defective contact with Wiring harness between CP01 (female) (10) – J08 – Resistance
connector) Max. 1 z
A06 – P26 (female) (A) value
Wiring harness between CP01 (female) (2) – P26 Resistance
Max. 1 z
(female) (C) value
GND circuit) Wiring harness between CP01 (female) (2) – P26 Resistance
Min. 1 Mz
(female) (C) and chassis ground value
troubleshooting.
Wiring harness between CP01 (female) (22) – A06 –
J25 – P26 (female) (B)
harness
Wiring harness between CP01 (female) (2) – P26
Voltage Max. 1 V
(female) (C) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and start engine and
carry out troubleshooting in each case.
6 Defective pump controller CP01 Voltage
Between (22) and (10) 4.5 – 5.5 V
Between (2) and (10) 0.5 – 4.5 V
26 PC600-8
Circuit diagram related to R pump pressure sensor
PC600-8 27
Failure code [DV20KB] Travel Alarm S/C
Action code Failure code Failure Travel Alarm S/C

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

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

Operated 20 – 30 V
Presumed cause and
If the above voltage is normal but the travel alarm does not operate, the travel alarm
is defective.
2
circuit) Min. 1 Mz
M14 (female) (1) and grounding value
3 Pump controller defective CP03 Travel lever Voltage
Neutral Max. 1 V
28 PC600-8
Circuit diagram related to travel alarm
PC600-8 29
Failure code [DW43KA] Travel Speed Sol. Disc.
Action code Failure code Failure Travel Speed Sol. Disc.

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

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

Presumed cause and
harness
Wiring harness from CP03 (female) (27) to A05 and V04 Resistance
(female) (2) value
tor) Wiring harness between V04 (female) (1) to J23, A05, Resistance
Max. 1 z
J08, CP03 (female) (3), (13), (23), J23 and grounding value
Hot short (Short circuit position during the troubleshooting.
Voltage Max. 1 V
A05, and V04 (female) (2) and grounding
CP03 (female) Resistance value
Between (27) and grounding 20 – 60 z
30 PC600-8
Electrical circuit diagram related to travel speed select solenoid
PC600-8 31
Failure code [DW43KB] Travel Speed Sol. S/C
Action code Failure code Failure Travel Speed Sol. S/C

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

Travel speed select position during the troubleshooting.
solenoid defective V04 (male) Resistance value
1
(Internal short-circuiting
Between (2) and (1) 20 – 60 z
Presumed cause and
or grounding fault)
2
(Contact with grounding Between wiring harness between CP03 (female) (27), Resistance
circuit) Min. 1 Mz
A05, and V04 (female) (2) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in high idling
during the troubleshooting.
3 Pump controller defective CP03 Travel speed select switch Voltage
Between (27) and Lo Max. 1 V
grounding Hi 20 – 30 V
32 PC600-8
Electrical circuit diagram related to travel speed select solenoid
PC600-8 33
Failure code [DW45KA] Swing Brake Sol. Disc.
Action code Failure code Failure Swing Brake Sol. Disc.

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

Swing holding brake position during the troubleshooting.
Between (2) and (1) 20 – 60 z
Assembled-type diode position during the troubleshooting.
2 D01 defective
D01 (male) Digital tester Continuity
Between (7) and (3) Diode mode Continued
Swing lock switch
3 defective S04 (female) Swing lock switch Resistance value
(Internal disconnection) OFF Max. 1 z

Between (3) and (4)
Presumed cause and
LOCK Min. 1 Mz
Wiring harness between CP03 (female) (37) and D01 Resistance
Disconnection of wiring Max. 1 z
(female) (7) value
harness
Wiring harness between D01 (female) (3), J04, and S04 Resistance
(male) (3) value
tor) Wiring harness between S04 (male) (4), V05 (female) Resistance
Max. 1 z
(2) value
Wiring harness between V05 (female) (1), J23, A05, J08 Resistance
Max. 1 z
and CP03 (female) (3), (13) and (23) value
harness Between wiring harness between CP03 (female) (37)
Voltage Max. 1 V
and D01 (female) (7)
6 Pump controller defective CP03 (female) Disconnect D01 and Resistance value
Between (37) and directly connect pins (3)
and (7) on the female side. 20 – 60 z
grounding
34 PC600-8
Electrical circuit diagram related to swing holding brake solenoid
PC600-8 35
Failure code [DW45KB] Swing Brake Sol. S/C
Action code Failure code Failure Swing Brake Sol. S/C

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

Swing holding brake position during the troubleshooting.
1
or grounding fault) Between (2) and (1) 20 – 60 z
Assembled-type diode

2 D01 defective
Presumed cause and
D01 (male) Resistance value (Continuitiy)

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

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

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

Presumed cause and
harness
(female) (2) value
Max. 1 z
J08, CP03 (female) (3), (13), (23) value
Voltage Max. 1 V
Pump controller position during the troubleshooting.
4
defective CP03 (female) Resistance value
38 PC600-8
Electrical circuit diagram related to CO cancel solenoid
PC600-8 39
Failure code [DW48KB] CO Cancel Sol. S/C
Action code Failure code Failure CO Cancel Sol. S/C

Failure content • Abnormal current flew to the CO cancel 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
• When the boom is raised and the machine travels, power is low (The pump CO function cannot be can-
occurring on
celled).
machine
Relative • Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02300: Solenoid 1)

CO cancel solenoid position during the troubleshooting.
defective V07 (male) Resistance value
1
Between (2) and (1) 20 – 60 z
Presumed cause and
or grounding fault)
2
circuit) Min. 1 Mz
A05 and V08 (female) (2) and grounding value
Pump controller CP03 Swing lock switch Voltage
3
defective
Between (28) and OFF Max. 1 V
grounding ON (Note) 20 – 30 V
Note: May be measured under the condition of "Power max. switch ON (for 8.5 seconds)" or "Single boom
RAISE operation" or "Travel operation".
40 PC600-8
Electrical circuit diagram related to CO cancel solenoid
PC600-8 41
Failure code [DW7BKA] Fan Reverse Sol. Disc.
Action code Failure code Failure Fan Reverse Sol. Disc.

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

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

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

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

reverse solenoid (Internal V17 (male) Resistance
1
short circuit or ground

Between (1) – (2) 20 – 60 z
Presumed cause and
fault)
Between (2) – chassis ground Min. 1 Mz
GND circuit) Wiring harness between CP03 (female) (25) – V17
troubleshooting.
3 Defective pump controller CP03 Working mode Voltage
Between (25) – Other than L-mode Max. 1 V
chassis ground L-mode 20 – 30 V
PC600-8 43
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc.
Action code Failure code Failure Bucket Curl Hi Cancel Sol. Disc.
— DW4XKA phenomenon (Pump controller system)
• Any current does not flow to the bucket Curl Hi cancel solenoid circuit, when power was supplied to the
Failure content
circuit.
Response from • None in particular (Since any current does not flow, the solenoid does not operate).
Phenomenon
• When the bucket and other work equipment are operated simultaneously, the speed of the other work
occurring on
equipment is low (The bucket Curl Hi function is not cancelled).
machine
• Operation of the bucket Curl Hi cancel solenoid (ON or OFF) can be checked in the monitoring function.
Relative
• Since the controller detects disconnection when the solenoid output is turned ON, be sure to turn the
information
solenoid output ON when checking for reproduction of the failure after repair. (For the method of check-
ing the ON/OFF state of the output, see troubleshooting for failure code [DW4XKB].)

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

Presumed cause and
harness (Disconnection Wiring harness between CP03 (female) (38), A05, and Resistance
2 Max. 1 z
or defective contact with V03 (female) (2) value
connector) Wiring harness between CP03 (female) (3), J08, and Resistance
Max. 1 z
V03 (female) (1) value
Voltage Max. 1 V
44 PC600-8
Electrical circuit diagram related to bucket curl Hi cancel solenoid
PC600-8 45
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C
Action code Failure code Failure Bucket Curl Hi Cancel Sol. S/C
— DW4XKB phenomenon (Pump controller system)
• Abnormal current flowed to the bucket Curl Hi cancel solenoid circuit, when power was supplied to the
Failure content
circuit.
• Power supply to the bucket Curl Hi cancel solenoid circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
• When the bucket and other work equipment are operated simultaneously, the speed of the other work
occurring on
equipment is low (The bucket Curl Hi function is not cancelled).
machine
Relative • Operation of the bucket Curl Hi cancel solenoid (ON or OFF) can be checked in the monitoring function.

Bucket Curl Hi cancel position during the troubleshooting.
1

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

ing +
20 – 30 V
Other work equipment
operation
46 PC600-8
Electrical circuit diagram related to bucket curl Hi cancel solenoid
PC600-8 47
Failure code [DWK0KA] 2-stage Relief Sol. Disc.
Action code Failure code Failure 2-stage Relief Sol. Disc.

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

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

Presumed cause and
harness
(female) (2) value
Max. 1 z
J08, CP03 (female) (3), (13), (23) value
Voltage Max. 1 V
48 PC600-8
Electrical circuit diagram related to 2-stage relief solenoid
PC600-8 49
Failure code [DWK0KB] 2-stage Relief Sol. S/C
Action code Failure code Failure 2-stage Relief Sol. S/C

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

2-stage relief solenoid position during the troubleshooting.
defective V08 (male) Resistance value
1
Between (2) and (1) 20 – 60 z
Presumed cause and
or grounding fault)
2
circuit) Min. 1 Mz
3 Pump controller defective CP03 Travel control lever Voltage
Between (17) and Neutral Max. 1 V
grounding Travel operation (Note) 20 – 30 V
Note: May be measured under the condition of "Power max. switch ON (for 8.5 seconds)" or "Single boom
RAISE operation".
50 PC600-8
Electrical circuit diagram related to 2-stage relief solenoid
PC600-8 51
Failure code [DX16KA] Fan Pump EPC Sol. Disc.
Action code Failure code Failure Fan Pump EPC Sol. Disc.
— DX16KA phenomenon (Pump controller system)
Failure content • No current flows in hydraulic fan EPC solenoid circuit.
Response from • 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 • Fan motor speed cannot be controlled.
machine
• If fan EPC solenoid system has disconnection or short circuit, fan cannot be reversed.
Relative
• Output (current) to hydraulic fan EPC solenoid can be checked with monitoring function.
information
(Code No. 31623: Hydraulic fan EPC solenoid current)

1 EPC solenoid (Internal
V13 (male) Resistance
disconnection)
Between (1) – (2) 7 – 14 z
starting switch ON.
Presumed cause and
harness (Disconnection Wiring harness between CP03 (female) (35) – V13

tact in connector) Wiring harness between V13 (female) (2) – CP03
Resistance Max. 1 z
(female) (3), (13), (23)
troubleshooting.
Wiring harness between CP03 (female) (35) – V13
3 with 24 V circuit) in wiring Voltage Max. 1 V
harness
Wiring harness between V13 (female) (2) – CP03
Voltage Max. 1 V
(female) (3), (13), (23)
starting switch ON.
CP03 (female) Resistance
Between (35) – (3), (13), (23) 7 – 14 z
52 PC600-8
PC600-8 53
Failure code [DX16KB] Fan Pump EPC Sol. S/C
Action code Failure code Failure Fan Pump EPC Sol. S/C
— DX16KB phenomenon (Pump controller system)
Failure content • Abnormal current flowed in hydraulic fan EPC solenoid circuit.
Response from • 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 • Fan motor speed cannot be controlled.
machine
• If fan EPC solenoid system has disconnection or short circuit, fan cannot be reversed.
Relative
• Output (current) to hydraulic fan EPC solenoid can be checked with monitoring function.
information
(Code No. 31623: Hydraulic fan EPC solenoid current)

EPC solenoid (Internal V13 (male) Resistance
1
short circuit or ground

Between (1) – (2) 7 – 14 z
Presumed cause and
fault)
GND circuit) Wiring harness between CP03 (female) (35) – V13
starting switch ON.
3 Defective pump controller CP03 (female) Resistance
Between (35) – (3), (12), (23) 7 – 14 z
54 PC600-8
PC600-8 55
Failure code [DXA0KA] TVC Sol. Disc.
Action code Failure code Failure TVC Sol. Disc.

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

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

Presumed cause and
Wiring harness between CP03 (female) (16) and S25 Resistance
(female) (3) value
harness
Wiring harness between S25 (female) (2) and V11 Resistance
(female) (1) value
tor) Wiring harness between CP03 (female) (3) and S25 Resistance
Max. 1 z
(female) (6) value
Wiring harness between S25 (female) (5) and V11 Resistance
Max. 1 z
(female) (2) value
Between wiring harness between CP03 (female) (16)
4 with 24 V circuit) in wiring Voltage Max. 1 V
and S25 (female) (3) and grounding
harness
Between wiring harness between S25 (female) (2) and
Voltage Max. 1 V
V11 (female) (1) and grounding
Between (16) and (3) 10 – 22 z
56 PC600-8
Electrical circuit diagram related to TVC solenoid
PC600-8 57
Failure code [DXA0KB] TVC Sol. S/C
Action code Failure code Failure TVC Sol. S/C

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

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

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

2 drive switch
or grounding fault) Between (3) and (4) Min. 1 Mz
NORML position
harness Between wiring harness between CP03 (female) (16) Resistance
3 Min. 1 Mz
(Contact with grounding and S25 (female) (3) and grounding value
circuit) Between wiring harness between S25 (female) (2) and Resistance
Min. 1 Mz
V11 (female) (1) and grounding value
4 Pump controller defective CP03 (female) Resistance value
Between (16) and (3) 10 – 22 z
58 PC600-8
Electrical circuit diagram related to TVC solenoid
PC600-8 59
Failure code [DY20KA] Wiper Working Abnormality
Single wiper specification
Action code Failure code Failure Wiper Working Abnormality

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

M05 (female) Windshield wiper blade Resistance value
Wiper motor defective
1 At upper end of operation
(Internal disconnection) Max. 1 z
range
Between (6) and (5)
Outside upper end of

Min. 1 Mz
operation range
Presumed cause and
harness Wiring harness between CM01 (female) (5) and M05 Resistance
2 Max. 1 z
(Disconnection or faulty (male) (6) value
contact with connector) Resistance
Wiring harness between M05 (male) (5) and grounding Max. 1 z
value
CM01 Wiper blade Voltage
Machine monitor
3 At upper end of
defective Max. 1 V
operation range
Outside upper end of
20 – 30 V
operation range
60 PC600-8
Electrical circuit diagram related to wiper motor (Single wiper specification.)
PC600-8 61
Failure code [DY20MA] Wiper Parking Abnormality
Double wiper specification
Action code Failure code Failure Wiper Parking Abnormality

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

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

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

4 grounding
defective Operation range 20 – 30 V
CM01 Lower wiper blade Voltage
Retraction range Max. 1 V
Operation range 20 – 30 V
62 PC600-8
Electrical circuit diagram related to wiper motor (Double wiper specification.)
PC600-8 63
Action code Failure code Failure Wiper Parking Abnormality

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

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

Presumed cause and
harness
(male) (4) value
tor) Resistance
Between wiring harness M05 (male) (5) and grounding Max. 1 z
value
Machine monitor CM01 Wiper blade Voltage
3
defective
Between (12) and Retraction range Max. 1V
grounding Operation range 20 – 30 V
64 PC600-8
Electrical circuit diagram related to wiper motor (Single wiper specification.)
PC600-8 65
Failure code [DY2CKB] Washer Drive S/C
Action code Failure code Failure Washer Drive S/C

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

Window washer drive position for the troubleshooting.
1 motor defective
M06 (male) Resistance value
Between (1) and (2) 5 – 20 z
Presumed cause and
2 with 24 V circuit) in wiring Between wiring harness from CM01 (female) (3) and
harness M06 (female) (2), or between wiring harness between Voltage Max. 1 V
CM01 (female) (3) and D04 (female) (6) and grounding
Machine monitor CM01 Window washer switch Voltage
3
defective
OFF 20 – 30 V
ON Max. 1 V
66 PC600-8
Electrical circuit diagram related to window washer motor
PC600-8 67
Failure code [DY2DKB] Wiper Drive (For) S/C
Action code Failure code Failure Wiper Drive (For) S/C

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

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

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

Grounding fault of wiring Between wiring harness between CM01 (female) (9)
Resistance
harness and M05 (male) (3) or between CM01 (female) (9) and Min. 1 Mz
4 value
(Contact with grounding D04 (female) (3) and grounding
circuit) Between wiring harness between CM01 (female) (5),
Resistance
M15 (male) (3) or between CM01 (female) (5) and D04 Min. 1 Mz
value
(female) (4) and grounding
Machine monitor
defective CM01 Upper wiper switch Voltage
(Upper wiper motor) OFF Max. 3 V
ON 20 – 30 V (Note)
5
Machine monitor
defective CM01 Lower wiper switch Voltage
(Lower wiper motor) OFF Max. 3 V
ON 20 – 30 V (Note)
Note: When the upper wiper and lower wiper are operated simultaneously: Max. 3 V 20 – 30 V (at regular
intervals)
68 PC600-8
Electrical Circuit diagram related to wiper motor (Double wiper specification)
PC600-8 69
Action code Failure code Failure Wiper Drive (For) S/C

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

1 (Internal short-circuiting M05 (female) Continuity and resistance value

Presumed cause and

2
circuit) Min. 1 Mz
and M05 (male) (3) and grounding value
Machine monitor CM01 Wiper switch Voltage
3
defective OFF Max. 3 V
Between (9) and grounding Max. 3 V 20 – 30 V
ON
(at constant cycle)
70 PC600-8
Electric circuit diagram related to wiper motor (Single wiper specification.)
PC600-8 71
Failure code [DY2EKB] Wiper Drive (Rev) S/C
Action code Failure code Failure Wiper Drive (Rev) S/C

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

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

Presumed cause and

2
circuit) Min. 1 Mz
and M05 (male) (1) and grounding value
3
defective OFF Max. 3 V
Between (10) and
grounding Max. 3 V 20 – 30 V
ON
(at constant cycle)
72 PC600-8
SEN00451-03
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up

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 1
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
2 PC600-8
E-1 Engine does not start (Engine does not rotate)
Failure
• The engine does not start. (Engine does not rotate)
information
Relative
• The engine starting circuit is equipped with the start lock mechanism of work equipment lock lever type.
information

Battery capacity position during the troubleshooting.
1
insufficient Battery voltage Electrolyte specific gravity
Min. 24 V Min. 1.26
Circuit breakers No. 1 or If a circuit breaker is turned OFF or a fuse is broken, the circuit probably has ground-
2
6 or fuse 2, 3, 6 defective ing fault (See cause 9).
position or start the engine during the troubleshooting.
Starting switch defective M06 (male) Starting switch Resistance value
3
OFF Min. 1 Mz
Between (1) and (4)
ON Max. 1 z
Work equipment lock
4 switch defective S14 (female) Work equipment lock lever Resistance value
(Internal short-circuiting) FREE Min. 1 Mz

Between (1) and (3)
Presumed cause and
LOCK Max. 1 z
Starting motor cut-out R06 (female) and R07 (female) Resistance value
5 relay defective
Between (1) and (2) 100 – 500 z
(Internal defect)
Between (3) and (5) Min. 1 Mz
Between (3) and (6) Max. 1 z
a Turn the engine starting switch OFF for the preparations (with the wiring harness
connected), and start the engine for troubleshooting.
Starting motor Voltage
B (Power
Between B and grounding 20 – 30 V
supply)
Starting motor defective
6 Between ST (1)
(Internal defect) S (Start) 20 – 30 V
and grounding
Between ST (2)
R (Charge) Max. 1 V
and grounding
If the above voltages are normal and the starting motor does not rotate, the starting
motor has a defect in it or the engine is defective.
a Turn the engine starting switch OFF for the preparations (with only wiring harness
Alternator defective R disconnected), and hold it in the ON position during the troubleshooting.
7
(Internal short-circuiting) Alternator Voltage
Between terminal R and grounding Max. 1 V
PC600-8 3

Wiring harness between battery relay terminal B and Resistance
Max. 1 z
B16 value
Resistance
Wiring harness between B26 and H06 (female) (1) Max. 1 z
value
Wiring harness between H06 (female) (4) and R06 Resistance
(female) (5) value
harness
Wiring harness between R06 (female) (3) and ST Resistance
(female) (1) value
tor) Resistance
Wiring harness between F01-3 and S14 (male) (1) Max. 1 z
value
Wiring harness between S14 (male) (3) and R06 Resistance
Max. 1 z
(female) (1) value
Wiring harness between R06 (female) (2) and R07 Resistance
Max. 1 z
(female) (6) value

Presumed cause and
Wiring harness between R07 (female) (3), J04, A07 and Resistance
Max. 1 z
grounding value
Between wiring harness between B26 and H06 (female) Resistance
Min. 1 Mz
(1) and grounding value
Between wiring harness between H06 (female) (4) and Resistance
Min. 1 Mz
R06 (female) (5) and grounding value
Grounding fault of wiring Between wiring harness between R06 (female) (3) and Resistance
Min. 1 Mz
harness ST (female) (1) and grounding value
9
(Contact with grounding Between wiring harness between F01-3 and S14 (male) Resistance
circuit) Min. 1 Mz
(1) and grounding value
Between wiring harness between S14 (male) (3) and Resistance
Min. 1 Mz
Between wiring harness between R06 (female) (2) and Resistance
Min. 1 Mz
Between wiring harness between R06 (female) (2) and Resistance
Min. 1 Mz
CM02 (female) (14) and grounding value
10 with 24 V circuit) in wiring Between wiring harness between ST (female) (2) and
harness alternator terminal R or between ST (female) (2), J02
Voltage Max. 1 V
and D01 (female) (6) or between ST (female) (2) and
CM02 (female) (11) and grounding
4 PC600-8
Electrical circuit diagram for engine preheating, starting, charging
PC600-8 5
E-2 Preheater does not operate
Failure (1) When the starting switch is turned to the HEAT posi-
• The preheater does not operate.
information tion, the preheating monitor does not light up.
• The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about
Relative 30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds).
information • Input of the preheating signal (ON or OFF) can be checked in the monitoring function.

Starting switch system If the preheater does not operate (the heater unit is not warmed), carry out trouble-
1
defective shooting (2).
Presumed cause and
Wiring harness between CM02 (female) (18) and J02 Resistance
tor) (male) (7) value
a Turn the engine starting switch OFF for the preparations , and hold it in the OFF or
HEAT position during troubleshooting.
Machine monitor CM02 Starting switch Voltage
3
defective
Between (18) and OFF Max. 1 V
grounding HEAT 20 – 30 V
Failure (2) When the starting switch is turned to the HEAT

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

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF or
HEAT position during troubleshooting.
Starting switch defective H06 (male) Starting switch Resistance value
1
OFF Min. 1 Mz
Between (1) and (3)
HEAT Max. 1 z
a Turn the engine starting switch OFF for the preparations (with the wiring harness
connected), and hold it in the OFF or HEAT position during troubleshooting.
Continuity and
Heater relay defective Heater relay Starting switch
resistance value
Presumed cause and
2
Between coil terminal
OFF Continued
and grounding
Between contact terminals HEAT Max. 1 z
Intake air heater position during the troubleshooting.
3 defective
Intake air heater Continuity
Between terminals Continued
Wiring harness between H06 (female) (3), J02, and Resistance
Max. 1 z
heater relay terminal R17 value
Disconnection of wiring Wiring harness between battery relay terminal B and Resistance
harness Max. 1 z
heater relay R15 value
Wiring harness between heater relay terminal R16 and Resistance
tor) intake air heater value
Resistance
Wiring harness between intake air heater and engine Max. 1 z
value
6 PC600-8
Electrical circuit diagram for engine preheating, starting, charging
PC600-8 7
E-3 Auto engine warm-up device does not work
Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine coolant temperature is below 30°C, and
raise the engine rotation up to 1,200 rpm.
Relative • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
information than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.
• If the engine coolant temperature is below 10°C, the turbocharger protection function operates to keep
the engine speed below 1,000 rpm for up to 5 seconds after the engine is started.

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

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

1 Engine coolant temperature
temperature signal fault 04107 indication with the actual
(low temperature)
engine coolant temperature.
If the display on the machine monitor is abnormal, carry out troubleshooting in "E-12
Engine coolant temperature gauge does not display correctly".
Engine controller If cause 1 is not detected, the engine controller may be defective. (Since trouble is in
2
defective the engine controller, troubleshooting cannot be carried out.)
8 PC600-8
E-4 Auto-decelerator does not operate
Failure
• The auto-decelerator does not operate.
information
• Since the auto-decelerator is set to 1,400 rpm, it does not operate if the fuel control dial is not set above
this level.
Relative
• Check the display on the monitor panel while the engine is running.
information
• If the display on the monitor panel is abnormal, carry out troubleshooting in E-18 to E-25 " is not
displayed normally in monitoring function".

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

Presumed cause and

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

If the fuse is blown, there is a big possibility that grounding fault occurred in the cir-
1 Fuse No. 3 fault
cuit. (See cause 6.)
Safety lock switch
2 defective S14 (female) Safety lock lever Resistance value
(Internal disconnection) Free Max. 1 z
Between (1) and (2)
Lock Min. 1 Mz
PPC lock solenoid defec-
tive
3 (Internal disconnection, V01 (male) Resistance value
short-circuiting, or Between (2) and (1) 20 – 60 z
grounding fault)
Presumed cause and
Assembled-type diode position during the troubleshooting.
4 D01 defective
Disconnection of wiring Resistance
harness Wiring harness between F01-3 outlet and S14 (male) (1) Max. 1 z
value
Wiring harness from S14 (male) (2) and V01 (female) Resistance
tor) (2) value
Resistance
Wiring harness between V01 (female) (1) and grounding Max. 1 z
value
Between wiring harness between F01-3 outlet and S14 Resistance
harness Min. 1 Mz
6 (male) (1) and grounding value
(Contact with grounding
circuit) Wiring harness from S14 (male) (2) to V01 (female) (2),
Resistance
or between wiring harness between S14 (male) (2) and Min. 1 Mz
value
D01 (female) (4) and grounding
10 PC600-8
Electrical circuit diagram for PPC lock solenoid
PC600-8 11
E-6 Power max. function does not operate
Failure
• Power max. function does not operate
information
• If the power max. switch is pressed while the engine is running, the power max. monitor is displayed on
Relative the monitor panel.
information • Input condition of the power max. switch (left knob switch) (ON or OFF) can be checked in the monitor-
ing function. (Code No. 02200: Switch input 1)

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

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


Presumed cause and
Machine push-up switch

1 defective S05 (female) Machine push-up switch Resistance value
(Internal short-circuiting) Low pressure position Max. 1 z
Between (1) and (2)
High pressure position Min. 1 Mz
Hot short (Short circuit position during troubleshooting.
2 with 24 V circuit) in wiring Between wiring harness between S05 (male) (2), J01
harness and V06 (female) (2) or between S05 (male) (2) and Voltage Max. 1 V
Electrical circuit diagram related to machine push-up solenoid
PC600-8 13
Failure • Machine push-up function does not operate

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

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

4 D03 defective
Disconnection of wiring Resistance
harness Wiring harness between F01-2 outlet and S05 (male) (1) Max. 1 z
value
Wiring harness between S05 (male) (2), J01 and V06 Resistance
Resistance
Wiring harness between V06 (female) (1) and grounding Max. 1 z
value
Grounding fault of wiring Between wiring harness between F01-2 outlet and S05
Resistance
harness (male) (1) or between F01-2 outlet and related circuits Min. 1 Mz
6 value
(Contact with grounding and grounding
circuit) Between wiring harness between S05 (male) (2), J01
Resistance
and V06 (female) (2) or between S05 (male) (2) and Min. 1 Mz
value
14 PC600-8
E-8 Any item is not displayed on machine monitor
Failure • Any item is not displayed on the machine When the starting switch is turned ON, any item is not
information monitor. displayed on the machine monitor.
Relative
information

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

Max. 1 z
M value
harness Between wiring harness between CM01 (female) (1), (2) Resistance
3 Min. 1 Mz
(Contact with grounding and F01-10 outlet and grounding value
circuit) Between wiring harness between F01 inlet and B21 and Resistance
Min. 1 Mz
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON or
OFF position during troubleshooting.
CM01 (female) Starting switch Voltage, Resistance value
Machine monitor
4 Between (1), (2)
defective ON Voltage: 20 – 30 V
and grounding
Between (6), (7) Resistance value:
OFF
and grounding Max. 1 z
Electrical circuit diagram related to machine monitor power supply
PC600-8 15
E-9 Part of display on machine monitor is missing
Failure Part of the display in the machine monitor is missing

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

Presumed cause and
a Turn the starting switch ON during the troubleshooting.
Machine monitor LCD If all the LCD (Liquid Crystal Display) in the machine monitor light up (i.e. the screen
1
fault becomes totally white) by the following switching operation, then the machine moni-
tor is normal.
• Switching operation: [ ] + [ A ] (push swiches simultaneously.)
Machine monitor If cause 1 is not detected, the machine monitor may be defective. (Since trouble is in
2
defective the machine monitor, troubleshooting cannot be carried out.)
E-10 Machine monitor displays contents irrelevant to the model
Failure
• The machine monitor displays contents that have nothing to do with the model on which it is installed.
information
Relative
—
information

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

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

Fuel level lowered
1 (system in normal Check the fuel level in the fuel tank. If it is low, add fuel.
condition)
Fuel level sensor fault P21 (male) Fuel level Resistance value
2
Presumed cause and
FULL (Upper limit) Approx. 12 z
EMPTY (Lower limit) 85 – 110 z
Machine monitor CM02 (female) Fuel level Resistance value
4
defective
Electrical circuit diagram related to fuel level sensor
PC600-8 17
E-12 Engine coolant temperature gauge does not display correctly

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

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

Presumed cause and
tor) Wiring harness between ENG (female) (38), JM03 and Resistance
Max. 1 z
TWTR (female) (2) value
3
(Contact with grounding Between wiring harness between ENG (female) (15) Resistance
circuit) Min. 1 Mz
and TWTR (female) (1) and grounding value
harness Between wiring harness between ENG (female) (15)
Voltage Max. 1 V
and TWTR (female) (1) and grounding
Engine controller ENG (female) Resistance value
5
defective
Between (15) and (38) 3.5 k – 90 kz
Between (15), (38) and grounding Min. 1 Mz
Machine monitor If causes 1 – 5 are not detected, the monitor panel may be defective. (Since trouble
6
defective is in the monitor panel, troubleshooting cannot be carried out.)
18 PC600-8
Electrical circuit diagram related to engine coolant high temperature sensor
PC600-8 19
E-13 Hydraulic oil temperature gauge does not display correctly

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

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

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

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

3
(Contact with grounding Between wiring harness between CM02 (female) (2) and Resistance
P21 (female) (1) and grounding value
harness Between wiring harness between CM02 (female) (2) and
Voltage Max. 1 V
P21 (female) (1) and grounding
Machine monitor CM02 (female) Fuel level Resistance value
5
defective
Electrical circuit diagram related to fuel level sensor
PC600-8 21
E-15 Swing lock monitor does not display correctly
(1) Though the swing lock switch was turned ON, the
Failure swing lock monitor does not light up.
• Swing lock monitor does not display correctly
information (2) Though the swing lock switch was turned OFF, the
swing lock monitor lights up.
Relative • Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.
information (Code No.: 04502 Monitor input 3)

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

Presumed cause and
tor) Wiring harness from S04 (male) (2) to J03 and ground- Resistance
Max. 1 z
ing value
harness
3 Between wiring harness from CM02 (female) (17) to J07
(GND) circuit) and S04 (male) (1), or between CM02 (female) (17) to Min. 1 Mz
value
CP02 (female) (38) and grounding
4 with 24 V circuit) in wiring Between wiring harness from CM02 (female) (17) to J07
harness and S04 (male) (1), or between CM02 (female) (17) to Voltage Max. 1 V
CP02 (female) (38) and grounding
Machine monitor CM02 Swing lock switch Voltage
5
defective
Between (17) and OFF 20 – 30 V
grounding ON Max. 1 V
22 PC600-8
Electrical circuit diagram related to swing holding brake
PC600-8 23
E-16 When monitor switch is operated, nothing is displayed
Failure • When monitor switch is operated, nothing is (1) When mode selector switch is operated, working
information displayed. mode monitor is not displayed.
Relative
—
information
Presumed Cause Standard value in normalcy and references for troubleshooting

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

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

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

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

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

cause and
PC600-8 25
E-17 Wiper and window washer do not work
Failure
• Wiper and window washer do not work (1) Upper wiper does not operate
information
Relative
—
information

Upper wiper motor position during the troubleshooting.
1 defective
M05 (female) Continuity and resistance value
Between (3) and (1) Continued

Presumed cause and
harness
(male) (3) value
tor) Resistance
value
3
defective
OFF Max. 3 V
ON 20 – 30 V (Note)
intervals)
26 PC600-8
PC600-8 27
Failure
• Wiper and window washer do not work (2) Lower wiper does not operate.
information
Relative
—
information

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

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

(male) (1) value
harness
Wiring harness between S08 (male) (2), J05 and Resistance
grounding value
tor) Wiring harness between CM01 (female) (10), J02 and Resistance
Max. 1 z
M15 (male) (3) value
Wiring harness between M15 (male) (1), J05 and Resistance
Max. 1 z
grounding value
Machine monitor defec-
tive (Lower wiper switch CM02 Lower wiper switch Voltage
system) Between (15) and OFF 20 – 30 V
grounding ON Max. 1 V
4
Machine monitor defec-
tive (Lower wiper motor CM01 Lower wiper switch Voltage
system) Between (10) and OFF Max. 3 V
grounding ON 20 – 30 V (Note)
intervals)
28 PC600-8
Electrical circuit diagram related to wiper motor (double wiper specification)
PC600-8 29
Failure
• Wiper and window washer do not work. (3) Wiper does not work.
information
Relative
—
information

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

(female) (3) value
tor) Wiring harness between CM01 (male) (10) and M05 Resistance
Max. 1 z
(female) (1) value
4
circuit) Min. 1 Mz
and S12 (male) (2) value
Machine monitor position during the troubleshooting.
defective CM02 Front window Voltage
(Window rear limit switch
system) Between (15) and When installed at front 20 – 30 V
grounding When retracted at rear Max. 1 V
5 a Turn the engine starting switch OFF for the preparations, and hold it in the ON
defective
(Wiper motor system) Between (9) and grounding, OFF Max. 3 V
Between (10) and Max. 3 V 20 – 30 V
grounding ON
(Constant cycle)
30 PC600-8
Electrical circuit diagram related to wiper motor (Single wiper specification)
PC600-8 31
Failure
• Wiper and window washer do not work. (4) Window washer does not operate.
information
Relative
—
information

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

harness
Wiring harness from F01-4 outlet to J02 and M06 Resistance
(female) (1) value
tor) Wiring harness from M06 (female) (2) and CM01 Resistance
Max. 1 z
(female) (3) value
harness
4 Between wiring harness from F01-4 outlet to J04 and
circuit) M06 (female) (1), or F01-4 outlet to D04 (female) (2), Min. 1 Mz
value
and to other relative circuits and grounding
Machine monitor CM01 Washer switch Voltage
5
defective
OFF 20 – 30 V
ON Max. 1 V
32 PC600-8
Electrical circuit diagram related to window washer motor
PC600-8 33
E-18 "Boom Raise" is not correctly displayed in monitoring function
"Boom Raise" is not correctly displayed in the moni-

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

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

(female) (2) value
Presumed cause and

tor) Resistance
value
3
circuit) Min. 1 Mz
Voltage Max. 1 V
a Turn the engine starting switch OFF for the preparations, and start the engine
R.H. work equipment
control lever
Between (10) and NEUTRAL 20 – 30 V
grounding Boom RAISE Max. 1 V
Electrical circuit diagram related to boom Raise PPC pressure switch
34 PC600-8
PC600-8 35
E-19 "Boom Lower" is not correctly displayed in monitoring function
"Boom Lower" is not correctly displayed in the moni-

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

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

(female) (2) value
Presumed cause and

tor) Resistance
value
3
circuit) Min. 1 Mz
Voltage Max. 1 V
R.H. work equipment
control lever
grounding Boom LOWER Max. 1 V
36 PC600-8
Electrical circuit diagram related to boom Lower PPC pressure switch
PC600-8 37
E-20 "Arm IN" is not correctly displayed in monitoring function
Failure • "Arm IN" is not correctly displayed in monitoring "Arm IN" is not correctly displayed in the monitoring
information function function (special function) on the machine monitor.
Relative
—
information

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

(female) (2) value
Presumed cause and

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

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

(female) (2) value
Presumed cause and

tor) Resistance
value
3
circuit) Min. 1 Mz
Voltage Max. 1 V
L.H. work equipment
control lever
grounding Arm OUT Max. 1 V
Electrical circuit diagram related to arm OUT PPC pressure switch
PC600-8 39
E-22 "Bucket CURL" is not correctly displayed in monitoring function
"Bucket CURL" is not correctly displayed in the mon-

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

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

(female) (2) value
Presumed cause and

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

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

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

(female) (2) value
Presumed cause and

tor) Resistance
value
3
circuit) Min. 1 Mz
Voltage Max. 1 V
R.H. work equipment
control lever
grounding Bucket DUMP Max. 1 V
Electrical circuit diagram related to bucket DUMP PPC pressure switch
PC600-8 41
E-24 "Swing" is not correctly displayed in monitoring function
Failure • "Swing" is not correctly displayed in monitoring "Swing" is not correctly displayed in the monitoring
information function function (special function) on the machine monitor.
Relative
—
information

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

(female) (2) value
Presumed cause and

tor) Resistance
value
3
(Contact with grounding Wiring harness between CP03 (female) (29) and P03 Resistance
(female) (2) and grounding value
harness Wiring harness between CP03 (female) (29) and P03
Voltage Max. 1 V
(female) (2) and grounding
R.H. work equipment
control lever
grounding Swing operated Max. 1 V
42 PC600-8
Electrical circuit diagram related to swing PPC pressure switch
PC600-8 43
E-25 "Travel" is not correctly displayed in monitoring function
Failure • "Travel" is not correctly displayed in the monitor- "Travel" is not correctly displayed in the monitoring
information ing function. function (special function) of the machine monitor.
Relative
—
information

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

(female) (2) value
Presumed cause and

tor) Resistance
value
3
circuit) Min. 1 Mz
Voltage Max. 1 V
Between (39) and Neutral 20 – 30 V
grounding Operated Max. 1 V
44 PC600-8
Electrical circuit diagram related to travel PPC pressure switch
PC600-8 45
E-26 Air conditioner does not work
Failure
• Air conditioner does not work.
information
Relative
—
information

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

(5) value
Presumed cause and

tor) Resistance
value
3
(Contact with grounding Between wiring harness between F01-11 outlet and M26
(GND) circuit) Voltage Min. 1 Mz
(male) (5) and grounding
Air conditioner unit M26 Voltage
4
defective Between (5) and (8) 20 – 30 V
If the above voltages are normal and the air conditioner does not operate, the air con-
ditioner unit is defective.
Electrical circuit diagram related to air conditioner
46 PC600-8
PC600-8 47
E-27 Step light does not light up or go off
Failure (1) When switch is pressed, light does not light up for
• Step light does not light up or go off
information 1 minute.
Relative
—
information

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

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

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

Wiring harness between R09 (female) (2) – CP02
starting switch ON.
Defective pump controller
(Step light switch input CP01 Step light switch Voltage
system) Between (24) – Released Max. 1 V
chassis ground Pressed 20 – 30 V
7
starting switch ON.
(Step light relay output CP02 Step light switch Voltage
system) Between (19) – Released Max. 1 V
chassis ground Pressed 20 – 30 V (60 seconds)
PC600-8 49
Failure
• Step light does not light up or go off (2) While switch is not pressed, light lights up.
information
Relative
—
information

starting switch ON.
Defective step light S13 (male) Step light switch Resistance
1
(Internal short circuit)
Released Min. 1 Mz
Between (1) – (2)
Pressed Max. 1 z
Defective step light relay starting switch ON.
2
(Internal defect) When step light relay is replaced with another relay, if condition
R09
becomes normal, step light relay is defective.
Presumed cause and
troubleshooting.
Hot short (Short circuit Wiring harness between S13 (female) (1) – J06 – CP01
3 with 24 V circuit) in wiring (female) (24), or D03 – J07 – CP03 (female) (14), (24) – Voltage Max. 1 V
harness chassis ground
Wiring harness between CP02 (female) (19) – R09
Voltage Max. 1 V
starting switch ON.
(Step light switch input CP01 Step light switch Voltage
system) Between (24) – chassis Released Max. 1 V
ground Pressed 20 – 30 V
4
starting switch ON.
(Step light relay output CP02 Step light switch Voltage
system) Between (19) – chassis Released Max. 1 V
ground Pressed 20 – 30 V (60 seconds)
50 PC600-8
Electrical circuit diagram related to step light
PC600-8 51
E-28 Electric grease gun does not operate
Failure
• Electric grease gun does not operate.
information
Relative
—
information

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

Presumed cause and
harness
Wiring harness between B01 (female) (F) and M16 Resistance
(male) (1) value
tor) Resistance
value
3
(Contact with grounding Wiring harness between B01 (female) (F) and M16 Resistance
circuit) Min. 1 Mz
(male) (1) and grounding value
If causes 1 – 3 are not detected, the grease pump may be defective. (Since trouble
4 Grease pump defective
is in the grease pump, troubleshooting cannot be carried out.)
Electrical circuit diagram related to electric grease gun
52 PC600-8
PC600-8 53
E-29 Travel alarm does not sound or does not stop sounding
(1) The alarm does not sound while the machine is trav-
Failure • Travel alarm does not sound or does not stop
eling.
information sounding.
(2) The alarm sounds while the machine is stopped.
Relative
—
information

1 Travel signal defective 01900 Lever operated: ON
Travel
If the display on the monitor panel is abnormal, carry out troubleshooting in " is
not displayed normally in monitoring function".
M14 (female) Travel lever Voltage
Travel alarm defective
2 Neutral Max. 1 V
(Internal defective) Between (1) and (2)
Presumed cause and
If the above voltages are normal and the travel alarm does not sound, the travel
alarm is defective.
harness
Wiring harness between CP03 (female) (8) and M14 Resistance
(female) (1) value
tor) Resistance
Wiring harness between M14 (female) (2) and grounding Max. 1 z
value
harness Between wiring harness between CP03 (female) (8) and
Voltage Max. 1 V
M14 (female) (1) and grounding
Neutral Max. 1 V
54 PC600-8
Electrical circuit diagram related to travel alarm
PC600-8 55
E-30 Horn does not sound

Failure
Horn does not sound.
information
Relative
information

1 Defective fuse No. 5 If fuse is broken, circuit probably has ground fault. (See Cause 6)
2 Defective horn relay If the horn sounds after replacing the relay, the relay was defective.
troubleshooting.
Between M07 (1) – chassis ground (with horn switch
Voltage 20 – 30 V
turned ON)
3 Defective high tone horn a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Resistance
Between M07 (female) (2) – chassis ground Max. 1 z
value
If above is normal, the horn is defective.
troubleshooting.
Between M08 (1) – chassis ground (with horn switch

Voltage 20 – 30 V
Presumed cause and
turned ON)
4 Defective low tone horn a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Resistance
Between M08 (female) (2) – chassis ground Max. 1 z
value
If above is normal, the horn is defective.
starting switch ON.
Disconnection in wiring Wiring harness between F01 (5) – S10 (female) – R08 Resistance
harness Max. 1 z
(female) (3) value
5 (Disconnection in wiring
Wiring harness between S10 (2) – R08 – M07 (female) Resistance
or defective contact in Max. 1 z
connector) (1) value
Wiring harness between R08 (female) (4) – M08 Resistance
Max. 1 z
(female) (1) value
starting switch ON.
Ground fault in wiring Wiring harness between F01 (5) – S10 (female) – R08 Resistance
Min. 1 Mz
harness (female) (3) and chassis ground value
6
(Short circuit with GND Wiring harness between S10 (female) (2) – R08 Resistance
circuit) Min. 1 Mz
(female) – M07 (female) (1) and chassis ground value
Wiring harness between R08 (female) (4) – M08 Resistance
Min. 1 Mz
(female) (1) and chassis ground value
56 PC600-8
Electrical circuit diagram related to horn
PC600-8 57
E-31 Bottom dump does not move

Failure
Bottom dump does not move.
information
Relative
information

Defective fuse
1 If fuse is broken, circuit probably has ground fault. (See Cause 6)
No. 5, No. 9
Defective bottom dump troubleshooting.
2
open
Between S10 (1) – (2) Voltage 20 – 30 V
Defective bottom dump troubleshooting.
3
close
Between S11 (1) – (3) Voltage 20 – 30 V
troubleshooting.
Presumed cause and
Between V20 (1) – (2) Voltage 20 – 30 V

Defective bottom dump
4
close solenoid valve a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Resistance
Between V20 (1) – chassis ground Min. 1 Mz
value
troubleshooting.
Between V21 (1) – (2) Voltage 20 – 30 V
Defective bottom dump
5
open solenoid valve a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Resistance
Between V21 (2) – chassis ground Min. 1 Mz
value
troubleshooting.
Resistance
6 Defective wiring harness Between S10 (2) – A11 – V21 (1) Max. 1 z
value
Resistance
Between S11 (3) – A11 – V20 (1) Max. 1 z
value
Failure
Bottom dump does not move.
information
Relative
information

Presumed cause and
troubleshooting.
Resistance
Between P13 (2) – A09 – CP02 (35) Max. 1 z
Defective bottom dump value
1
pressure switch a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Resistance
Between P13 (2) – chassis ground Min. 1 Mz
value
a Solenoid valve and bottom dump pressure switch are connected by hydraulic line.
58 PC600-8
Electrical circuit diagram related to bottom dump
PC600-8 59
©2009 KOMATSU
All Rights Reserved
60
SEN00452-02
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up

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

CO•NC valve defective
CO•NC valve defective

Servo valve defective
Jet sensor defective
Jet sensor defective

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

L.H. travel motor
Remedy A: Adjust
Remedy X: Repair or replace
Remedy
A A A A A A
No.
X X X X X X X X X X X X X X X X
Diagnosis
1
Machine "deviates to right" and work equipment speed
and swing speed are low.
q q q q q q q
2
Machine "deviates to right" and single swing speed is
particularly low.
q q q q q q
3
Machine "deviates to right" and single swing speed is
normal.
q
4 Travel relief pressure of front pump circuit is low. q
Machine "deviates to right"
5
(Deviation does not change).
q q q
When result of 4 is nor-
6
mal, exchange front and Machine "deviates to left"
rear outlet hoses of No. 2 (Deviation changes).
q q
pump.
7
Speed of both travel motors
is low.
q q
8
When phenomenon of 5 occurs, servo valve of No. 1
front pump is normal.
q
9
front pump is normal.
q
10
When phenomenon of 7 occurs, jet sensor differential
pressure of right side 5-spool valve is abnormal.
q
11
When result of 10 is normal, No. 1 front NC valve output
pressure is abnormal.
q
12
Machine "deviates to left" and work equipment speed is
low.
q q q q q q q
13
Machine "deviates to left" and bucket dump speed is
particularly low.
q q q q q q
14
Machine "deviates to left" and bucket dump speed is
normal.
q
15 Travel relief pressure of rear pump circuit is low. q
Machine "deviates to left"
16
Machine "deviates to left"
(Deviation does not change).
q q q
When result of 15 is nor-
17
mal, exchange front and
rear outlet hoses of No. 2
(Deviation changes).
q q
pump.
18
Speed of both travel motors
is low.
q
19
rear pump is normal.
q
20
rear pump is normal.
q
21
When phenomenon of 18 occurs, jet sensor differential
pressure of left side 4-spool valve is abnormal.
q
22
When result of 18 is normal, No. 1 front NC valve output
pressure is abnormal.
q
6 PC600-8
How to exchange outlet hoses of No. 2 pump and hydraulic circuit diagram after they are exchanged
PC600-8 7
Information in troubleshooting table
a Tables and related circuit diagrams concerning troubleshooting contains the following information. Please
understand the contents sufficiently before carrying out troubleshooting.
Failure
Phenomena on machine
Phenomenon
Related
Information concerning to failure or troubleshooting.
Information
1
Presumed cause and
2
Causes for presumed
failure
<Contents>
(The attached No. for fil-
• Standard values for judgement of possible causes.
ing and reference pur-
• Remarks for judgement
pose only. It does not
stand for any priority)
3
8 PC600-8
PC600-8 9
H-1 Speed or power of all work equipment, travel, and swing is low
Failure
• Speed or power of all work equipment, travel, and swing is low
information
• Measure the speed of the work equipment, travel, and swing speed and check that all of them are slow
(or their power is low).
• Check that abnormal sound is not heard from around the pump.
Relative
(If abnormal sound is heard, carry out the related troubleshooting.)
information
• Check that the machine does not deviate.
(If the machine deviates, carry out the related troubleshooting.)
• Carry out all the troubleshooting in working mode P.

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

Presumed cause and
Wrong adjustment or 3.14

+0.39
MPa
0
4 malfunction of control All levers in neutral +4
relief valve {32 0 kg/cm2}
If the oil pressure is still abnormal after adjustment, check cause 5. If cause 5 is not
detected, the control relief valve operation may be defective. Check the control relief
valve directly.
a Stop the engine and block (1) – (7) in Fig. 1 in order. Run the engine at high idle
and check.
Leakage in control Control levers Control relief pressure
5
system devices +0.39
3.14 0 MPa
All levers in neutral +4
{32 0 kg/cm2}
troubleshooting.
Right work equipment control lever Main relief pressure

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

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

Wrong adjustment or All levers in neutral
Presumed cause and
7 {Min. 18 kg/cm2}
malfunction of TVC valve
+0.20
1.05 –0.53 MPa
Boom RAISE relief
+2.0
{10.7 –5.4 kg/cm2}
If the oil pressure is still abnormal after adjustment, the TVC valve may be defective.
Check the TVC valve directly.
troubleshooting.
Malfunction of CO Swing lock switch Solenoid valve outlet pressure
8
cancel solenoid valve Min. 2.74 MPa
ON
{Min. 28 kg/cm2}
OFF 0 MPa {0 kg/cm2}
Fig. 1: Control system devices
PC600-8 11
PC600-8 13
H-3 All work equipment, travel, and swing systems do not work
Failure
• All work equipment, travel, and swing systems do not work
information
Relative
information

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

Presumed cause and
Wrong adjustment or 3.14

+0.39
MPa
0
4 malfunction of control All levers in neutral +4
relief valve {32 0 kg/cm2}
If the oil pressure is still abnormal after adjustment, check cause 5. If cause 5 is not
detected, the control relief valve operation may be defective. Check the control relief
valve directly.
a Stop the engine and block (1) – (9) in Fig. 1 in order. Run the engine at high idle
and check.
Leakage in control Control levers Control relief pressure
5
system devices +0.39
3.14 0 MPa
All levers in neutral +4
{32 0 kg/cm2}
troubleshooting.
Malfunction of PPC lock Work equipment lock lever Solenoid valve outlet pressure
6
solenoid valve Min. 2.74 MPa
FREE
{28 kg/cm2}
LOCK 0 MPa {0 kg/cm2}
14 PC600-8
Fig. 1: Control system devices
PC600-8 15
H-4 Abnormal sound is heard from around pump
Failure
• Abnormal sound is heard from around pump
Phenomenon
Related
—
Information

Presumed cause and standard
1 Low hydraulic oil level Since the hydraulic oil level may be low, check it directly.
value in normalcy
Since a piping clamp between the hydraulic tank and hydraulic pump may be loos-
2 Loosened piping clamp
ened, check it directly.
Clogged hydraulic tank
3 Since the hydraulic tank strainer may be clogged, check it directly.
strainer
Internal defect of hydrau-
4 Since the hydraulic pump may have a defect in it, check it directly.
lic pump
If a cause cannot be found by troubleshooting, operate the machine as it is for a
5 Observation of condition
while and observe the condition for change.
16 PC600-8
H-5 Auto-decelerator is not reset
Failure
• Auto-decelerator is not reset (1) When machine swings, auto-decelerator is not reset.
information
• The signal pressure of the swing PPC circuit is input through the arm•swing PPC shuttle valve (swing
Relative
side) to the swing PPC pressure switch.
information
• Carry out all troubleshooting in working mode P.

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

Swing left • right stroke end
{Min. 28 kg/cm2}
Failure
• Auto-decelerator is not reset (2) When machine travels, auto-decelerator is not reset.
information
• The signal pressure of the travel PPC circuit is input through the travel PPC shuttle valve (in the travel
Relative
PPC valve) to the travel PPC pressure switch.
information

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

R.H. and L.H. forward-reverse stroke end
{Min. 28 kg/cm2}
PC600-8 17
H-6 Boom speed or power is low
Failure
• Boom speed or power is low (1) Boom speed or power is low in normal mode.
information
• The normal mode means the condition that machine push-up switch are turned OFF.
• Check that other work equipment, travel system, and swing system are normal. (If any of them is
Relative abnormal, carry out troubleshooting related to it.)
information • Check that the machine does not deviate during travel. (If the machine deviates, carry out trouble-
shooting related to travel deviation.)

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

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

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

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

Presumed cause and
troubleshooting.
Malfunction of machine Machine push-up switch Solenoid valve outlet pressure
1
push-up solenoid valve Min. 2.74 MPa
OFF
{Min. 28 kg/cm2}
ON 0 MPa {0 kg/cm2}
Malfunction of boom
The safety & suction valve of the boom regeneration valve (on the high pressure set
2 regeneration valve
side) may malfunction. Check it directly.
PC600-8 19
H-7 Arm speed or power is low
Failure
• Arm speed or power is low
Phenomenon
• Check that the speeds of the other work equipment, travel, and swing are normal.
(If they are abnormal, carry out the related troubleshooting.)
Related
Information

a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
Malfunction of left PPC
1 L.H. work equipment control lever PPC valve output pressure
valve (arm circuit)
Arm IN, OUT Min. 2.74 MPa
full stroke {Min. 28 kg/cm2}

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

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

value in normalcy
Malfunction of right PPC high idle.

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

value in normalcy
high idle.
valve (arm circuit)
Arm IN, OUT Min. 2.74 MPa
Malfunction of arm Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it
2
22 PC600-8
H-11 Bucket does not move
Failure
• Bucket does not move
Phenomenon
Related
Information

value in normalcy
high idle.
Bucket CURL, DUMP Min. 2.74 MPa
Malfunction of bucket Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it
2
H-12 Bottom dump does not move
Failure
• Bottom dump does not move
Phenomenon
• Check that operations of the other work equipment, travel and swing are normal.
Related
Information

high idle.
value in normalcy
Min. 2.74 MPa

Bucket DUMP full stroke
{Min. 28 kg/cm2}
Malfunction of right PPC high idle.
2 valve (bottom dump R.H. work equipment control lever PPC valve output pressure
circuit) Min. 2.74 MPa
Bottom dump OPEN, CLOSE full stroke
{Min. 28 kg/cm2}
Malfunction of bucket Since the spool of the bucket control valve (Hi) may have a malfunction, check it
3
PC600-8 23
H-13 Hydraulic drift of work equipment is large
Failure
• Hydraulic drift of work equipment is large (1) Hydraulic drift of boom is large
Phenomenon
Related
—
Information


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

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

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

Defective seal of bucket Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it
1
value in normalcy
Since the safety & suction valve (bottom side) of the bucket control valve (Lo, Hi)
Malfunction of bucket may have a malfunction, check it directly. (The safety & suction valve may be
2 control valve checked by replacing it with one of another work equipment circuit. After checking,
(safety & suction valve) however, be sure to return the safety & suction valve since its set pressure and struc-
ture are different from the others.)
Defective seal of bucket high idle.
3
Relieved in bucket CURL position Max. 20 cc/min
24 PC600-8
H-14 Time lag of work equipment is large
Failure
• Time lag of work equipment is large (1) Time lag of boom is large
Phenomenon
Related
—
Information

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

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

Presumed Since the safety & suction valve (bottom side) of the bucket control valve (Lo,
cause and Malfunction of bucket Hi) may have a malfunction, check it directly. (The safety & suction valve may
standard value 1 control valve (safety be checked by replacing it with one of another work equipment circuit. After
in normalcy & suction valve) checking, however, be sure to return the safety & suction valve since its set
pressure and structure are different from the others.)
PC600-8 25
H-15 Power max. function does not operate or stop
Failure
• Power max. function does not operate or stop
Phenomenon
Related
Information

a Stop the engine for the preparations, and keep it running at high idle during
the troubleshooting.
Presumed Malfunction of Power max. switch Solenoid valve outlet pressure
cause and 1 2-stage relief 0 MPa
standard value solenoid valve OFF
{0 kg/cm2}
in normalcy
Min. 2.74 MPa
ON
{Min. 28 kg/cm2}
Malfunction of main
2 The main relief valve of the control valve may malfunction. Check it directly.
relief valve
H-16 Machine push-up function does not operate or stop
Failure
• Machine push-up function does not operate or stop
Phenomenon
Related
—
Information

cause and
standard value 1 Check by (3) in "H-6 Boom speed or power is low".
in normalcy
26 PC600-8
H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is
low
Failure
• When arm and boom, bucket are operated simultaneously, boom, bucket speed is low
Phenomenon
• Check that all the operations are normal when performed singly. (If any of them is abnormal, carry out
Related
troubleshooting related to it.)
Information

Malfunction of boom, R.H. work equipment control lever Shuttle valve outlet pressure
Presumed
1 bucket PPC shuttle 0 MPa
cause and NEUTRAL
valve {0 kg/cm2}
standard value
in normalcy Min. 2.74 MPa
Boom or bucket full stroke
{Min. 28 kg/cm2}
Malfunction of control
2 valve The arm throttle valve of the control valve may malfunction. Check it directly.
(arm throttle valve)
H-18 When bucket and boom, arm, swing, travel are operated simultaneously, boom,
arm, swing, travel speed is low
Failure • When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel
Phenomenon speed is low
• Check that all the operations are normal when performed singly. (If any of them is abnormal, carry out
Related
Information

Presumed
L.H. and R.H. work equipment control
cause and Malfunction of bucket Solenoid valve outlet pressure
levers and travel lever
standard value 1 CURL Hi cancel
in normalcy solenoid valve Min. 2.35 MPa
Single operation of bucket CURL
{Min. 24 kg/cm2}
Operations other than single 0 MPa
operation of bucket CURL {0 kg/cm2}
PC600-8 27
H-19 When arm and swing are operated simultaneously, swing speed is low
Failure
• When arm and swing are operated simultaneously, swing speed is low
Phenomenon
• Check that both operations are normal when performed singly. (If either of them is abnormal, carry out
Related
Information

Malfunction of arm, L.H. work equipment control lever Shuttle valve outlet pressure
Presumed
1 swing PPC shuttle 0 MPa
cause and Neutral
valve (arm side) {0 kg/cm2}
standard value
in normalcy Min. 2.74 MPa
Arm IN or OUT full stroke
{Min. 28 kg/cm2}
The swing priority valve of the control valve may malfunction. Check it
2 valve (swing priority
directly.
valve)
28 PC600-8
H-20 Machine deviates in one direction
Failure (1) Machine deviates in the same direction, regardless

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

Troubleshooting with Carry out troubleshooting by using the judgment matrix in “Before troubleshooting H-
1
judgment matrix mode”.
Wrong adjustment of
2 See Testing and adjusting, “Testing and adjusting travel deviation”.
main pump
Presumed cause and standard value in normalcy
high idle.
3 Travel lever PPC valve output pressure
valve
FORWARD, REVERSE 2.74 MPa
Full stroke {28 kg/cm2}
Malfunction of travel
4 Since the spool of the travel control valve may have a malfunction, check it directly.
Defective travel control
5 Since the body of the travel control valve may have a malfunction, check it directly.
valve (body)
high idle.
Defective seal of center Travel lever Leakage from swivel joint
6
swivel joint
Relieved on one side Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 2.
high idle.
7 Leakage in travel motor
Travel lever Leakage from travel motor
Relieved on one side Max. 20 l/min
8 Defective travel motor Since the travel motor may be defective, check it directly.
Internal defect of final Since the final drive may have a defect in it, check it directly. (The defect can be
9
drive judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.)
Fig. 2 Defective seals in center swivel joint and travel deviation directions
PC600-8 29
Failure (2) Machine deviates in different directions, depending

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

high idle.
PPC valve
FORWARD, REVERSE 2.74 MPa
full stroke {28 kg/cm2}
Presumed cause and
high idle.
Defective seal of center Travel lever Leakage from swivel joint
3
swivel joint
Relieved on one side Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 2.
high idle.
Low set pressure of Travel lever Travel relief pressure
4
travel motor safety valve
35.3 ± 1.47 MPa
Relieved on one side
{360 ± 15 kg/cm2}
Fig. 2 Defective seals in center swivel joint and travel deviation directions
30 PC600-8
H-21 Machine deviates largely at start
Failure (1) Machine deviates only when started with travel lever
• Machine deviates largely at start
Phenomenon at full stroke
• Check that the machine does not deviate during constant-speed travel.
Related
(If the machine deviates even during constant-speed travel, carry out the related troubleshooting.)
Information

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

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

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

Full stroke on one side (Idle travel)
Presumed cause and
{Min. 17 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the CO, NC valve may have
a malfunction or may be adjusted defectively. Check the CO, NC valve directly.
Malfunction of main Since the servo-valve of main pump may have a malfunction, check it directly.
2
pump servo-valve (Test the servo-valve unit or measure its stroke.)
high idle.
Travel lever Differential pressure of jet sensor
Min. 1.5 MPa
Defective adjustment or Neutral
3 {Min. 15 kg/cm2}
malfunction of jet sensor
Max. 0.2 MPa
Full stroke on one side (Idle travel)
{Max. 2 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the relief valve may have a
malfunction or the orifice may be defective. Check the relief valve and orifice directly.
PC600-8 31
H-22 Travel deviation is large during compound operation
Failure
• Travel deviation is large during compound operation
Phenomenon
• Check that the machine does not deviate while any work equipment is not operated.
Related
(If the machine deviates, carry out troubleshooting related to travel deviation.)
Information

troubleshooting.
R.H. work equipment control lever Shuttle valve outlet pressure
Malfunction of boom,
1 0 MPa
bucket PPC shuttle valve Neutral
{0 kg/cm2}
Min. 2.74 MPa
Boom or bucket full stroke
{Min. 28 kg/cm2}
troubleshooting.
Malfunction of arm, swing L.H. work equipment control lever Shuttle valve outlet pressure
value in normalcy
2 PPC shuttle valve (arm 0 MPa

side) Neutral
{0 kg/cm2}
Min. 2.74 MPa
Arm CURL • DUMP full stroke
{Min. 28 kg/cm2}
troubleshooting.
Malfunction of arm, swing Left work equipment control lever Shuttle valve outlet pressure
3 PPC shuttle valve (swing 0 MPa
side) Neutral
{0 kg/cm2}
Min. 2.74 MPa
Swing LEFT, RIGHT full stroke
{Min. 28 kg/cm2}
4 valve The travel shuttle valve of the control valve may malfunction. Check it directly.
(travel shuttle valve)
5 valve The straight travel valve of the control valve may malfunction. Check it directly.
(straight travel valve)
32 PC600-8
H-23 Travel speed or power is low
Failure
• Travel speed or power is low
Phenomenon
Related
Information

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

Presumed cause and
Min. 2.74 MPa

Operated
{Min. 28 kg/cm2}
troubleshooting.
Malfunction of 2-stage Travel lever Solenoid valve outlet pressure
3
relief solenoid valve Neutral 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Operated
{Min. 28 kg/cm2}
troubleshooting.
Travel lever Travel relief pressure
Wrong adjustment or
4 malfunction of main relief 35.3 ± 1.47 MPa
valve Either side relieved
{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
H-24 Machine does not travel (only one track)
Failure
• Machine does not travel (only one track) (1) Machine does not travel in either direction.
Phenomenon
Related
—
Information

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

high idle.
1 Travel levers PPC valve output pressure
valve
FORWARD, REVERSE Min. 2.74 MPa
Presumed cause and
Defective travel control Since the suction valve of the travel control valve may have a malfunction, check it
3
valve (suction valve) directly. (The suction valve can be checked by replacing it with normal one.)
high idle.
Malfunction of travel Travel levers Travel relief pressure
4
motor (safety valve)
Relieved on one side 35.3 ± 1.47 MPa
(Direction in which machine does not travel) {360 ± 15 kg/cm2}
Since the counterbalance valve of the travel motor may have a malfunction, check it
5 motor
directly.
(counterbalance valve)
34 PC600-8
H-25 Travel speed does not change
Failure
• Travel speed does not change
Phenomenon
• Check that the Lo and Hi travel speeds are normal.
Related • The travel speed selection system has the automatic speed changing function. If the oil pressure rises
Information above 33.4 MPa {340 kg/cm2} during travel, the travel speed is changed to Lo even while the machine
is traveling at Hi (Hi is still displayed on the monitor panel).

Presumed cause and
high idle.
Malfunction of travel Travel speed select switch Solenoid valve outlet pressure
1 speed select solenoid
valve Lo 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Hi
{Min.28 kg/cm2}
Malfunction of travel Since the servo mechanism of the travel motor may have a malfunction, check it
2
motor (servo mechanism) directly.
PC600-8 35
H-26 Upper structure does not swing
Failure
• Upper structure does not swing (1) Upper structure swings in neither direction.
Phenomenon
• Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out
Related troubleshooting related to it.)
Information • When carrying out the following troubleshooting, set the swing lock switch in OFF and the working
mode in the P mode.

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

troubleshooting.
valve (swing circuit)
Min. 2.74 MPa

Swing RIGHT, LEFT full stroke
Presumed cause and
{Min.28 kg/cm2}
2 The spool of the swing control valve may malfunction. Check it directly.
Malfunction of swing The suction valve of the swing control valve may malfunction. Check it directly.
3 control valve (The suction valves of the right and left swing control valves can be checked by
(suction valve) exchanging them with each other and seeing the change of the phenomenon.)
The suction valve of the swing motor may malfunction. Check it directly.
4 (The suction valves of the right and left swing motors can be checked by exchanging
motor (suction valve)
them with each other and seeing the change of the phenomenon.)
The check valve of the swing motor may malfunction. Check it directly.
5 (The check valves of the right and left swing motors can be checked by exchanging
motor (check valve)
36 PC600-8
H-27 Swing speed or acceleration is low
Failure (1) Swing speed or acceleration is low in both direc-

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

troubleshooting.
1 Leakage in swing motor
L.H. work equipment control lever Leakage from swing motor
Swing relief (in either direction) Max. 10 l/min
Presumed cause and
troubleshooting.
Wrong adjustment or
Swing machinery may have a defect in it. Check it directly. (The swing machinery
Swing machinery
5 can be checked by abnormal sound, abnormal heating, metal dust in the drained oil,
etc.)
Failure (2) Swing speed or acceleration is low in only one direc-

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

troubleshooting.
Min. 2.74 MPa

Presumed cause and
{Min. 28 kg/cm2}
Malfunction of swing The suction valve of the swing control valve may malfunction. Check it directly. (The
3 control valve suction valves of the right and left swing control valves can be checked by exchang-
(suction valve) ing them with each other and seeing the change of the phenomenon.)
motor (check valve)
PC600-8 37
H-28 Upper structure overruns excessively when it stops swinging
Failure • Upper structure overruns excessively when it (1) Upper structure overruns excessively when it stops
Phenomenon stops swinging swinging in both directions.
Related
—
Information

troubleshooting.

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

troubleshooting.
Min. 2.74 MPa

Presumed cause and
{Min. 28 kg/cm2}
The suction valve of the swing control valve may malfunction. Check it directly.
Malfunction of swing con-
3 (The suction valves of the right and left swing control valves can be checked by
trol valve (suction valve)
exchanging them with each other and seeing the change of the phenomenon.)
motor (check valve)
38 PC600-8
H-29 Large shock is made when upper structure stops swinging
Failure • Large shock is made when upper structure (1) Large shock is made when the upper structure stops
Phenomenon stops swinging swinging in both directions.
Related • When carrying out the following troubleshooting, set the working mode in the P mode and turn the
Information swing lock switch OFF.

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

troubleshooting.
Presumed cause and
Malfunction of left PPC L.H. work equipment control lever PPC valve output pressure
1
valve (swing circuit) Neutral 0 MPa {0 kg/cm2}
Min. 2.74 MPa
{Min. 28 kg/cm2}
PC600-8 39
H-30 Large abnormal sound is made when upper structure stops swinging
Failure • Large abnormal sound is made when upper (1) Large abnormal sound is made when the upper
Phenomenon structure stops swinging structure stops swinging in both directions.
Related
—
Information

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

Presumed cause and
Malfunction of swing The suction valve of the swing control valve may malfunction. Check it directly.
1 control valve (The suction valves of the right and left swing control valves can be checked by
(suction valve) exchanging them with each other and seeing the change of the phenomenon.)
40 PC600-8
H-31 Hydraulic drift of swing is large
Failure
• Hydraulic drift of swing is large (1) While the swing holding brake is applied.
Phenomenon
Related
• When carrying out the following troubleshooting, set the working mode in the P mode.
Information

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


Presumed cause and
2 control valve The suction valve of the swing control valve may malfunction. Check it directly.
(suction valve)
3 The safety valve of the swing motor may malfunction. Check it directly.
motor (safety valve)
4 The suction valve of the swing motor may malfunction. Check it directly.
5 The check valve of the swing motor may malfunction. Check it directly.
motor (check valve)
PC600-8 41
©2009 KOMATSU
All Rights Reserved
42
SEN00453-02
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up

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 1
2 PC600-8
Method of using troubleshooting chart

The troubleshooting chart consists of the "ques-
tions", "check items", "causes", and "troubleshoot-
ing" blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right. The items in A are basic ones. The items
in B can be drawn from the user or operator,
depending on their level.
[Check items]
Simple check items used by the serviceman to
narrow the causes. They correspond to C in the
chart on the right.
[Causes]
Items to be narrowed from the questions and
check items. The serviceman narrows down the
probable causes from A, B, and C.
[Troubleshooting]
Items used to find out the true cause by verifying
the narrowed causes finally in order from the
most probable one by applying troubleshooting
tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the
causes cannot be narrowed, however, you may apply them.)
PC600-8 3
<Example of troubleshooting> Exhaust gas 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].
4 PC600-8
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 5
S-1 Starting performance is poor
General causes why starting performance is poor Causes
• Defective electrical system
Cracked EGR cooler (Coolant in exhaust pipe)

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

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

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

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

Clogged air cleaner element
Clogged fuel filter, element

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

Degree of use of
machine Operated for long period EE EE E
Became worse gradually Q Q w w Q Q
Starting performance
w
Questions
Engine starts easily when warm

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

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

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

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

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

General causes why engine does not turn
Defective starting motor (safety relay section)

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

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

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

Broken flywheel ring gear
• Defective electrical system
Defective starting switch

Defective battery relay
• Defective hydraulic pump or PTO

Degree of use of
Questions
Operated for long period EEE

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

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

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

q
terminal E
When terminal B and terminal C of starting switch are connected,

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

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

—
8 PC600-8

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

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

Wrong connection of supply pump PCV

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

Broken supply pump shaft, key

• Improper selection of fuel (particularly in winter)
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

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

machine
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w EE
Replacement of filters has not been carried out according to Operation and Main-
w w E Q
tenance Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is not fuel in it w w
w
Check items
Fuel is leaking from fuel piping

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

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

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

General causes why exhaust smoke comes out but engine does not start
Leaking or clogged fuel system, entry of air

• Lack of rotating force due to defective electrical system

Defective intake air heater system

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

Clogged fuel filter, strainer

Use of improper fuel

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

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

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

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

Seized turbocharger, interference of turbocharger

• Defective condition of fuel spray


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

because of an error in electrical system)


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

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

Non-specified fuel is being used w w w w
w w w
nance Manual
Oil must be added more frequently w
Rust and water are found when fuel tank is drained w w
Q w
some cylinders is low
Color of exhaust Blue under light load w
Check items
gas Black w Q w w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q

Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” q
Troubleshooting
Inspect valve clearance directly q

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

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

• Seized parts inside engine

• There is overheating
Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Defective hydraulic pump or PTO

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

Leaking, clogged fuel piping
Broken, seized feed pump

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

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

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

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

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

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

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

• Defective bypass valve
Defective Ne speed sensor, wiring harness

Defective G speed sensor, wiring harness

Defective operation of bypass valve
Defective operation of EGR valve

Low setting of low idle speed

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

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

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

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

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

Defective fuel temperature sensor, wiring harness

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

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


Air leakage from air intake piping

Leaking, clogged fuel piping

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

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

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

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

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

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


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

• Defective condition of fuel injection


Improper fuel injection pressure

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

Crushed, clogged muffler
Abnormally worn injector

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

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

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

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

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

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

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

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

Clogged breather, breather hose
Worn seal at turbocharger end
Oil leakage from oil drain plug

• External leakage of oil
Worn, damaged rear oil seal
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

• Wear of parts in lubrication system
Broken piston ring
Broken oil cooler

Degree of use of
Questions
Operated for long period EEEE E

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

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

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

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

• Clogging of lubrication passage
Clogged breather, breather hose

• Use of improper fuel
Defective oil filter safety valve

• Use of improper oil
Worn valve, valve guide

Worn EGR valve guide
Exhaust smoke is bad

• Operation under excessive load
Clogged oil cooler

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

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

See S-7
Inspect breather and breather hose directly q

Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
18 PC600-8
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes

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

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

Defective feed pump oil seal
Defective spray by injector

Degree of use of
Questions
Operated for long period EE E

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

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

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

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

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

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

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

Suddenly increased Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
w w
Check
There are excessive air bubbles in radiator, coolant spurts back

items
Pressure-tightness test of cylinder head shows there is leakage q

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

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

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

• Defective oil pressure control
• Selection of oil by the temperature etc. specified in the "Operation and
Clogged, broken pipe in oil pan
Defective oil pump relief valve
Leaking EGR hydraulic piping

Maintenance Manual" is not observed.
Clogged strainer in oil pan
Defective EGR oil pump

• Deterioration of oil due to overheatingl
Worn journal of bearing

Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Degree of use of
Operated for long period E E E
Questions
machine
Oil pressure monitor indicates low oil pressure Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and
w
Maintenance Manual
Indicates pressure drop at low idle w Q Q
Oil pressure Indicates pressure drop at low, high idle Q w w w Q Q Q
monitor 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
Check items
Oil is milky or smells of diesel oil w

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

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

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

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

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

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

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

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

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

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

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

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

• Problem in coolant circulation system
Defective coolant temperature gauge

Defective fan drive pump or motor

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

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

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

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

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

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

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

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

starting troubleshooting.
Cracked, leaking EGR gas piping

a The engine is operated in the low-temperature mode while it is not
Improper gear train backlash

warmed up sufficiently. Accordingly, the engine sound becomes
Clogged, seized injector

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

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

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

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

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

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

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

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

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

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

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

Vibration follows engine speed Q Q Q
Exhaust smoke is black w

Troubleshooting
Inspect main bearing and connecting rod bearing directly q

Inspect gear train directly q
Inspect camshaft bushing directly q
Confirm with monitoring function on machine monitor q
Inspect engine mounting bolts and cushions directly q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
—
26 PC600-8
PC600-8 27
©2009 KOMATSU
All Rights Reserved
28
SEN01062-04
PC600-8
PC600LC-8

PC600-8 30001 and up
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 1
SEN01062-04 50 Disassembly and assembly
How to read this manual 1

(Rev. 2009.1)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
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 precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
model. They have a new part num- 6 : Amount of oil or coolant to be drained
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
2 PC600-8
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special 6 : Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively. q In “Assembly” section, the work procedures,
R: Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2]••• etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in “Assem-
any modification. bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of “Sketches of a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
5
79 T- - :
* *** ****
means that they are not available
: Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
PC600-8 3
Coating materials list 1

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene, poly-
propylene, tetrafluoroethylene and vinyl chlo-
20 g Polyethylene
LT-1B 790-129-9050 ride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
Gasket sealant
• Used to seal oil pan, final drive case, etc.

• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
• Used for rough surfaces such as the circle
LG-9 gear top seal which does not need to be
ThreeBond 790-129-9310 200 g Tube clamped, water resistance of the clearance at
1206D the welded area, etc.
• Can be coated with paint.
4 PC600-8
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
LG-10 • Used as lubricant/sealant when the radiator
ThreeBond 790-129-9320 200 g Tube hoses are inserted.
Gasket sealant
1206E • Can be coated with paint.

LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
Seizure
pound with metallic super-fine-grain, etc.

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
SYG2-400T-A • Seizure resistance, heat resistance and water

Hyper White
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
PC600-8 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 PC600-8
Special tools list 1
a Tools with part number 79 T- - means that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
* *** ****
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
“Sketches of special tools”).
New/remodel
Necessity
Sketch
Q’ty
Component Symbol Part No. Part Name Nature of work, remarks
Removal and instal- 795-630-5500 Standard puller t 1

lation of fuel supply 1 01010-81090 Bolt t 2 Pulling out of drive gear
pump assembly 01643-31032 Washer t 2
Removal and instal-
lation of cylinder Tightening of cylinder head bolt,
2 790-331-1110 Wrench q 1
head assembly, flywheel bolt
engine rear seal
3 795-931-1100 Seal puller t 1 Pulling out of oil seal
795T-521-1111 Push tool t 1 N Q
Press fitting of engine front seal
4 01050-31655 Bolt t 4
(Standard type, sleeve type)
01050-31635 Bolt t 4
A 795T-521-1150 Push tool t 1 N Q Press fitting of engine front seal
5
01050-31635 Bolt t 4 (Sleeve type)
Removal and instal- 795T-421-1270 Push tool t 1 N Q

Press fitting of engine rear seal
lation of engine front 6 01050-31645 Bolt t 4 N
(Standard type)
seal, rear seal 01643-31645 Washer t 8 N
795T-421-1240 Push tool t 1 N Q
7 01050-31645 Bolt t 4 N
01643-31645 Washer t 4 N Press fitting of engine rear seal
795T-421-1250 Push tool t 1 N Q (Sleeve type)
8 01050-31645 Bolt t 4 N
01643-31645 Washer t 8 N
Disassembly, 1 796T-626-1110 Push tool t 1 Q Press fitting of bearing
assembly of swing F
machinery assembly 2 790-331-1110 Wrench t 1 Tightening of ring gear bolt
790-501-5000 Unit repair stand q 1 AC100V
Disassembly, 1 790-501-5200 Unit repair stand q 1 AC110V, 220V
assembly of final J 790-901-4110 Bracket q 1
drive assembly Disassembly, assembly of final
2 796T-627-1510 Plate q 1 Q
drive
3 796T-627-1520 Plate q 1 Q
PC600-8 7
New/remodel
Necessity
Sketch
Q’ty
790-431-1031 Block t 1
791-730-1130 Bolt t 2
790-101-2360 Plate t 2
01643-32060 Washer t 2
01580-12016 Nut t 2
4 796-627-1420 Adapter t 2 Removal of travel motor
790-201-2790 Spacer t 1
790-201-2690 Plate t 1
Puller
790-101-2102 t 1
(294 kN {30 ton})
Disassembly, 790-101-1102 Pump t 1
assembly of final J
5 796-627-1020 Installer t 1 Press fitting of floating seal
drive assembly
790-101-2510 Block t 1
791-830-1320 Rod t 2
790-101-2570 Washer t 2
01643-31645 Washer t 2
6 01580-11613 Nut t 2 Press fitting of bearing
796-627-1410 Adapter t 2
796T-627-1330 Push tool q 1 Q
790-101-2102 Puller t 1
790-101-1102 Pump t 1
7 790-331-1110 Wrench t 1 Tightening angle of cover bolt
Disassembly, 1 791-575-1520 Installer t 1 Installation of floating seal
assembly of idler 791-601-1000 Oil pump assembly q 1 Filling with oil, check sealing
assembly 2
790-701-3600 Adapter q 1 AC110 – 220 V, AC220 – 240 V
assembly of track L 791-601-1000 Oil pump assembly q 1 Filling with oil, check sealing
roller assembly 4
790-701-3600 Adapter q 1 AC110 – 220 V, AC220 – 240 V
assembly of 791-601-1000 Oil pump assembly q 1 Filling with oil, check sealing
carrier roller 6
790-701-3600 Adapter q 1 AC110 – 220 V, AC220 – 240 V
791-685-8502 Compressor t 1
791-635-3160 Extension t 1
Disassembly, Disassembly, assembly of recoil
1 Cylinder
assembly of recoil 790-101-1600 t 1 spring
(686 kN {70 ton})
spring assembly
790-101-1102 Pump t 1
2 790-201-1500 Push tool t 1 Installation of push tool
M 796-632-1200 Remover, installer t 1
Cylinder
790-101-4300 t 1
Removal and (1,471 kN {150 ton})
3
installation of track Puller
790-101-4200 t 1
shoe assembly (294 kN {30 ton})
790-101-1102 Pump t 1
4 790-331-1100 Wrench t 1
8 PC600-8
New/remodel
Necessity
Sketch
Q’ty
791-680-9580 Adapter t 1
791-680-9590 Guide t 1
1
01010-52760 Bolt t 2
01010-51440 Bolt t 2
790-101-1102 Pump t 1
2 1,471 kN
790-101-4300 Cylinder t 1
{150 ton}
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
3 791-680-9570 Adapter t 1
01010-51030 Bolt t 1
04530-12030 Eyebolt t 1
790-101-1102 Pump t 1
1,471 kN
790-101-4300 Cylinder t 1
{150 ton}
791-685-9540 Rod t 1
4
Disassembly, 791-685-9550 Nut t 3
Removal, press fitting of
assembly of 1 link at N 791-685-9510 Frame t 1
master pin and regular pin
field 791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
791-680-5520 Guide t 1
5 791-126-0140 Pusher t 1
791-680-9570 Adapter t 1
01010-51030 Bolt t 1
04530-12030 Eyebolt t 1
791-685-9620 Extension t 1
790-101-1102 Pump t 1
1,471 kN
790-101-4300 Cylinder t 1
{150 ton}
790-101-1102 Pump t 1
6 294 kN
790-101-4200 Puller t 1
{30 ton}
791-680-5542 Adapter t 1
7
791-632-1110 Adapter t 1
8 791-680-5580 Guide t 1
PC600-8 9
New/remodel
Necessity
Sketch
Q’ty
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
9
01010-51030 Bolt t 1
791-685-9620 Extension t 1
791-680-5542 Adapter t 1
791-680-5560 Guide t 1
790-101-1102 Pump t 1
1,471 kN
790-101-4300 Cylinder t 1
{150 ton}
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
Disassembly, 10 01010-51030 Bolt t 1 Removal, press fitting of
assembly of 1 link at N
field 791-685-9620 Extension t 1 master pin and regular pin
791-680-5560 Guide t 1
791-632-1110 Adapter t 1
791-680-9630 Adapter t 1
790-101-1102 Pump t 1
1,471 kN
790-101-4300 Cylinder t 1
{150 ton}
11 791-680-1520 Guide t 1
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
12
791-680-5560 Guide t 1
791-680-9570 Adapter t 1
01010-51030 Bolt t 1
791-680-1520 Guide t 1
790-101-1102 Pump t 1
1,471 kN
790-101-4300 Cylinder t 1
{150 ton}
10 PC600-8
New/remodel
Necessity
Sketch
Q’ty
790-101-1102 Pump t 1
13 294 kN
790-101-4200 Puller t 1
{30 ton}
Disassembly, 791-680-9501 Remover, installer t 1 Removal, press fitting of
assembly of 1 link at N 790-101-1102 Pump t 1 master pin and regular pin
field
294 kN
14 790-101-4200 Puller t 1
{30 ton}
1,471 kN
790-101-4300 Cylinder t 1
{150 ton}
Removal, installa-
tion of engine, PTO, S 796-660-2010 Oil stopper q 1 Stopping hydraulic oil
hydraulic pumps, etc
790-101-2501 Push-puller t 1
790-101-2510 • Block t 1
790-101-2520 • Screw t 1
Disassembly, 791-112-1180 • Nut t 1
assembly of center
1 790-101-2540 • Washer t 1 Disconnection of rotor and shaft
swivel joint assem-
bly 790-101-2630 • Leg t 2
T
790-101-2570 • Plate t 2
790-101-2560 • Nut t 2
790-101-2660 • Adapter t 2
Disassembly and 2 796T-416-1040 Push tool t 1 Q
assembly of travel 3 796T-416-1050 Push tool t 1 Q Press fitting of bushing
PPC valve assembly 4 796T-416-1020 Push tool t 1 Q
Cylinder repair Disassembly, assembly of
1 790-502-1003 q 1
stand hydraulic cylinder
2 790-720-1000 Expander q 1 Expansion of piston ring
796-720-1670 Ring q 1
3 Installation of piston ring
07281-01279 Clamp q 1
790-201-1702 Push tool kit t 1
Press fitting of
790-101-5021 • Grip 1
cylinder head bushing
01010-50816 • Bolt 1
4
Disassembly, 790-201-1871 • Push tool 1 Boom
assembly of 790-445-4210 • Push tool 1 Bucket
U
hydraulic cylinder
assembly 790-201-1881 • Push tool 1 Arm
790-101-5021 • Grip 1
01010-50816 • Bolt 1
5 Press fitting of dust seal
790-201-1680 • Plate 1
790-201-1970 • Plate 1 Bucket
790-201-1690 • Plate 1 Arm
790-102-4300 Wrench t 1
6 Removal, installation of piston
790-102-4310 Pin t 2
PC600-8 11
New/remodel
Necessity
Sketch
Q’ty
796T-670-1210 Sleeve t 1 Q Boom foot pin

796T-670-1220 Sleeve t 1 Q Boom top pin
791-775-1130 Plate t 1
796-670-1130 Screw t 1
Removal of boom, 796-870-1110 Adapter t 1
V 1
arm assembly 01643-33080 Washer t 1
Removal of pin
01803-13034 Nut t 1
Puller
790-101-4000 t 1
(490 kN {50 ton})
790-101-1102 Pump t 1
Operator’s cab 1 793-498-1210 Lifter (Suction cup) t 2 Installation of operator’s cab
Y
glass 2 20Y-54-13180 Adapter t 2 glass
12 PC600-8
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A4. Push tool
A5. Push tool
PC600-8 13
A6. Push tool
A7. Push tool
14 PC600-8
A8. Push tool
F1. Push tool
PC600-8 15
J2. Plate
J3. Plate
16 PC600-8
J6. Push tool
36
2
5
2
100
)
49
(3
150
CDP00509
HEAT TREATMENT MATERIAL

STKM13A
PART NAME QTY
PUSH TOOL 1
796T-627-1330
T2 Push tool
PC600-8 17
T3 Push tool
T4. Push tool
18 PC600-8
V1. Sleeve
V1. Sleeve
PC600-8 19
SEN01062-04

© 2009 KOMATSU
All Rights Reserved
20
SEN01063-02
PC600-8
PC600LC-8

PC600-8 30001 and up

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 1
Removal and installation of fuel 4. Disconnect hose clamps (4).

supply pump assembly 1 a Disconnect the clamp of hose (H), too.
Special tools 5. Remove frame (5).
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
795-630-5500 Standard puller t 1

A 1 01010-81090 Bolt t 2
01643-31032 Washer t 2
Removal
k Lower the work equipment to the ground
and stop the engine.
k Disconnect the cable from the negative (–)
terminal of the battery.
6. Disconnect connector M34 (6) from air condi-
tioner compressor (7).
1. Remove the counterweight assembly. For
Loosen locknut (8) and disconnect air condi-
details, see “Removal and installation of coun-
tioner compressor (7). [*1]
terweight assembly”.
a Do not disconnect air conditioner hoses.
2. Remove the fan, fan motor and shroud assem-
7. Remove air conditioner compressor belt (9).
bly (1). For details, see “Removal and installa-
tion of fan motor assembly”.
8. Disconnect clamp (10).
9. Remove bracket (11).
10. Remove blow-by hose (12).
3. Remove covers (2) and (3).
2 PC600-8
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). [*2]
13. Disconnect filter (14).

20. Disconnect lubrication tube (23). [*6]
14. Remove fuel tube (15). [*3]
15. Remove oil gauge (16).
22. Remove lubrication tube and fuel tube assem-
16. Remove fuel tube (17). [*4] bly (25).
a (25-1): Lubrication tube, (25-2): Fuel tube
[*8]
23. Remove fuel tube assembly (26). [*9]
25. Remove clamps (28).
28. Remove 4 covers (31).

17. Remove lubrication tube (18). [*5] a Remove 2 covers each from the fuel sup-
ply pump side and common rail side.
PC600-8 3
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 2·5 TOP is
almost at the top.
4 PC600-8
36. Disconnect bracket (35). Installation

37. Remove fuel supply pump (36). 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.
k Never bend a high-pressure pipe for the
convenience sake.
k Before installing a high-pressure pipe, con-
firm the following points.
If any abnormality was found, replace it
with another healthy one. Otherwise, leak-
age 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 por-
tion 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)
PC600-8 5
2. Tighten all of supply pump (36), bracket (35), q Carry out the following installation in the
and high-pressure pipes (32) temporarily with reverse order to removal.
the fingers.
[*1]
3. Tighten high-pressure pipes (32) permanently. Adjust the air conditioner compressor belt tension.
3 Sleeve nut: For details, see Testing and adjusting, “Testing and
39.2 – 58.8 Nm {4 – 6 kgm} adjusting air conditioner compressor belt tension”.
(Common rail side)
39.2 – 49 Nm {4 – 5 kgm} [*2]
(Supply pump side) 3 Sleeve nut of fuel hose (13):
43 – 47 Nm {4.4 – 4.8 kgm}
4. Tighten supply pump (36) permanently.
[*3]
5. Tighten bracket (35) permanently. 3 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)
[*4]
3 Sleeve nut of fuel tube (17):
43 – 47 Nm {4.4 – 4.8 kgm}
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.
7. Install bracket (27).
8. Tighten the brackets and upper and lower

clamps of high-pressure pipe clamps (28), [*5]
(29), and (30) temporarily with the fingers and 3 Joint bolt of lubrication tube (18):
then tighten them permanently in order. 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Clamping bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm} [*6]
3 Lubrication tube (23):
43 – 47 Nm {4.4 – 4.8 kgm}
[*7]
3 Joint bolt of fuel hose (24):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
6 PC600-8
[*8]
3 Clamp of fuel tube and lubrication tube
assembly (25): 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
3 Joint bolt of lubrication tube (25-1):
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
3 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)
[*9]
3 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)
[*10]
3 Mounting nut of fuel supply pump drive gear:
176 – 196 Nm {18 – 20 kgm}
k Check that the fuel injector wiring harness

is at least 10 mm apart from the high-pres-
sure pipe.
q Bleed air from the fuel system. For details, see

Testing and adjusting, “Bleeding air from fuel
system”.
PC600-8 7
Removal and installation of 5. Remove radiator undercover (4).

cylinder head assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
A2 790-331-1110 Wrench (Angle) q 1
Removal
terminal of the battery. 6. Drain the coolant.
6 Coolant: 58 l
terweight assembly”. 7. Remove undercover (A).
2. Sling engine hood (1) temporarily.
3. Remove pin (2).
4. Fix bolt (B) to hole (A) of bar (3) and erect

engine hood (1) upright.
8 PC600-8
9. Disconnect filter bracket (6). 12. Remove covers (9) and (10).
a Disconnect the fuel hose clamp (HC).
13. Disconnect clamps (11) and (12).

10. Disconnect reservoir tank hoses (7). a Disconnect the clamp of hose (H), too.
14. Remove stay (13).
11. Lift off frame (8).
PC600-8 9
16. Remove air hose, tube and bracket assembly 20. Disconnect fuel hose (19). [*3]
(15).
[*1] 21. Remove filter assembly (20).
a Make a mark on the tube at the end of
each hose to indicate the insertion posi- 22. Remove fuel tube (21). [*4]
tion of the hose. (See the figure below.)
23. Remove oil level gauge (22).
17. Loosen air hose clamps (16). [*2]
24. Remove fuel tube assembly (23). [*5]
25. Disconnect wiring harness (24).
19. Lift off muffler (18).

a Remove the hose clamp from the bottom.
10 PC600-8
a Disconnect the following parts from around 32. Disconnect oil tubes (26).
cover (25).
33. Remove oil filter (27).
27. Disconnect connector SBP (71).
28. Disconnect connectors BP (72), EGR (73), and

SEGR (74).
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).
Exhaust side
37. Remove covers (78) – (80).
PC600-8 11
38. Remove cover (81). 44. Remove brackets (34).
39. Remove brackets (82). 45. Disconnect lubrication tube (35). [*8]
a Disconnect lubrication tube (35) from the
40. Disconnect clamps (83) and (84). clamp and cylinder block side and take it
out after removing the exhaust manifold.
41. Remove brackets (85) – (87).
42. Disconnect bypass tube (88). [*7]
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 PC600-8
50. Sling the turbocharger, exhaust manifold and 59. Lift off pump and diffuser assembly (46).
connector assembly (39) temporarily and a Take care of exposed bleeding tube (C).
remove the exhaust manifold mounting bolts.
[*10]
51. Disconnect hose (H).
52. Lift off the turbocharger, exhaust manifold and

connector assembly (39).
4 Turbocharger, exhaust manifold and
connector assembly: 70 kg
61. Remove fuel return tube (48). [*13]
62. Remove fuel return tube (49). [*13]
63. Disconnect connector TIM (50), TFUEL (51).
64. Disconnect connector PIM (52) by the follow-

ing method. [*14]
53. Disconnect heater terminal (40). 1) Rotate housing (H1) in the direction of the
arrow.
54. Loosen clamps (41). [*11] 2) Pull housing (H1) in the direction of the
arrow.
55. Disconnect air intake connector (42).
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.
PC600-8 13
69. Lubrication tubes (59) and (60). [*16]
70. Remove bypass valve (61). [*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.
68. Disconnect lubrication tube (56). [*15]
14 PC600-8
75. Disconnect high-pressure pipe clamps (67) 80. Remove clamp (95).
and (68).
a There are clamps on the right side, too. 81. Remove cover (96).
76. Sling air intake manifold assembly (69) and 82. Remove bracket (97).
remove the mounting bolts.

77. Lift off air intake manifold assembly (69).
4
84. Remove clamps (99) and (100).
Air intake manifold assembly: 40 kg
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 screw-
driver 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]
PC600-8 15
87. Disconnect wiring harness (103). 93. Remove push rod (109).
88. Remove spill tube (104).
89. Remove cylinder head cover (105).
94. Remove capture nut (111) from fuel injector

(110) and disconnect the wiring harness.
90. By barring the engine with bolt (BB), set stamp 96. Remove holder mounting bolt (113).
of 1·6 TOP of the damper to pointer (P).
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 adjust-

ment screw (107) fully.
92. Remove rocker arm shaft assembly (108).
16 PC600-8
98. Loosen locknut (114) and adjustment screw Installation

(115). a Before installing the cylinder head, check the
following items.
99. Remove crosshead assembly (116). 1) Measure stem length (e) of every bolt.
2) Make sure that stem length (e) of every
100.Remove mounting bolts (117) and auxiliary bolt is as follows.
bolt. 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) Check that the cylinder head mounting
face and inside of the cylinder are free
from foreign matter.
5) When fitting the gasket, check that the
grommets are fitted correctly.
1. Set cylinder head gasket (119).
2. Install cylinder head (118).
PC600-8 17
a Tighten cylinder head mounting bolts (1) – 2] When not using tool A2
(6) and auxiliary bolt (7) in the following Make marks (a) and (b) on the bolts
order. and cylinder head, then retighten
a A special socket is required to tighten the each bolt by 90° +30°
+0 in the order of (1)
head bolts. – (6).
2 Mounting bolt: a After tightening bolts (1) – (6),
Molybdenum disulfide lubricant tighten auxiliary bolt (7).
(LM-P) 3 Auxiliary bolt (7)
3 Mounting bolts ((1) – (6) in the following 66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}
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°
+0 in the
order of (1) – (6).
3. Crosshead
Install crosshead (116).
a Adjust the crosshead according to the fol-
lowing 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 PC600-8
4. Fuel injector 5. Push rod

a Check that the inside of the injector sleeve Install push rods (109).
is free from dirt. a Check that the point of push rod is in the
1] Install gasket (120) and O-rings (121) cam follower socket area.
to fuel injector (110).
2 O-ring: Engine oil (EO30-DH)
2] Install holder (122) in fuel injector
(110), then insert the injector connec-
tor 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.
6. Install connector (102).
a Install the connector before installing the
high-pressure pipe.
4] Install wiring harness terminal right

and left (111) to fuel injector (110) with
the nuts.
3 Terminal nut: 7. High-pressure pipe
1.8 – 2.2 Nm {0.18 – 0.22 kgm} k The clamp used for fixing a high-pressure
5] Install spring clamp (124) and wiring pipe must be a genuine Komatsu part and it
harness holder clamp (112). must be tightened to the specified torque.
a Slack off the wiring harness and k Never bend a high-pressure pipe for the
press it against the injector. convenience sake.
k Before installing a high-pressure pipe, con-
firm the following points.
If any abnormality was found, replace it
with another healthy one. Otherwise, leak-
age 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 por-
tion is free from deformation).
PC600-8 19
1) Put sleeve nut (126) of high-pressure pipe 8. Install rocker arm and shaft assembly (108).
(101) in the fuel high-pressure pipe inser- a Before tightening the mounting bolt, check
tion part and tighten it temporarily. that the ball of adjustment screw (107) is
a Check that the O-rings are fitted to fitted to the socket of the push rod (109)
both of the injector and sleeve nut. securely.
2) Rotate sleeve nut (127) by 2 turns with the 3 Mounting bolt:
fingers on the threads of the injector, and 93 – 103 Nm {9.5 – 10.5 kgm}
then tighten sleeve nut (127) with a span- a Adjust the valve clearance.
ner (do not tighten it permanently at this For details, see “Adjusting valve clear-
time). ance” in Testing and adjusting.
a If sleeve nut (127) does not catch the 3 Locknut (106):
threads of the injector, press its end 53 – 64.7 Nm {5.4 – 6.6 kgm}
with another small spanner etc. and a After tightening the locknut, check the
rotate its hexagonal part with the valve clearance again.
spanner.
a After tightening sleeve nut (127),
check that the O-ring is not projected
from the end of the sleeve nut (127).
3) Tighten mounting bolts (113) of holder
(122) permanently.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
4) 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}
20 PC600-8
9. Install cylinder head cover (105). 15. Install the air intake manifold.
3 Cylinder head cover mounting bolt: a Before installing the air intake manifold,
29.4 – 34.3 Nm {3.0 – 3.5 kgm} insert 3 bolts (B).
a Tighten the mounting bolts of air intake
10. Install covers (98) to the sleeve nut of high- manifold assembly in the order of [1] – [24]
pressure pipes (101). shown below.
a Direct the slit as follows. 3 Air intake manifold assembly mounting
Cylinder head side: Direct the slit down. bolt: 59 – 74 Nm {6 – 7.5 kgm}
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.
14. Insert lubrication tube (129) of turbocharger

(TC).
a The lubrication tube cannot be inserted
after the air intake manifold is installed.
PC600-8 21
16. High-pressure pipe clamp q Carry out the following installation in the
1) Tighten high-pressure pipe clamps (126) reverse order to removal.
above the air intake manifold (described
above) and stay (127) permanently. [*1]
a Bend the rubber in advance. 3 Air hose clamp (Right and left):
3 Clamping bolt: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
9.8 ± 1 Nm {1 ± 0.1 kgm}
2) Tighten stays (128) of clamps (99) under [*2]
the air intake manifold (described above) MIKALOR clamp
temporarily. a Use a new MIKALOR clamp.
3) Install high-pressure pipe clamp (100) and 1) Set the hose to the original position. (Insertion
bracket (96) temporarily with the fingers. depth of air hose: 80 mm)
4) Install high-pressure pipe clamp (95) and 2) Set bridge (BR) under the clamp bolt and
bracket (97) temporarily. adjust its overlap (b) with bridge (BR) and band
5) Tighten high-pressure pipe clamps (100) to at least 5 mm.
and (95) permanently first. 3) Tightening of the clamp.
3 Clamping bolt: 2 Threads of clamp bolt (BC):
9.8 ± 1 Nm {1 ± 0.1 kgm} Lubricating oil (THREEBOND PANDO 18B)
6) Tighten brackets (96) and (97) perma- a Do not use an impact wrench.
nently. q When reusing the hose.
7) Tighten high-pressure pipe clamps (99) Install the clamp to the clamp mark made
permanently. on the hose.
3 Clamping bolt: 3 Clamp bolt: Min. 6 Nm {0.6 kgm}
9.8 ± 1 Nm {1 ± 0.1 kgm} q When using a new hose.
8) Tighten stays (128) permanently. Tighten until dimension (a) is 5 – 8 mm.
[*3]
3 Tightening torque for fuel hose (19):
43 – 47 Nm {4.4 – 4.8 kgm}
[*4]
3 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)
[*5]
3 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)
[*7]
3 Mounting bolt of bypass tube (88):
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
22 PC600-8
[*8] [*14]
3 Joint bolt of turbocharger lubrication tube 1) Set the connector groove in position and insert
(35): 24.5 – 34.3 Nm {2.5 – 3.5 kgm} to the end.
2) Rotate housing (H1) in the direction of the
[*9] arrow until it clicks.
3 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. [*15]
a Tighten the 3 bolts of (1) – (3) shown 3 Joint bolt of lubrication tube (56):
below temporarily in the numeric order 34.3 – 44.1 Nm {3.5 – 4.5 kgm}
and then tighten other bolts (4) – (24) tem-
porarily in the numeric order. Then, tighten [*16] – [*18]
all bolts (1) – (24) to the specified torque 3 Joint bolts of lubrication tubes (60) and (63):
in the numeric order. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2 Mounting bolt: 3 Mounting bolts of EGR valve (64) and
Seizure prevention compound (LC-G) bypass valve (61): 59 – 74 Nm {6 – 7.5 kgm}
(NEVER-SEEZ (Bostik, Inc.) or equivalent)
3 Mounting bolt: [*19]
59 – 74 Nm {6 – 7.5 kgm} 3 Joint bolt of air vent tube (94):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
q 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
q Bleed air from the fuel system. For details, see

Testing and adjusting, “Bleeding air from fuel
system”.
[*11]
See MIKALOR clamp [*2]. k Before starting the engine, check that the
wiring harnesses are at least 10 mm apart
[*12] from the high-pressure pipe.
3 Corrosion resistor joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*13]
3 Fuel return tube joint bolts (48) and (49):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
PC600-8 23
Removal and installation of fuel 5. Remove covers (4).

injector assembly 1 a Remove the common rail side, too.
Removal 6. Remove the clamp and high-pressure pipes

1. Remove the counterweight assembly. For (5).
terweight assembly”. 7. Disconnect connector (6) of the injector wiring.
(The counterweight must be removed to bar a Insert flat-head screwdriver [3] in shoulder
the engine.) (a). While pressing stopper (b), move the
screwdriver in direction (X), and connector
2. Remove the air intake manifold assembly (1). (c) is disconnected.
For details, see “Removal and installation of (d): Fuel injector wiring side
cylinder head assembly”.
8. Remove cylinder head covers (7).
3. Remove clamp (2).
4. Remove brackets (3).
9. By barring the engine with bolt (BB), set stamp

1·6TOP of the damper to pointer (P).
24 PC600-8
10. Remove the mounting bolts and rocker arm 12. Remove holder mounting bolt (19) of fuel injec-
assembly (8). tor assembly (11) and then remove fuel injector
a Loosen locknut (9), and then loosen assembly (11).
adjustment screw (10) by 2 – 3 turns so a Insert small L-shaped bar [2] under the
that an excessive force will not be applied connection of the fuel injector and pry off
to the push rod when the rocker arm the injector slowly.
assembly is installed. a Do not grip the solenoid valve on the fuel
injector with pliers etc. to remove.
11. Disconnect the injector wiring harness accord-

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
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 con-
nector (15) to remove. [*1]
PC600-8 25
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.
q Carry out the following installation in the

reverse order to removal.
a When installing the parts, observe the precau-

tions described in “Removal and installation of
cylinder head assembly”.
[*1]
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 har-
ness 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).
26 PC600-8
Removal and installation of 3) Insert the top end of tool A3 into the
engine front seal 1 drilled hole, and remove the front seal
by the impact of slide hammer (SH).
Special tools (Apply the slide hammer evenly not to
tilt the front seal.)
a
Necessity
Remove the metal powders completely.
Symbol
Sketch
a
Q’ty
N/R
Part number Part name When the sleeve is attached, cut sleeve
(6) using a gad and hammer to remove it.
a Take care not to damage crankshaft (5).
3 795-931-1100 Seal puller t 1
795T-521-1111 Push tool t 1 N Q
4 01050-31655 Bolt t 3
A
01050-31635 Bolt t 3
795T-521-1150 Push tool t 1 N Q
5
01050-31635 Bolt t 3
Removal
1. Remove the fan and fan shroud assembly. For
details, see "Removal and installation of fan
motor assembly".
2. 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.
3. Remove front seal (3) from housing (4) accord-

a Take care in the removal not to damage
front seal (3) installation position on hous-
ing (4) and the seal contact face on crank-
shaft (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 proce-
dure.
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.
PC600-8 27
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".
a (7): Plastic inside cylinder which is also used
as installation guide.
a (6): Sleeve.
a Do not remove installation guide (7) from front
seal (3) before installing the front seal.
a Handle front seal (3) and sleeve (6) as an
assembly and never separate them from each
other.
Standard spare seal Sleeved seal
2) 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
1. Procedure for installing standard seal plastic hammer evenly.
a Before installing the seal, check that the a Do not hit it strongly.
end corners and lip sliding surfaces of the 3) After pushing in the seal, remove plastic
crankshaft are free from flaw, burr, and inside cylinder (7).
rust of the housing. a When removing the inside cylinder,
a When installing the seal, do not apply oil take care not to damage the seal lip.
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 plas-
tic inside cylinder (7) to the end of crank-
shaft (5).
a Take care not to mistake the direction
of the plastic inside cylinder.
28 PC600-8
4) Using tool A4, tighten the 3 bolts evenly to 2) Set the sleeve of the front seal to the end
press fit seal (3) until the end of tool A4 of crankshaft (5) and tighten the 3 bolts
reaches the end of crankshaft (5). evenly to press fit sleeve and front seal
a Tighten tool A4 first until the 55-mm assembly (9) until the end of tool A5
bolts stop and then replace the 55- reaches the end of crankshaft (5).
mm bolts with the 35-mm bolts and
a Tighten tool A5 (for press fitting the
tighten them.
a Seal driving distance (a) from crank- sleeved seal) until the 35-mm bolt
shaft: 9.1 – 10.1 mm stops.
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.
3) Remove tool A5 (for press fitting the

sleeved seal) and install tool A4 (for press
fitting the seal).
4) Tighten the 35-mm bolts of tool A4 evenly
to press fit seal and sleeve assembly (9)
2. Procedure for installing sleeved seal until the end of tool A4 reaches the end of
a When installing the front seal, do not apply crankshaft (5).
oil or grease to the shaft, inside cylinder a Seal driving distance (a) from crank-
surface of sleeve (6) and seal lip. shaft: 9.1 – 10.1 mm
1) Set sleeve (6) and front seal (3) assembly a When press fitting the seal, take care
not to damage the lip of the seal with
to tool A5 (for fitting the sleeved seal).
2 Sleeve (6) inside cylinder surface:
the tool set etc.
Gasket sealant (LG-7) red sealant layer from its periphery.
PC600-8 29
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 PC600-8
Removal and installation of 5. Remove rear seal (2) according to the follow-
engine rear seal 1 ing procedure.
a Measure the distance from the end of the
Special tools housing.
1) Before pulling out rear seal (2), drive in it a
Necessity
little to separate it from the flywheel hous-
Symbol
Sketch
Q’ty
N/R
Part number Part name ing (FWH).
3 795-931-1100 Seal puller t 1

795T-421-1270 Push tool t 1 Q
6 01050-31645 Bolt t 4
01643-31645 Washer t 8
795T-421-1240 Push tool t 1 Q
A
7 01050-31645 Bolt t 4
01643-31645 Washer t 4
795T-421-1250 Push tool t 1 Q
8 01050-31645 Bolt t 4
01643-31645 Washer t 8
2) If the seal is sleeved, cut and remove

Removal sleeve (5) with a chisel and a hammer.
1. Remove the PTO assembly and hub assembly. a When cutting, take care extremely not
For details, see "Removal and installation of to damage crankshaft (4).
PTO assembly". 3) Hitch the end of tool A3 to the metal ring
of rear seal (2) and pull out the seal with
2. Remove 1 mounting bolt of flywheel (1) and impacts of slide hammer (SH).
install guide bolt. a Do not use a drill etc. since chips may
enter the engine.
3. Using eyebolt [1] (12 mm, P = 1.75), sling fly- a If chips were made, remove all of
wheel (1) temporarily and remove the 8 mount- them.
ing bolts. q Tool A3
4. 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 fly-
wheel.
4 Flywheel: 65 kg
PC600-8 31
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.
q Standard spare seal q Sleeved seal
a Clean, degrease, and dry the seal surface

on the flywheel housing side.
a Clean, degrease, and dry the seal lip sur-
face (periphery of the crankshaft).
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.
32 PC600-8
1. Procedure for installing standard seal 4) Tighten the 3 bolts evenly to press fit rear
a When installing rear seal (2), do not apply seal (2) until the end of tool A6 (for press
oil or grease to the shaft and seal lip. fitting the seal) reaches the end of crank-
1) Set large inside diameter side (b) of plas- shaft (4).
tic inside cylinder (3) of rear seal (2) to the a Tighten tool A6 (for press fitting the
end of crankshaft (4). seal) first until it reaches the bolt (45
a Take care not to mistake the direction mm) and then tighten the bolt (25
of the plastic inside cylinder. mm).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set etc.
red sealant layer from its periphery.
2) Hold the metal ring of rear oil seal (2) with

both hands and push it in evenly.
3) 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
2) Set sleeve of the rear seal to the end of 3. Flywheel

crankshaft (4) and tighten the 4 bolts of Using eyebolt [1] (12 mm, P = 1.75), sling fly-
tool A7 evenly to press fit sleeve and rear wheel (1), install it to the crankshaft, and
seal assembly (6). tighten the bolts.
a Tighten tool A7 (for press fitting the a If there are 5 punch marks on a bolt, do
sleeved seal) with 1 washer inserted not use that bolt but replace it.
in each bolt until the bolts reach the 2 Threads and seat of bolt:
end. Engine oil (EO30-DH)
4 Flywheel: 65 kg
3) Remove tool A7 (for press fitting the

sleeved seal) and install tool A8 (for press
fitting the seal). a Tighten the mounting bolts according to the fol-
4) Tighten the 4 bolts evenly to press fit lowing procedure.
sleeve and rear seal assembly (6) until the 3 Flywheel mounting bolts
end of tool A8 (for press fitting the seal) 1st time: 118 ± 4.9 Nm {12 ± 0.5 kgm}
reaches the end of crankshaft (4). 2nd time: 1) When using tool A2 (See the
a Tighten the bolt of tool A8 (for press tools list)
fitting the seal) without washer until it Retighten each bolt by 90° +30°+0 in
reaches, and then tighten the bolt the order of [1] – [8].
using 2 washers (for each bolt). 2) When not using tool A2
a After press fitting the seal, remove the Make marks (f) on each bolt and
red sealant layer from its periphery. flywheel with paint, then retighten
a Seal driving depth (b) from the end of each bolt by 90° +30°
+0 in the order
crankshaft: 13.2 ± 0.2 mm of [1] – [8].
34 PC600-8
a After tightening, make 1 punch mark (g) on

each bolt head to indicate the number of tight-
ening time.
a 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
q Carry out the following installation in the

reverse order to removal.
PC600-8 35
SEN01063-02

© 2009 KOMATSU
All Rights Reserved
36
SEN01064-02
PC600-8
PC600LC-8

PC600-8 30001 and up

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 1
Removal and installation of 3. Set engine hood (1) vertically as shown below.
engine, PTO and hydraulic pump 1) Sling engine hood (1) temporarily.
2) Remove pin (2) and stay (3).
assembly 1 3) Fix hole (A) of stay (3) with bolt (B).
a Take care of the direction of stay (3).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
S 796-660-2010 Oil stopper q 1
Removal
k Loosen the cap of the hydraulic tank gradu-
ally to release the internal pressure of the
hydraulic tank.
a Install oil stopper plugs to the disconnected

tubes and hoses.
a Before disconnecting each hose, mark it with a
tag etc. to indicate its position.
1. 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
2. Remove the counterweight assembly. For 4. Remove undercover (4).

terweight assembly”.
5. Drain the coolant.

6 Coolant: 58 l
2 PC600-8
6. Remove 3 covers (5). 9. Lift off frame (8).
7. Remove filter bracket (6). 10. Remove covers (9) and (10).
a Disconnect the fuel hose clamp (HC).

8. Disconnect reservoir tank hoses (7). a Disconnect the clamp of hose (H), too.
PC600-8 3
13. Remove handrail (14).
14. Disconnect hoses (15) from reservoir tank

(RT).
15. Disconnect connector P24 from under reser-

voir tank (RT).
20. Disconnect air hose (21). [*1]

a Make a mark on the tube to show the posi-
tion of the hose end.
21. Remove air tube and bracket assembly (22).

[*2]
22. Disconnect bracket (23).
23. Remove air tube (24). [*3]
24. Disconnect radiator hose (25). [*4]
25. Disconnect heater hoses (26) and (27).
17. Remove cover assembly (17).

a Lift off the cover and frame together.
18. Remove covers (18) and (19).
4 PC600-8
33. Disconnect heater terminal (36).

26. Disconnect dust indicator hose (28).
34. Disconnect hose (37). [*7]
27. Remove air cleaner bands (29) and air cleaner
(30). [*5] 35. Disconnect connector M34 (38).
28. Lift off frame, stay and bracket assembly (31). 36. Loosen locknut (39) and disconnect air condi-
tioner compressor (40). [*8]
a Do not disconnect the air conditioner
hose.
37. Remove the air conditioner compressor belt.
38. Disconnect cover (41).
29. Disconnect hose (32).
30. Disconnect reservoir tank hoses (33).
31. Remove radiator hose (34). [*6]
32. Disconnect hose clamp (35).
41. Remove undercovers (44) and (45).
PC600-8 5
48. Disconnect 2 hoses (57) from pump No. 1.
49. Disconnect hoses (58) – (61).
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 53. Disconnect hose (66) from under the PTO.
the PTO.
44. Disconnect connector (49).
45. Remove 2 hoses (50) from pump No. 2.
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).
6 PC600-8
57. Disconnect suction connector (71) from pump 63. Disconnect starting motor terminal (84).
No. 2.
65. Disconnect ground wire (86).
66. Remove mounting bolts (87). [*11]
58. Disconnect fuel return hose (72). [*10]
59. Remove controller cover (73).
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).
a Use 2 M30 eyebolts (EB).
PC600-8 7
Installation [*8]
q Carry out installation in the reverse order to Adjust the air conditioner compressor belt tension.
removal. For details, see Testing and adjusting, Testing and
adjusting air conditioner compressor belt tension.
[*1], [*2]
3 Air hose clamps (right and left): [*9]
8.3 – 9.3 Nm {0.85 – 0.95 kgm} 3 Tightening torque for fuel hose (41):
43 – 47 Nm {4.4 – 4.8 kgm}
[*3], [*7]
MIKALOR clamp [*10]
a Use a new MIKALOR clamp. 3 Joint bolt of fuel return hose (72):
1) Set the hose to the original position. 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
(Insertion depth of air hose: 80 mm)
2) Set bridge (BR) under the clamp bolt and [*11]
adjust its overlap (b) with bridge (BR) and band 2 Engine mounting bolt: Adhesive (LT-2)
to at least 5 mm. 3 Engine mounting bolt:
3) Tightening of the clamp. 824 – 1,030 Nm {84 – 105 kgm}
2 Threads of clamp bolt (BC):
Lubricating oil (THREEBOND PANDO 18B)
a Do not use an impact wrench. q Refilling with coolant
q When reusing the hose. Add coolant through the coolant filler to the
Install the clamp to the clamp mark made specified level. Run the engine to circulate the
on the hose. coolant through the system. Then, check the
3 Clamp bolt: Min. 6 Nm {0.6 kgm} coolant level again.
5
q When using a new hose. Coolant: 58 l
Tighten until dimension (a) is 5 – 8 mm.
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.
5 Hydraulic oil: 360 l
[*4]
3 Radiator hose clamp:
8.3 – 9.3 Nm {0.85 – 0.95 kgm}
[*5]
3 Air cleaner band:
17.6 – 21.6 Nm {1.8 – 2.2 kgm}
[*6]
8.3 – 9.3 Nm {0.85 – 0.95 kgm}
8 PC600-8
Removal and installation of 4. Remove undercover (4).

radiator assembly 1
Removal
hydraulic tank.
tubes and hoses.
6
1. Sling engine hood (1) temporarily. Coolant: 58 l
2. Remove pin (2).
6. Disconnect reservoir tank hoses (5).
3. Fix bolt (B) to hole (A) of bar (3) and set engine
hood (1) vertically. 7. Disconnect radiator hose (6).
a Take care of the direction of bar (3).
PC600-8 9
11. Disconnect 2 fan hoses (11). 17. Lift off radiator assembly (18) and (19).
4
(These hoses must be disconnected to remove
Radiator assembly: 25 kg (One side)
radiator hose (13).)
a Prepare an oil receiver.
a Fit a plug.
q Adapter size: #06 --- 2 pieces
Installation
q Carry out installation in the reverse order to
12. Disconnect radiator hose (12). [*3] removal.
13. Remove radiator hose (13). [*4] [*1] – [*4]

14. Remove covers (14) – (16). 8.3 – 9.3 Nm {0.85 – 0.95 kgm}

again.

5 Coolant: 58 l
16. Remove covers (C) – (E).
10 PC600-8
Removal and installation of 8. Remove lower mounting bolts (6).

hydraulic oil cooler assembly 1
Removal
hydraulic tank.
1. Sling engine hood (1) temporarily and lift it off.

[*1]
2. Open right and left covers (2).
3. Remove plate (3). 9. Disconnect tube (7) from the top of the hydrau-
lic oil cooler.
10. Remove net (8).
11. Sling hydraulic oil cooler assembly (10) tempo-

rarily with (A).
13. Lift off hydraulic oil cooler assembly (10).

4 Hydraulic oil cooler assembly: 40 kg
a AC: Air conditioner condenser,
FC: Fuel cooler
4. Remove undercover (4).
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.
7. Disconnect tube (5) from the bottom of the

hydraulic oil cooler.
PC600-8 11
Installation
removal.
[*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 stop-
per (S).
3. Adjust the positions of hinge (H), bracket (B),
catcher (C), and U-bolt (UB).

again.
5 Hydraulic oil tank: 360 l (Refill capacity)
12 PC600-8
Removal and installation of 4. Disconnect aftercooler hose (4). [*2]

aftercooler assembly 1 a Make a mark on the tube to show the posi-
Removal
k Lower the work equipment to the ground 5. Disconnect oil cooler hoses (5) and (6).
6. Disconnect aftercooler hose (7). [*2]
1. Remove engine hood (1). [*1] a Make a mark on the tube to show the posi-
2. Remove right cover (2).
7. Sling aftercooler assembly (8) temporarily and
3. Remove plate (3). remove 6 mounting bolts (9) from the back
side.
8. Lift off aftercooler assembly (8).

4 Aftercooler assembly (8): 40 kg
PC600-8 13
Installation [*2]
q Carry out installation in the reverse order to MIKALOR clamp
removal. a Use new MIKALOR clamps.
1) Set each hose to the original position.
[*1] (Insertion depth of air hose: 80 mm)
Precautions for installing engine hood 2) Set bridge (BR) under the clamp bolt and
1. Secure clearance (FC) of at least 10 mm adjust its overlap (b) with bridge (BR) and band
between the engine hood and oil cooler frame. to at least 5 mm.
2. The engine hood must not interfere with stop- 3) Tightening of the clamp.
per (S). 2 Threads of clamp bolt (BC):
3. Adjust the positions of hinge (H), bracket (B), Lubricating oil (THREEBOND PANDO 18B)
catcher (C), and U-bolt (UB). 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
Removal and installation of fan 4. Remove undercover (4).

motor assembly 1
Removal
hydraulic tank.
tubes and hoses.
6
1. Sling engine hood (1) temporarily. Coolant: 58 l
2. Remove pin (2).
6. Remove the counterweight. For details, see
3. Fix bolt (B) to hole (A) of bar (3) and set engine “Removal of counterweight assembly”.
hood (1) vertically.
8. Disconnect filter bracket (6).

a Disconnect the hose clamp (HC).
PC600-8 15
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 Fit a plug.
q Adapter size: #06 --- 2 pieces
#04 --- 2 pieces
a Remove the clip, too.
12. Disconnect 2 reservoir tank hoses (10).
17. Disconnect connector A16 (16).
16 PC600-8
20. Remove cover (19). 25. Lift off fan and fan motor shroud assembly
(21).
4
21. Remove front and rear covers (20).
Fan and fan motor shroud assembly:
100 kg
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.
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
a Puller fixing tap (T) (4 × M10 × 1.5 × 20) Installation

made on boss (BS) can be used. q Carry out installation in the reverse order to
removal.
[*1]
8.3 – 9.3 Nm {0.85 – 0.95 kgm}
[*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 clock-
wise to match the hole.)
[*3]
3 Fan mounting nut:
29. Disconnect connector V16 (26). 833 – 882 Nm {85 – 90 kgm}
30. Remove cover (27). a After installing the nut, measure dimension (d).
(d): 1.2 – 3.0 mm
31. Disconnect tubes (28), (29), and (30).
a Disconnect the clamps, too.
32. Remove fan motor assembly (31).
[*4]
q Degrease both hole and shaft.

5 Coolant: 58 l

again.
18 PC600-8
Removal and installation of fuel 4. Disconnect fuel supply hose (3) and return
tank assembly 1 hoses (4).
Removal
1. Open the drain valve to drain the fuel.

6 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 5. Remove fuel tank mounting bolt. [*1]
fuel tank.
6. Lift off fuel tank assembly (5).
4 Fuel tank assembly: 500 kg
Installation
removal.
[*1]
3 Fuel tank mounting bolt:
319 – 608 Nm {32.5 – 62 kgm}
PC600-8 19
SEN01064-02

© 2009 KOMATSU
All Rights Reserved
20
SEN01065-03
PC600-8
PC600LC-8

PC600-8 30001 and up
50 Disassembly and assembly

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 1
Removal and installation of PTO 3. Remove partition cover (1) between the engine
assembly 1 and pump.
Removal
hydraulic tank.
tubes and hoses.
1. Remove the counterweight assembly. For 4. Drain the PTO lubricating oil.
6
details, see "Removal and installation of coun- Lubricating oil: 6 l
terweight assembly".
2. Lift off each hydraulic pump assembly. For 5. Disconnect clamp (2).
details, see "Removal and installation of
hydraulic pump assembly". 6. Disconnect lubrication hose (3).
a Disconnect lower lubrication hose, too.
4 Pump No. 1 assembly (No. 1): 170 kg
4 Cooling fan pump (Control, PTO lubrica-
tion and fan pump) assembly (G.P.):
90 kg
7. Using 2 M30 eyebolts, lift off PTO assembly

(6). [*1]
4 PTO assembly: 210 kg
2 PC600-8
8. Remove shaft (7). [*2] Installation

Note: Do not remove coupling unit (8) from hub q Carry out installation in the reverse order to
assembly (9). When coupling (8) needs to removal.
be replaced, replace it together with hub
assembly (9). [*1]
3 PTO mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*2]
3 Hub assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
q 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)
q FWH: Flywheel housing
PC600-8 3
Disassembly and assembly of 4. Bearing

PTO assembly 1 1) Using puller [1], remove bearings (7) from
gears (2) and (3).
Disassembly
1. Remove all lubrication tubes (20).
2) Remove snap ring (8).

3) Using puller [1], remove bearings (9) and
2. Case (10) from gear (4).
Remove the mounting bolts and then remove
case (1) with a forcing screw.
a Check the quantity and thickness of the
inserted shims.
3. Gear assemblies
Remove gear assemblies (2), (3), and (4).
a Using a puller, remove each gear assem-
bly.
a When removing gears (2) and (3), remove
nipples (5) and (6) first and then use the
puller.
4) Remove snap ring (11) from case (1).

5) Remove outer race (12).
4 PC600-8
5. Oil seal 2. Bearing

Remove oil seal (13) from case (14). 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 3) Press fit bearings (9) and (10) to gear (4).
damage. Coat their sliding surfaces with 4) Install snap ring (8).
engine oil before installing.
1. 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%.
5) Press fit bearings (7) to gears (2) and (3).
PC600-8 5
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)
4. Case
Install case (1).
2 Mating face of case:
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
6 PC600-8
Removal and installation of swing

motor and swing machinery
assembly 1
Removal
hydraulic tank.
1. Remove step (1).
2. Disconnect 4 hoses (2) between the control

valve and swing motor.
a Install tags and oil stopper plugs to all the Installation
disconnected hoses. q Carry out installation in the reverse order to
removal.
3. Disconnect 2 suction hoses (3).
[*1]
4. Disconnect 2 swing holding brake hoses (4). 3 Swing motor and swing machinery assembly
mounting bolt:
5. Disconnect 3 drain hoses (5). 824 – 1,030 Nm {84 – 105 kg}
6. Remove hose bracket (6). q Refilling with oil (Hydraulic tank)

7. Disconnect drain plug assembly (8) from the level. Run the engine to circulate the oil
chassis at the rear of swing motor and swing through the system. Then, check the oil level
machinery assembly (7). again.
8. Remove mounting bolts (9) and lift off swing q Bleeding air
motor and swing machinery assembly (7). [*1] Bleed air from the swing motor. For details,
4
see Testing and adjusting, "Bleeding air from
Swing motor and swing machinery each part".
assembly: 440 kg (1 piece)
PC600-8 7
Disassembly and assembly of 3) Remove No. 1 carrier assembly (4).

swing machinery assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
1 796T-626-1110 Push tool t 1 Q

F
2 790-331-1110 Wrench t 1
Disassembly
1. Draining oil
Loosen drain plug and drain oil from swing
machinery. 4. Disassembly of No. 1 carrier assembly
1) Push pin (5) in shaft (6), and knock out
6 Swing machinery case: 12.8 – 13.1 l shaft (6) from carrier (7).
a After removing the shaft, remove pin
2. Cover (5).
Remove mounting bolts, then lift off cover (1). 2) Remove thrust washer (8), gear (9), bear-
ing (10), and thrust washer (11).
5 10 7
8
9 11 6
CEP00208
3. No. 1 carrier assembly.

1) Remove thrust washer (2). 5. Ring gear
2) Remove No. 1 sun gear (3). Lift off ring gear (12).
8 PC600-8
6. No. 1 sun gear 8. Disassembly of No. 2 carrier assembly

1) Remove thrust washer (13). 1) Push in pin (18), and knock out shaft (19)
2) Remove button (36) and spacer (14). from carrier (17).
3) Remove No. 1 sun gear (15). a After removing the shaft, remove pin
(18).
2) Remove thrust washer (20), gear (21),
bearing (22), and thrust washer (23).
19 22 17
20
21
23
4) Remove thrust washer (16). 18

CEP00213
9. 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 9
4) Turn over case and pinion assembly (29), Assembly

and set on press stand, then using push a Clean all parts, and check for dirt or damage.
tool [1], remove pinion shaft assembly (30) Coat the sliding surfaces of all parts with
with press. engine oil before installing.
a Set a wooden block under the press,
and be careful not to damage the pin- 1. Bearing
ion shaft assembly when removing it. Using push tool [3], press fit bearing (31) to
case (35).
10. Disassembly of pinion shaft assembly

1) Using push tool [2], remove cover assem- 2. Cover assembly
bly (27) and bearing (31) from shaft (32). 1) Using push tool [4], press fit oil seal (33) to
2) Remove oil seal (33) from cover (27). cover (27).
2 Outside circumference of oil seal:
a Be careful not to let the gasket seal-
ant (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
2) Fit cover assembly (27) to case (35), and 2) Bearing

tighten mounting bolts (28). Using tool F1, press fit bearing (34).
a Be careful not to let the gasket seal- a Press the bearing inner race and
ant (LG-6) get on the oil seal lip when outer race at the same time when
press fitting. press fitting. Do not press only the
a Take care that gasket sealant will not inner race when press fitting.
be projected into the oil pass. a After press fitting the bearing, check
2 Cover mounting surface: that the case rotates smoothly.
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%.
3) Gear, holder
Assemble gear (26), then fit holder (25)
and tighten bolt (24).
2 Mounting bolt:
Thread tightener (LT-2)
3. Case assembly 3 Mounting bolt:
1) Set case assembly (35) to shaft (32), then 179 – 196 Nm {16 – 20 kgm}
using push tool [5], press fit bearing inner
race portion.
a When setting the case assembly to 24
the shaft, be extremely careful not to
26
damage the oil seal.
25
CEP00214
PC600-8 11
4. Assembly of No. 2 carrier assembly 5. No. 2 carrier assembly

a There are the remains of caulking after fit- 1) Assemble thrust washer (16).
ting 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).
22 17
20
21
23 2) Raise No. 2 carrier assembly (17) and

install.
a Align the position so that the tip of the
h gear shaft enters at 4 places, then
CEP00226
install.
2) 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.
3) Insert pin (18).
a After inserting the pin, caulk the pin
portion of the carrier.
a After assembling the carrier assem-
bly, check that gear (21) rotates
smoothly.
6. No. 2 sun gear

21 19 1) Install No. 2 sun gear (15) to No. 2 carrier.
2) Install spacer (14) and button (36).
3) Install thrust washer (13).
18
CEP00227
12 PC600-8
7. Ring gear 2) Align position of pin holes of shaft and car-

Raise ring gear (12) and install. rier, 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.
3) Insert pin (5).
a After inserting the pin, caulk the pin
portion of the carrier.
a After assembling the carrier assembly,
check that gear (9) rotates smoothly.
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:
9 6
CEP00229

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 10 7
8
9 11
CEP00228
PC600-8 13
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:
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
Removal and installation of swing Installation

circle assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove the revolving frame assembly. [*1]
For details, see "Removal of revolving frame 2 Mounting bolt: Thread tightener (LT-2)
assembly". 3 Mounting bolt:
1,180 – 1,470 Nm {120 – 150 kgm}
2. Remove grease tube from swing circle.
[*2]
3. Remove mounting bolts (1). [*1] 2 Swing circle mounting surface
a Amount of grease (G2-LI) in oil bath:
Approx. 31 l
a Coat inside teeth with grease (G2-LI).
a Install the inner ring soft zone position (S-
mark), 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
Disassembly and assembly of Disassembly

final drive assembly 1 1. Draining oil
Set drain plug (1) at bottom and remove it to
Special tools drain oil from final drive case.
6 Final drive case: 10.5 l (Each side)
Necessity
Symbol
Sketch
Q’ty
N/R
790-501-5000 Unit repair stand q 1

1 790-501-5200 Unit repair stand q 1
790-901-4110 Bracket q 1
2 796T-627-1510 Plate q 1 Q
3 796T-627-1520 Plate q 1 Q
970-431-1031 Block t 1
791-730-1130 Bolt t 2
790-101-2360 Plate t 2
01643-32060 Washer t 2
01580-12016 Nut t 2
2. Cover
4 796-627-1420 Adapter t 2
1) Using tools J1 and J2, support final drive
790-201-2790 Spacer t 1 assembly.
790-201-2690 Plate t 1 a Install by using the sprocket mounting bolt
J Puller holes on the hub.
790-101-2102 t 1
(294 N {30 ton})
790-101-1102 Pump t 1
5 796-627-1020 Installer t 1
790-101-2510 Block t 1
791-830-1320 Rod t 2
790-101-2570 Washer t 2
01643-31645 Washer t 2
6 01580-11613 Nut t 2
796-627-1410 Adapter t 2
796T-627-1330 Push tool q 1 Q
790-101-2102 Puller t 1
790-101-1102 Pump t 1 2) Using eyebolts [1], lift off cover (2).
7 790-331-1110 Wrench t 1
16 PC600-8
3. Spacer 3] Remove 2 thrust washers (9), plane-

Remove spacer (3). tary gear (10), and bearing (11).
4. No. 1 sun gear shaft

Remove No. 1 sun gear shaft (4).
6. No. 1 ring gear

Using eyebolts [2], lift off No. 1 ring gear (12).

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
8. Thrust washer 2) Disassemble No. 2 carrier assembly as

Remove thrust washer (14). follows.
1] Push pin (18) in shaft.
9. No. 2 sun gear 2] Remove shaft (19) from carrier (20).
Remove No. 2 sun gear (15).
3] Remove 2 thrust washers (21), plane-

10. Thrust washer tary gear (22), and bearing (23).
Remove thrust washer (16).
12. Retainer
11. No. 2 carrier assembly 1) Sling the final drive assembly and remove
1) Lift off No. 2 carrier assembly (17). 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
3) Remove 22 mounting bolts (24) and 14 3) Disassemble hub assembly as follows.

mounting bolts (25), then remove retainer 1] Remove floating seal cover assem-
(26). bly (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) 14. Floating seal
from travel motor assembly (29). 1) Remove floating seal (34) from cover (35).
2) Using eyebolts [4], lift off hub assembly
(28).
PC600-8 19
2) Remove floating seal (36) from travel

motor (37).
3. Hub assembly
1) Assemble the hub assembly as follows.
1] Using push tool [5], press fit bearing
Assembly (32) to hub (31).
a Clean all parts, and check for dirt or damage. a Similarly, press fit bearing (33).
Coat the sliding surfaces of all parts with a Press fit the bearing until it fits to
engine oil before installing. the hub.
1. Travel motor assembly

Install travel motor assembly to tools J1 and
J3.
2. 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. 2] Install floating seal cover assembly
(30) to hub (31).
2 Cover fitting face:
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 installa-
tion in 1) above.
20 PC600-8
2) Using eyebolts, sling and install hub

assembly (28) to travel motor assembly.
3) 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.
4) 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. 2) Install retainer (26) and tighten 22 mount-
Thickness of spacer = ing bolts (24) and 14 mounting bolts (25).
Distance (a) – (0.10 to 0.15) 2 Mounting bolts (24), (25):
a Distance (a) (Standard): 3.5 mm Thread tightener (LT-2)
a Thickness of spacer (Standard): 3 Mounting bolts (24), (25):
(t) = 3.4 mm 853 – 931 Nm {87 – 95 kgm}
a Thicknesses of spacers:
t = 3.25, t = 3.3, t = 3.35, t = 3.4,
t = 3.45, t = 3.5, t = 3.55
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

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.
a When inserting the pin, assemble

so that the 3 notched parts (por-
tion a) on the circumference on
the pin do not overlap the thin
metal part (portion b) of the car-
rier. (Basically, the inside of the
chassis (direction A) is the thin
metal side).
3) Assemble No. 2 carrier assembly as fol- However, with the actual part, the
lows. thin metal may be on the oppo-
a There is caulking left at the pin fitting site side, so check the part and
pa r t o f t h e c a r r i e r. R e m o v e t h e make sure when assembling that
swelled part inside the hole in the protruding parts of the pin is
advance. not at the same place as the thin
1] Install bearing (23) and 2 thrust wash- metal.
ers (21) to planetary gear (22), then a After inserting the pin, caulk the
install them to carrier (20). pin portion of the carrier.
2] Tap shaft (19) to install it to carrier a After assembling the carrier assem-
(20). bly, check that planetary gear (22)
a When installing shaft (19), rotate rotates smoothly.
planetary gear (22), and take
care not to damage the thrust
washers.
3] Insert pin (18).
22 PC600-8
4) Sling and install No. 2 carrier assembly 10. No. 2 ring gear
(17). 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 fit-
ting 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).
a Install the ring gear with the identifica-

tion cut (b) up.
8. No. 2 sun gear

Install No. 2 sun gear (15).
9. Thrust washer
Install thrust washer (14).
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
12. No. 1 carrier assembly a After assembling the carrier assem-

1) Assemble No. 1 carrier assembly as fol- bly, check that planetary gear (10)
lows. rotates smoothly.
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 wash-
ers (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.
3] Insert pin (6).

a When inserting the pin, assemble
so that the 3 notched parts (por-
tion c) on the circumference on 2) Sling and install No. 1 carrier assembly
the pin do not overlap the thin (5).
metal part (portion d) of the car-
rier. (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 oppo-
site 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.
24 PC600-8
13. No. 1 sun gear shaft q Refilling with oil

Install No. 1 sun gear shaft (4). 1) Tighten drain plug (1) and remove oil filler
plug (38).
14. Spacer 3 Drain plug:
Install spacer (3). 59 – 78 Nm {6 – 8 kgm}
2) Set cover with "TOP" position up, and sup-
ply oil up to bottom of oil filler.
5 Final drive case (Each side):
10.5 l (EO30-DH)
3) Tighten oil filler plug (38).
3 Oil filler plug:
59 – 78 Nm {6 – 8 kgm}
a After installing the final drive assem-
bly to the machine, check the oil level
again by the above method.
15. Cover
1) Using eyebolts [1], sling and install cover
(2).
2 Fitting face of cover:
2) Tighten the cover mounting bolts in the fol-

lowing 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
SEN01065-03

© 2010 KOMATSU
All Rights Reserved
26
SEN01066-04
PC600-8
PC600LC-8

PC600-8 30001 and up

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 1
Removal and installation of track 3. Using tool M, pull out master pin.
shoe assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
796-632-1200 Remover, installer t 1

Cylinder (1,471
790-101-4300 t 1
kN {150 ton})
3
M Puller
790-101-4200 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
4 790-331-1100 Wrench t 1 4. Fit block or hydraulic jack [1] (10 ton) under
shoe at idler end, then remove guide pin [2].
[*2]
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.
2. Loosen track shoe tension. [*1]

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. Raise tip of track shoe with crane, and move

machine slowly to rear to open track shoe
assembly (3).
2 PC600-8
Installation
removal.
[*1]
a Adjust the track shoe tension.
For details, see Testing and adjusting, “Adjust-
ing 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 3
Disassembly and assembly of 1
Necessity
Symbol
Sketch
Q’ty
link in field 1
N/R
Special tools 791-685-9560 Bolt t 4

t 1
Necessity
791-126-0150 Adapter
Symbol
Sketch
Q’ty
N/R
Part number Part name 01010-51030 Bolt t 1
791-685-9620 Extension t 1
9
791-680-9580 Adapter t 1 791-680-5542 Adapter t 1
791-680-9590 Guide t 1 791-680-5560 Guide t 1
1
01010-52760 Bolt t 2 790-101-1102 Pump t 1
01010-51440 Bolt t 2 790-101-4300 Cylinder (*1) t 1
790-101-1102 Pump t 1 791-685-9510 Frame t 1
2
790-101-4300 Cylinder (*1) t 1 791-685-9520 Frame t 1
791-685-9510 Frame t 1 791-685-9530 Rod t 1
791-685-9520 Frame t 1 791-685-9540 Rod t 1
791-685-9530 Rod t 1 791-685-9550 Nut t 3
791-685-9550 Nut t 3 791-685-9560 Bolt t 4
791-685-9560 Bolt t 4 791-126-0150 Adapter t 1
3 10
791-680-9570 Adapter t 1 01010-51030 Bolt t 1
01010-51030 Bolt t 1 791-685-9620 Extension t 1
04530-12030 Eyebolt t 1 791-680-5560 Guide t 1
790-101-1102 Pump t 1 791-632-1110 Adapter t 1
790-101-4300 Cylinder (*1) t 1 791-680-9630 Adapter t 1
791-685-9540 Rod t 1 790-101-1102 Pump t 1
4 N
791-685-9550 Nut t 3 790-101-4300 Cylinder (*1) t 1
791-685-9510 Frame t 1 11 790-680-1520 Guide t 1
791-685-9520 Frame t 1 791-685-9510 Frame t 1
791-685-9530 Rod t 1 791-685-9520 Frame t 1
N
791-685-9550 Nut t 3 791-685-9530 Rod t 1
791-685-9560 Bolt t 4 791-685-9540 Rod t 1
791-126-0150 Adapter t 1 791-685-9550 Nut t 3
791-680-5520 Guide t 1 791-685-9560 Bolt t 4
5
791-126-0140 Pusher t 1 12 791-126-0150 Adapter t 1
791-680-9570 Adapter t 1 791-680-5560 Guide t 1
01010-51030 Bolt t 1 791-680-9570 Adapter t 1
04530-12030 Eyebolt t 1 01010-51030 Bolt t 1
791-685-9620 Extension t 1 791-680-1520 Guide t 1
791-101-1102 Pump t 1 790-101-1102 Pump t 1
790-101-4300 Cylinder (*1) t 1 790-101-4300 Cylinder (*1) t 1
790-101-1102 Pump t 1 790-101-1102 Pump t 1
6 13
790-101-4200 Puller (*2) t 1 790-101-4200 Puller (*2) t 1
791-680-5542 Adapter t 1 791-680-9501 Remover, installer t 1
7
791-632-1110 Adapter t 1 790-101-1102 Pump t 1
14
8 791-680-5580 Guide t 1 790-101-4200 Puller (*2) t 1
791-685-9510 Frame t 1 790-101-4300 Cylinder (*1) t 1
791-685-9520 Frame t 1
9 791-685-9530 Rod t 1 (*1) : 1,471 kN{150 ton}
791-685-9540 Rod t 1 (*2) : 294 kN{30 ton}
791-685-9550 Nut t 3
4 PC600-8
Disassembly 4. Set tool N5 (adapter, guide, pusher) in posi-

1. Using two bolts (2), install tool N1 (adapter, tion, then apply hydraulic pressure and remove
guide, bolt) to link (1). pin (3).
a It is also possible to use 2 track bolts for When the cylinder reaches the end of its
bolt (2). 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 5. Set tool N6 (294 kN {30 ton} puller) and spacer
1, eyebolt), then raise chassis and set on track. [1] to center of roller tread of link to be disas-
sembled, 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 5
Assembly 4. Set tools N9 and N10 in same way as for oper-

1. Assemble the link sub-assembly. ation to remove pin, then use tool N9 (adapter,
1) Set tool N7 to end face of link, then press extension, guide, adapter, bolt) for press fitting
fit bushing (1). pin, and tool N10 (extension, guide, adapter,
2) Set tool N7 to end face of link (pin end), bolt) for press fitting bushing, and press fit in
and press fit pin (2). turn.
2. Set link sub-assembly (3) on link to be con- 5. Use tool N13 (294 kN {30 t} puller) in same
nected. 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).
6 PC600-8
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:
PC600-8 7
Removal and installation of idler, 3. Disconnect recoil spring assembly (4) from
recoil spring assembly 1 idler assembly (3). [*1]
4 Idler assembly: 350 kg
Removal
4 Recoil spring assembly: 460 kg
1. Remove track shoe assembly.
For details, see “Removal and installation of
track shoe assembly.”
a Remove lubricator (1).
Installation
2. Sling idler and recoil spring assembly (2), and removal.
pull out to the front to remove.
[*1]
4 Idler and recoil spring assembly: 3 Mounting bolt between idler and recoil
Approx. 800 kg spring: 824 – 1,030 Nm {84 – 105 kgm}
8 PC600-8
Disassembly and assembly of 4. Turn over idler assembly, remove pin (6), then
idler assembly 1 remove support (7).
Special tools 5. Remove shaft (8) from idler.
Necessity
Symbol
Sketch
Q’ty
N/R
1 791-575-1520 Installer t 1
Oil pump assem-
L 791-601-1000 q 1
2 bly
790-701-3600 Adapter q 1
4 Idler assembly: 350 kg
Disassembly
6. Remove 2 floating seals (4) from idler (7).
1. Remove plug (1) and drain oil.
6 Idler: 400 – 500 cc
7. Remove bushings (9) and (10) from idler.
2. Set idler assembly (2) on block [1], remove pin

(3), then remove support (5).
3. Remove floating seal (4).
PC600-8 9
8. Remove floating seals (4) from supports (5) Assembly

and (7). a Clean all parts, and check for dirt or damage.
1. Using tool L1, assemble floating seals (4) to

supports (6) and (3).
a 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.
a 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
3. Using tool L1, assemble floating seal (4) to 8. Turn over idler, and assemble support (5) to
idler. shaft.
a For precautions for installing the floating a When installing the support to the shaft,
seal, see 1. align their pin hole with each other.
9. Install pin (3) to secure support (5).
4. Turn over idler and using tool L1, assemble

floating seal (4).
a For precautions for installing the floating 10. Using tool L2, supply oil by specified quantity,
seal, see 1. then tighten plug (1).
5 Idler: 400 – 500 cc (EO30-DH)
3 Plug: 16.66 – 37.86 Nm {1.7 – 3.8 kgm}
5. Install shaft (8) to idler.
6. Assemble support (7) to shaft.

a When installing the support to the shaft,
align their pin hole with each other.
7. Install pin (6) to secure support (7).
PC600-8 11
Disassembly and assembly of

recoil spring assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
791-685-8502 Compressor t 1
791-635-3160 Extension t 1
1 Cylinder
M 790-101-1600 t 1
(686 N {70 ton})
790-101-1102 Pump t 1
2 790-201-1500 Push tool t 1
Disassembly
8 2
7
10
5
6
3 4
9
14
12 13 11
1 CEP00054
1. Remove piston assembly (2) from recoil spring 2) Apply hydraulic pressure slowly to com-
assembly. press spring, then remove lock plate (3),
and remove nut (4).
2. Disassembly of recoil spring assembly a Compress the spring to a point where
1) Set tool M1 to recoil spring assembly (1). the nut becomes loose.
k The recoil spring is under large a Free length of spring:
installed load, so be sure to set the Approx. 859 mm
tool properly. Failure to do this is 3) Remove yoke (6), cylinder (7) and dust
dangerous. seal (8) from spring (5).
a Installed load of spring:
291.8 kN {29,770 kg} 3. Disassembly of piston assembly
1) Remove lock plate (10) from piston (9),
then remove valve (11).
1 M1 2) Remove snap ring (12), then remove U-
packing (13) and ring (14).
CEP00055
12 PC600-8
Assembly 3. Assemble piston assembly (2) to recoil spring

1. Assembly of piston assembly assembly (1).
1) Assemble ring (14) and U-packing (13) to 2 Piston sliding portion and wear ring:
piston (9), and secure with snap ring (12). Grease (G2-LI)
2) Tighten valve (11) temporarily, and secure a Assemble the cylinder assembly so that
with lock plate (10). the mounting position of the valve is 90° to
the side.
2. Assembly of recoil spring assembly a Fill the inside of the cylinder with approx.
1) Using tool M2, assemble dust seal (8) to 200 cc of grease (G2-LI), then bleed the
cylinder (7). air and check that grease comes out of the
grease hole.
M2
8
CEP00062
2) Assemble cylinder (7) and yoke (6) to

spring (5), then set to tool M1.
2 Sliding portion of cylinder:
Grease (G2-LI)
3) Apply hydraulic pressure slowly to com-
press 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
Removal and installation of track 3. Lower chassis completely, remove mounting

roller assembly 1 bolts of track roller assembly (3), then jack up
machine with work equipment, and remove
Removal track roller assembly (3) to outside of machine.
1. Lower work equipment to ground, then loosen [*3]
lubricator (1), and relieve track tension. [*1] 4 Track roller assembly: Approx. 110 kg
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.
Installation
removal.
2. Remove mounting bolts of track roller guard [*1]

(2), then swing work equipment 90°, jack up a Adjust the track tension.
machine with work equipment, and remove For details, see Testing and adjusting, “Testing
track roller guard (2) towards outside of and adjusting track shoe tension.”
machine. [*2]
[*2]
4 Track roller guard: 50 kg 2 Roller guard mounting bolt:
3 Roller guard mounting bolt:
1,180 – 1,470 Nm {120 – 150 kgm}
[*3]
2 Track roller assembly mounting bolt:
3 Track roller assembly mounting bolt:
980 – 1,176 Nm {100 – 126 kgm}
14 PC600-8

track roller assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
3 791-560-1520 Installer t 1
Oil pump
L 791-601-1000 q 1
4 assembly
790-701-3600 Adapter q 1
4 Track roller assembly: 110 kg
Disassembly
7 8 5
6
10
4
9
3
1
2
11
CEP00084
1. Remove pin (1), then remove collar (2). 3. Pull out roller (4) from shaft (5).
a It is filled with 540 – 660 cc. of oil, so drain
2. Remove floating seals (3) from collar (2) and the oil at this point or lay a cloth to prevent
roller (4). the area from becoming dirty.
4. Remove floating seals (6) on opposite side

from roller (4) and collar (8).
PC600-8 15
5. Remove pin (7), then remove collar (8) from Assembly

shaft (5). 1. Using push tool [1], press fit bushings (9) and
(10) to roller (4).
6. Remove bushings (9) and (10) from roller (4).
2. Assemble collar (8) to shaft (5), and install pin
(7).
3. Using tool L3, install floating seals (6) to shaft

(5).
a When installing the floating seal, clean,
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
a After installing the floating seal, check that
its angle is within 1 mm and its projection
(a) is 5 – 7 mm.
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
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 main-
tained for 10 seconds and the indicator of
the gauge shall not go down.
L4
6. Turn over roller (4) and shaft (5) assembly.
7. 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 Track roller oil:
540 – 660 cc (EO30-DH)
3 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
1 To vacuum tank
2 CEP00201
11
5
CEP00099
CEP00202
PC600-8 17
Removal and installation of Installation

carrier roller assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Lower work equipment to ground, then loosen [*1]
lubricator (1), and relieve track tension. [*1] a Adjust the track tension.
k The adjustment cylinder is under For details, see Testing and adjusting, “Testing
extremely high pressure, so never and adjusting track shoe tension.”
loosen the lubricator more than one
turn. If the grease does not come out, [*2]
move the machine backwards and for- 3 Carrier roller assembly mounting bolt:
wards. 490 – 607 Nm {50 – 62 kgm}
2. Using hydraulic jacks, push up track to a posi-

tion where carrier roller assembly can be
removed, then remove carrier roller assembly
(2). [*2]
4 Carrier roller assembly: 50 kg
18 PC600-8
Disassembly and assembly of 5. Remove floating seal (6) from support (7).
carrier roller assembly 1
6. Secure support (7) with block [3].
Special tools
7. Using push tool [4], push shaft (8) out of sup-
Necessity
port (7) with press.
Symbol
Sketch
Q’ty
N/R
5 791-651-1510 Installer t 1
Oil pump assem-
L 791-601-1000 q 1
6 bly
790-701-3600 Adapter q 1
4 Carrier roller assembly: 50 kg
Disassembly
1. Remove plug (1) to drain oil.
6 Carrier roller assembly: 135 – 165 cc 8. Remove floating seal (9) from roller (5).
9. Remove bushings (10) and (11).
4. Remove shaft (4) from roller (5).

a If roller (5) is erected, shaft assembly (4)
falls. Take care.
PC600-8 19
Assembly 3. Using push tool [4], press fit shaft (8) to sup-
1. Using tool [5], press fit bushing (10) to roller port (7).
(5).
a Press fit bushing (11) similarly. 4. Using tool L5, press fit floating seal (6) to sup-
port (7).
2. Using tool L5, press fit floating seal (9) to roller a For fitting procedure of the floating seal,
(5). see 2 above.
a When installing the floating seal, clean, 5. Install shaft assembly (4) to roller (5).
faces of the O-ring and floating seal 6. Install cover (3).
(hatched parts in the figure below). Take 3 Mounting bolt:
care that dirt does not stick to the contact 44.12 – 53.93 Nm {4.5 – 5.5 kgm}
a After installing the floating seal, check that 7. Install cover (2).
its angle is within 1 mm and its projection 3 Mounting bolt:
(a) is 9 – 11 mm. 44.12 – 53.93 Nm {4.5 – 5.5 kgm}
20 PC600-8
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 pres-
sure 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 Carrier roller: 135 – 165 cc (EO30-DH)
3 Plug:
30.89 – 37.75 Nm {3.15 – 3.85 kgm}
PC600-8 21
Removal and installation of 5. Disconnect all upper pipes (2) of the center
revolving frame assembly 1 swivel joint.
a Before disconnecting each hose, mark it
Removal with a tag etc. to indicate its position.
a Install oil stopper plugs to the discon-
1. Remove the work equipment assembly. For nected hoses.
details, see “Removal and installation of work
equipment assembly.” 6. Pull out pin (3) and move link (4) toward the
frame.
k Stop the engine.
hydraulic tank.

terweight assembly.”
3. Disconnect grease tube from the swing circle.
4. 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 7. Revolving frame assembly [*1], [*2]
bolts. 1) Using M46 eyebolts (EB) (Length: Min.
a If the engine is not started, remove the 450 mm), install wires to the counter-
swing motor and swing the upper structure weight mounting portion and boom cylin-
with a crane. der 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
Installation
removal.
[*1]
3 Mounting bolt:
1,860 – 1,910 Nm {189 – 195 kgm}
[*2]
2 Top of swing circle: Gasket sealant (LG-6)

again.
PC600-8 23

counterweight assembly 1 q Carry out installation in the reverse order to
removal.
Removal
k Lower the work equipment to the ground [*1]
and stop the engine. a Evenly adjust the clearance between the door
and counterweight and that between the
1. Sling counterweight assembly (1) temporarily. revolving frame and counterweight to 15 ± 5
a No eyebolts are necessary. mm.
3 Counterweight mounting bolt:
2. Remove mounting bolts (2). 3,430 – 4,212 Nm {350 – 430 kgm}

a Width across flats: 65 mm
3. Lift off counterweight assembly (1). [*1]

4 Counterweight assembly:
10,750 kg (For countries other than USA)
13,500 kg (For USA)
24 PC600-8
Removal and installation of

counterweight remover assembly1
Removal
tubes and hoses.
1. Remove the mounting bolts and lower counter-

weight (2). [*1]
a Width across flats of mounting bolt: 65 mm
4. Disconnect hoses (7) – (9).
ally to release the internal pressure of the 5. Disconnect clamp (10).
hydraulic tank.
2. Remove pin (1) and disconnect counterweight

(2).
6. Disconnect clamps (13) – (17).
3. Disconnect hoses (3), (5) and (6).

PC600-8 25
7. Sling counterweight remover assembly (11). Installation

removal.
[*1]
3 Counterweight mounting bolt:
3,430 – 4,212 Nm {350 – 430 kgm}

again.
8. Remove mounting bolts (12) and lift off coun-

terweight remover assembly (11).
4 Counterweight remover assembly:
1,270 kg
26 PC600-8
Attaching procedure for counterweight noise

insulation sheet
a Attach the counterweight noise insulation
sheets according to the following procedure.
1. Attach the noise insulation sheets (1), (2), (3),
(4), (5), (6), (7) and (8) to the front surface of
the counterweight.
a The surface of the counterweight for noise
insulation sheets to be attached should be
degreased and free from rust completely.
2. Attach the noise insulation sheets with the sur-
face (a) which has no SG sheet (black surface)
facing downward.
PC600-8 27
SEN01066-04

© 2011 KOMATSU
All Rights Reserved
28
SEN01067-03
PC600-8
PC600LC-8

PC600-8 30001 and up

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 1
Removal and installation of 5. Disconnect hose (4) from filter (F).

hydraulic tank assembly 1
Removal
hydraulic tank.
tubes and hoses.
6. Disconnect hoses (5) – (8) from under filter (F).
1. Drain the hydraulic oil.
6 Hydraulic oil: 360 l (Refill capacity)
2. Remove handrails (1).
3. Remove plate (2).
7. Remove the undercover.
8. Disconnect hoses (9) – (12) from the inside

rear of hydraulic tank (27).
2 PC600-8
9. Disconnect hoses (13) – (22) from the rear of 13. Remove 4 bolts (26) from the front of the
the hydraulic tank. hydraulic tank.

a There is another clamp under clamp (23).
11. Disconnect connector P22 (24).
14. Remove the mounting bolts and lift off hydrau-

lic tank (27).
4 Hydraulic tank assembly: 430 kg
12. Disconnect suction tube (25). Installation

a Since suction hose (SH) is fixed with q Carry out installation in the reverse order to
MIKALOR clamp, do not disconnect it. If it removal.
is disconnected, see “Removal and instal-
lation of hydraulic pump assembly”, Instal- q Refilling with oil (Hydraulic tank)
lation. Add oil through the oil filler to the specified
again.
5 Hydraulic oil: 360 l (Refill capacity)
PC600-8 3
Removal and installation of 7. Remove cover (3).

hydraulic pump assembly 1
Special tool
Necessity
Symbol
Sketch
Q’ty
N/R
S 796-660-2010 Oil stopper q 1
Removal
hydraulic tank.
tubes and hoses.
1. 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:
8. Lift off cover assembly (5).
360 l (Refill capacity)
9. Disconnect dust indicator hose (6).
10. Disconnect hose clamp (7). [*1]
11. Remove air cleaner bands (8). [*2]
12. Remove air cleaner (9).
13. Remove air cleaner bracket.
4. Remove handrail (2).
5. Disconnect hose (4) from reservoir tank (RT)

under cover (3).
6. Disconnect connector P24 from the bottom of

reservoir tank (RT).
4 PC600-8
14. Upper side of pump No. 2 16. Lower side of pump No. 2
1) Remove bracket (11). 1) Disconnect 3 hoses (28).
2) Disconnect 4 hoses (12). 2) Disconnect suction connector (29).
3) Disconnect hose (13). a Since suction hose (SH2) is fixed with
MIKALOR clamp, do not disconnect
Upper side of cooling fan pump (G.P.) it.
Disconnect hoses (14) – (18).
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 discon-
nect 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 18. Lift off each pump
4
it.
Pump No. 1 assembly (No. 1): 170 kg
4 Cooling fan pump assembly (G.P.): 90 kg
PC600-8 5
Installation 3) Set bridge (BR) under the clamp bolt and adjust
q Carry out installation in the reverse order to its overlap (b) with bridge (BR) to at least 5 mm.
removal. 4) Tightening of the clamp.
2 Threads of clamp bolt (BC):
[*1] Lubricating oil (THREEBOND PANDO 18B)

3 Air hose clamps (right and left): a Do not use an impact wrench.
8.3 – 9.3 Nm {0.85 – 0.95 kgm} q When reusing the hose
Install the clamp to the clamp mark made
[*2] on the hose.
3 Air cleaner band: 3 Clamp bolt: Min. 6 Nm {0.6 kgm}
17.6 – 21.6 Nm {1.8 – 2.2 kgm} q When using a new hose

Tighten until dimension (a) is as follows.
Reference 12 – 15 mm: SH
q When suction hoses (SH), (SH1), (SH2), and 7 – 10 mm: SH1, SH2, SHG
(SHG) are disconnected
a Since these hoses are fixed with MIKALOR
clamps, observe the following precautions
when installing them.

1) Use new MIKALOR clamps. again.
Set each hose to the original position. 5 Hydraulic oil: 360 l (Refill capacity)
2) Insertion depth: 95 mm (SH)
85 mm (SH1, SH2)
80 mm (SHG) q Bleeding air
Bleed air from the hydraulic circuit. For details,
a Apply adhesive evenly over the tube side. see Testing and adjusting, “Bleeding air from
2 Apply evenly over the tube side:
each part”.
Adhesive (THREEBOND 4314)
6 PC600-8

control valve and solenoid valve
assembly 1
Removal
hydraulic tank.
k Bleed air from the hydraulic circuit. For
details, see Testing and adjusting, “Releas-
ing remaining pressure in hydraulic cir-
cuit.”
a Before disconnecting each hose, make a
match mark on it or fit a tag to it to indicate its
position.
tubes and hoses.
1. 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).

valve and arm and bucket cylinders.
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 7
5. Remove hose (22) between the control valve 14. Sling control valve and solenoid valve assem-
and return filter. bly (32) temporarily and remove it together
with the bracket.
4
6. Disconnect 2 hoses (23) between the line filter
Control valve and solenoid valve assembly:
and control valve.
330 kg
7. Disconnect 3 return hoses (24).
9. Disconnect 3 hoses (26).
10. Disconnect connectors P03 (27) and P26 (28).
Installation
removal.

11. Disconnect each tube (29) from the control
again.
valve side or opposite side.
a Disconnect the tubes from the chassis 5 Hydraulic oil: 360 l (Refill capacity)
completely, if necessary.
q Bleeding air
12. Disconnect all PPC hoses (30) from the front
Bleed air from the hydraulic circuit. For details,
and rear of the control valve.
see Testing and adjusting, “Bleeding air from
each part”.
13. Disconnect all hoses (31) from each solenoid
valve.
8 PC600-8

control valve assembly 1
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 direc-
tions.
a Apply liquid seal (SEALEND 242 or equivalent)

to the mating faces.
2 Mating faces:
Liquid seal (SEALEND 242 or equivalent)
PC600-8 9
Disassembly and assembly of main control valve assembly 1

Disassembly
10 PC600-8
a Since the set pressure of the safety valve can- 6. Bucket valve
not be adjusted without removing it from the 1) Remove case (28). Remove spring (29)
machine, do not disassemble it. and retainer (30), then pull out spool (31).
q The left main control valve is explained below 2) Remove case (32), then remove spring
as an example. (33) and retainer (34).
q Apply to the spools of the arm LO valve,
1. Main relief valve, jet sensor relief valve service valve (right control valve) and arm
Remove main relief valve (1) and jet sensor HI valve (left control valve).
relief valve (2). q Arm LO valve (Right control valve)
A retainer is installed between case
2. Safety valves having suction ports (32) and spring (33).
Remove safety valves (3) and (5) having suc- q Arm HI (Left control valve)
tion ports. Shim (35) is installed.
3. Check valve 7. Straight travel valve

Remove plug (6), then remove spring (7) and 1) Remove plate (36), then remove spring (37).
check valve (8). 2) Remove plug (38), then pull out spool (39).
4. 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.
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.
5. 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 pri-
ority valve (right control valve) in 1) and 2)
above are installed reversely.
PC600-8 11
Assembly
12 PC600-8
1. Straight travel valve 5. Check valve

1) Install spool (39) and fit the O-ring, then Install check valve (8) and spring (7), then fit
install plug (38). the O-ring and install plug (6).
2) Install spring (37), then install plate (36). 3 Plug: 177 – 216 Nm {18 – 22 kgm}
2. Bucket valve 6. Safety valves having suction ports

1) Install spool (31). Install retainer (34) and Fit the O-ring, then install safety valves (5) and
spring (33), then fit the O-ring and install (3) having suction ports.
case (32). 3 Safety valve having suction port:
2) Install retainer (30) and spring (29), then fit 216 – 235 Nm {22 – 24 kgm}
the O-ring and install case (28).
q Apply to the spools of the arm LO valve, 7. Jet sensor relief valve and main relief valve
service valve (right control valve), and arm Install jet sensor relief valve (2) and main relief
HI valve (left control valve). valve (1).
q Arm LO valve (Right control valve) 3 Jet sensor relief valve:
Install the retainer between case (32) 49 – 58.8 Nm {5 – 6 kgm}
and spring (33). 3 Main relief valve:
q Arm HI valve (Left control valve) 177 – 196 Nm {18 – 20 kgm}
Install shim (35).
3. 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 con-
trol valve) in 1) and 2) above.
4. 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)
not installed.
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.
PC600-8 13
Removal and installation of swing Installation

motor assembly 1 q Carry out installation in the reverse order to
removal.
Removal
k Lower the work equipment to the ground [*1]
and stop the engine. a When installing, apply gasket sealant to the
k Loosen the cap of the hydraulic tank gradu- following parts. (Apply the gasket sealant
ally to release the internal pressure of the around the bolt hole only at oil check hole (a).)
hydraulic tank. a When applying the gasket sealant to the ring
gear, take care.
1. Remove step (1). 2 Mating face of swing motor assembly:
valve and swing motor.
a Install tags and oil stopper plugs to all the
disconnected hoses.
3. Disconnect 2 suction hoses (3).
4. Disconnect 2 swing holding brake hoses (4).
5. Disconnect 3 drain hoses (5).
6. Remove hose bracket (6).
7. Lift off swing motor assembly (7). [*1]

4
Swing motor assembly: 60 kg (1 piece)
again.
q Bleeding air
Bleed air from the swing motor. For details, see
Testing and adjusting, “Bleeding air from each
part”.
14 PC600-8
Removal and installation of center Installation

swivel joint assembly 1 q Carry out installation in the reverse order to
removal.
Removal
k Lower the work equipment completely to q Refilling with oil (hydraulic tank)
the ground and stop the engine. Then Add oil through the oil filler to the specified
loosen the oil filler cap of the hydraulic tank level. Run the engine to circulate the oil
slowly to release the pressure inside the through the system. Then check the oil level
hydraulic tank. again.
1. Disconnect all hoses (1) at bottom of center q Bleeding air

swivel joint assembly. Bleed the air from the travel motor.
a Before disconnecting, mark all the hoses For details, see Testing and adjusting, “Bleed-
with tags to prevent mistakes in the ing air from each part”.
mounting position when installing.
2. Remove elbow (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.
4. Pull out pin (4) and move link (5) towards frame.
5. Sling center swivel joint assembly (6), then

remove 4 mounting bolts from bottom.
4 Center swivel joint assembly: 45 kg
PC600-8 15

center swivel joint assembly 1 1
Special tools
2
Necessity
Symbol
Sketch
Q’ty
3
N/R
790-101-2501 Push-puller t 1
790-101-2510 • Block t 1 4
790-101-2520 • Screw t 1
791-112-1180 • Nut t 1
T1 790-101-2540 • Washer t 1
7
790-101-2630 • Leg t 2
790-101-2570 • Plate t 2
790-101-2560 • Nut t 2 6
790-101-2660 • Adapter t 2
Disassembly 5
2. Remove snap ring (2). CEP00381
3. Using tools T1, pull out swivel rotor (4) and ring
(3) from swivel shaft (5).
4. Remove O-rings (6) and slipper seals (7) from

swivel rotor (4).
16 PC600-8
Assembly
1. Assemble slipper seals (7) and O-rings (6) to 1
swivel rotor.
2. Set swivel shaft (5) on block [2], then using 2

push tool [1], tap swivel rotor (4) with a plastic
hammer to install. 3
2 Contact surface of rotor, shaft:
Grease (G2-LI)
a When installing the rotor, be extremely
4
careful not to damage the slipper seal and
O-ring.
CEP00381
3. Install ring (3) and secure with snap ring (2).
4. Fit O-ring and install cover (1).

3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
PC600-8 17

work equipment PPC valve 1
assembly 1
Disassembly 2
1. Remove nut (1), then remove disc (2) and boot
(3).
4
2. Remove bolts, then remove plate (5).
a Do not remove joint (4) unless it is to be
replaced.
3
3. Remove seal (6) and collar (7).
4. Pull out piston (8), and remove retainer (9),

springs (10) and (11), and shim (12). a 5
a Spring (10) consists of two springs each of
two types with different installed loads, so 6
check the mounting position (hydraulic
port) and mark with tags to prevent mis- 7
takes when installing.
8
5. Pull out valve (13) from body (14).
9
10
11
12
13
14
CEP00424
18 PC600-8
Assembly 7. Assemble boot (3) and disc (2), and tighten

1. Assemble valve (13) to body (14). with nut (1).
3 Nut: 112.8 ± 14.7 Nm {11.5 ± 1.5 kgm}
2. Assemble shim (12) and spring (11) to valve a After assembling the disc, adjust the
(13). height of the disc.
a When assembling spring (11), set the end For details, see Testing and adjusting,
with the small coil diameter (inside diame- “Adjusting PPC valve”.
ter) at shim (12) end.
3. 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 Free length of spring (mm)
P1, P2 44.4
P3, P4 42.4
a 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 out-
side of the piston and the inside of the
hole in the body with grease.
4. Fit O-ring to collar (7) and assemble in body

(14), then install seal (6).
5. Install plate (5).

3 Mounting bolt:
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
6. Install joint (4).

2 Sliding portion of joint: Grease (G2-LI)
2 Female thread of body:
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.
PC600-8 19

travel PPC valve assembly 1
Special tool
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
2 796T-416-1040 Push tool t 1 Q
T 3 796T-416-1050 Push tool t 1 Q
4 796T-416-1020 Push tool t 1 Q
Disassembly
1. Remove screw (27) to remove lever (26). 6. Remove seal (8) and collar (10).
2. Remove mounting bolt (15) to remove case 7. Remove piston (7) to remove retainer (5),
(11), shaft (16) and lever (13) assembly. springs (6) and (4) and shim (3).
a Store shim (3) after checking the thickness
3. Remove pin (19). and the number of shims at each mount-
ing position.
4. Remove shaft (13), bushings (20) (20a) and
lever (12) from the case. 8. Remove valve (2) from body (1).
5. 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).
20 PC600-8
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.
a When installing piston (7), apply grease (G2-

LI) to its outside and the inside of the body
hole.
a Install spring (4) with its small diameter side on

the shim (3) side.
q Diameter of spring (Inside diameter) 3) Install lever (12).
Small diameter side: 4.9, Large diameter 4) Install shaft (13).
side: 5.55 5) Using tool T4, install pin (19).
a Installing dimension (C) of the pin
a Assemble shaft (13) with the following proce- (17) should be as follows.
dure. q C: 0 – 0.5 mm
1) Using tool T2, install bushing (20) to case. a Do not apply shock load to the pin
a Install bushing from 10° chamfered directly.
side.
a Installing dimension (A) of the bush-
ing should be as follows.
q A: 24.8 ± 0.3 mm
Do not apply shock load to the bushing
directly.
a 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:
2) Using tool T3, install bushing (20a) to 4 – 8 cc/periphery
case. Contact surfaces of lever and piston:
a Install bushing from 10° chamfered 0.3 – 0.8 cc/place
side. Contact surfaces of plate and pin:
a Installing dimension (B) of the bush- 0.3 – 0.8 cc/place
ing (14a) should be as follows. (End
surface of bushing will tightly fit to the a Install washer (18) 1.6 mm thick first. If the dif-
end surface of case.) ference between both sides at the stroke end
q B: 5.3 ± 0.3 mm of the lever exceeds 0.7°, change the washer
a Do not apply shock load to the bush- thickness to reduce the difference to below
ing directly. 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
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
Disassembly and assembly of 4) Disassemble piston rod assembly as fol-

hydraulic cylinder assembly 1 lows.
1] Set piston rod assembly (2) to tool
Special tools U1.
Necessity
Symbol
Sketch
Q’ty
N/R
Cylinder repair
1 790-502-1003 q 1
stand
2 790-720-1000 Expander q 1
796-720-1670 Ring q 1
3
07281-01279 Clamp q 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
4
790-201-1871 • Push tool 1 2] Remove piston assembly stopper
U 790-445-4210 • Push tool 1 screw (3).
790-201-1881 • Push tool 1 Screw size:
M12 × pitch 1.75: Boom, Arm, Bucket
790-101-5021 • Grip 1
01010-50816 • Bolt 1
5
790-201-1680 • Plate 1
790-201-1970 • Plate 1
790-201-1690 • Plate 1
790-102-4300 Wrench t 1
6
790-102-4310 Pin t 2
Disassembly
1. Piston rod assembly
1) Remove piping from cylinder assembly.
2) Remove mounting bolts, and disconnect a If screw (3) has been caulked
head assembly (1). strongly and cannot be removed,
3) Pull out piston rod assembly (2). screw it in fully, then fit a tap to
a Place a container under the cylinder the thread and pull it out.
to catch the oil.
PC600-8 23
3] Using tool U6, remove piston assem- 2. Disassembly of piston assembly

bly (4). 1) Remove ring (11).
q When not using tool U6, use the 2) Remove wear ring (12).
drill holes (ø10: 2 places) and a 2 pieces are installed to each of the
loosen the piston assembly. 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] Remove plunger (5).

5] Remove collar (6).
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
Assembly 2. Assembly of piston assembly

a Be careful not to damage the packings, dust 1) Using tool U2, expand piston ring (13).
seals, and O-rings. a Set the piston ring on tool U2, and
a Do not try to force the backup ring into posi- tu rn the han dle 8 – 1 0 times to
tion. Warm it in warm water (50 – 60°C) before expand the ring.
fitting it. 2) Set tool U3 in position, and compress pis-
ton ring (13).
1. 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).
3) Install O-ring and backup ring (14).

4) Assemble wear rings (12).
5) 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
3. Piston rod assembly 6) Assemble piston assembly (4) as follows.

1) Set piston rod assembly (2) to tool U1. q When using rod and piston assem-
bly (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) Assemble head assembly (7).

3) Fit O-ring and backup ring to collar (6),
then assemble.
4) 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}
3] Caulk thread at 4 places with
punch.
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
q 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] After machining, wash thor-
oughly to remove all metal parti-
cles and dust.
4] Tighten screw (3).
2 Threaded part:
Adhesive
(Locktite No. 262 or equivalent)
3 Screw:
58.9 – 73.6 Nm {6 – 7.5 kgm}
5] Caulk thread at 4 places with
punch.
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
Drill Tap
Cylinder hole Tap used
diameter depth
depth
Bucket
10.3 36 12 x 1.75 29
Boom
Arm 10.3 43 12 x 1.75 36
PC600-8 27
7) Assemble piston rod assembly (2).

2 Seal portion: Grease (G2-LI)
a Set the end gap of the ring at the hor-
izontal (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 Tightening torque

Bucket, Boom 892 ± 137 Nm {91.0 ± 14 kgm}
Arm 1,270 ± 200 Nm {130 ± 20 kgm}
9) Install piping.
28 PC600-8
Disassembly and assembly of Assembly

grease gun assembly 1 1. Install joint (1) to the hose.
a Wind seal tape two to three times around
Disassembly the threaded portion as to bite into it start-
1. Remove joint (1) from the hose. ing from a position one winding away from
the end of the threaded portion.
2. Remove gun assembly (2) from joint (1). 3 Joint screwing portion:
5.9 – 11.8 Nm {0.6 – 1.2 kgm}
3. Remove nozzle (3) from gun assembly (2).
2. Install gun assembly (2) to joint (1).
4. Remove cap (4) from nozzle (3). a Wind seal tape two to three times around
the threaded portion as to bite into it start-
ing 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}
3. Install nozzle (3) to gun assembly (2).

a Wind seal tape two to three times around
the threaded portion as to bite into it start-
ing 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 fur-
ther screw in using nozzle (3).
4. Install cap (4) to nozzle (3).
PC600-8 29
SEN01067-03

© 2009 KOMATSU
All Rights Reserved
30
SEN01068-02
PC600-8
PC600LC-8

PC600-8 30001 and up

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 1
Removal and installation of 5. Sling bucket cylinder assembly (3) temporarily

bucket cylinder assembly and remove pin (4) on the bottom side and
then remove bucket cylinder assembly. [*2]
(Backhoe specification) 1 a Check the quantity and positions of the
inserted shims.
Removal
k Retract the bucket cylinder piston rod to 4 Pin (4): 25 kg
4
about 200 mm before the dump stroke end,
Bucket cylinder assembly: 470 kg
lower the work equipment to the ground,
and set the lock lever in the lock position.
1. Set block [1] under the arm top, block [2]

between the link and arm, and block [3]
between the bucket cylinder and arm.
2. Remove pin (1) on the head side. [*1]
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 resid-
ual pressure from the hydraulic cir-
cuit. For details, see Testing and
adjusting, "Releasing remaining pres-
sure in hydraulic circuit."
4. Disconnect right and left hoses (2).
2 PC600-8
Installation q Bleeding air

q Carry out installation in the reverse order to Bleed air from the hydraulic cylinder. For
removal. details, see Testing and adjusting, "Bleeding
air from each part."
[*1]
2 Inside surface of bushing: q Refilling with oil (Hydraulic tank)
Molybdenum disulfide lubricant (LM-P) Add oil through the oil filler to the specified
2 Greasing after installing pin: level. Run the engine to circulate the oil
Molybdenum disulfide grease (LM-G) through the system. Then, check the oil level
k When aligning the pin holes, never insert again.
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]
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
a Adjust clearance (b) between the bottom end
of cylinder (3) and bracket (7) to below 1 mm
with the shim.
PC600-8 3
Removal and installation of 3. Disconnect grease tube (2).

bucket cylinder assembly
(Loading shovel specification) 1
Removal
k Extend the arm cylinder fully, set the bot-
tom of the bucket horizontal, lower the
work equipment completely to the ground
and stop the engine. Operate the control
levers several times to release the remain-
ing pressure in the hydraulic piping.
k Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
a Fit plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering.
1. Sling bucket cylinder assembly, and remove

plate, then using forcing screws (Thread dia. = 5. Sling piston rod end and bottom end, and
16 mm, Pitch = 2.0 mm), remove pin (1). [*1] remove plate, then using forcing screws (Thread
dia. = 16 mm, Pitch = 2.0 mm), pull out pin (4).
4 Pin: 40 kg [*2]
a Pull out the pin to a position where the cyl-
inder 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. 6. Raise bucket cylinder assembly (5) carefully
For details, see Testing and adjusting, and remove.
“Releasing pressure in PPC circuit”. 4 Bucket cylinder assembly: 410 kg
4 PC600-8
Installation
removal.
[*1]
k When aligning the mounting position of the
pin, do not insert your fingers in the pin
hole.
[*2]
hole.
a Adjust with shims so that the clearance at
the cylinder bottom end is less than 1 mm.
a Bleed the air from the work equipment circuit.

For details, see Testing and adjusting, “Bleed-
ing air from hydraulic cylinder”.
q Refilling with oil

a Add oil to the specified level, and run the
engine to circulate the oil through the sys-
tem. Then check the oil level again.
PC600-8 5
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.
1. Set block [2] between the arm cylinder and

boom.
2. Disconnect grease hose (1).

3. Pull out head pin (2). [*1]
a If the head pin cannot be pulled out, use 7. Sling arm cylinder assembly (6) temporarily,
tool [1]. remove plate (7), and pull out bottom pin (8).
4
[*2]
Pin (3): 35 kg
a If the bottom pin cannot be pulled out, use
4. Run the engine and retract the piston rod and tool [1].
bind it with wires etc. to prevent it from coming a Check the quantity and positions of the
out. inserted shims.
k Release the residual pressure from the 4 Pin (8): 40 kg
hydraulic circuit. For details, see Test-

ing and adjusting, "Releasing remain- 8. Remove arm cylinder assembly (6).
ing pressure in hydraulic circuit." 4 Arm cylinder assembly: 730 kg

a Fit an oil stopper plug to the disconnected
hose to prevent foreign matter from enter-
ing the hose.
6 PC600-8
Installation
removal.
[*1]
[*2]
a Adjust clearance (a) between the bottom end
of cylinder (6) and bracket (9) to below 1 mm
with the shim.
q Bleeding air
Bleed air from the hydraulic cylinder. For
details, see Testing and adjusting, "Bleeding
air from each part."

again.
PC600-8 7
Removal and installation of arm 3. Disconnect hoses (3).

cylinder assembly
4. Sling piston rod end and bottom end, and
(Loading shovel specification) 1 remove plate, then pull out pin (4). [*2]
a Pull out the pin to a position where the cyl-
Removal
k
inder bottom can be disconnected.
Retract boom cylinder fully, and extend arm
cylinder, then set the bottom of the bucket 4 Pin: 30 kg
horizontal, lower the work equipment com-
pletely to the ground and stop the engine.
Operate the control levers several times to
release the remaining pressure in the
hydraulic piping.
a Fit blind plugs in the hoses after disconnecting
1. Sling arm cylinder assembly, and remove plate,

then pull out pin (2). [*1]
a Pull out the pin to a position where the pis-
ton rod can be disconnected.
4 Pin: 30 kg 5. Lift off arm cylinder assembly (5) carefully.
4 Arm cylinder assembly: 600 kg

k Tie the rod with wire to prevent it from
coming out.
pressure inside the piping.
For details, see Testing and adjusting,
“Releasing pressure in PPC circuit”.
8 PC600-8
Installation
removal.
[*1]
hole.
[*2]
hole.


PC600-8 9
Removal and installation of boom 6. Start engine, and retract piston rod, then tie
cylinder assembly piston rod with wire to prevent it from coming
out.
k Stop the engine and release the
remaining pressure in the circuit. For
Removal
k
details, see Testing and adjusting,
Retract the arm and bucket cylinder piston
"Releasing remaining pressure in
rods fully, lower the work equipment com-
hydraulic circuit."
pletely to the ground, then put the work
equipment lock lever in the LOCK position.
7. Support boom cylinder assembly (2) with a
a Fit blind plugs in the hoses to prevent dust or
stand, etc., and disconnect hose (4).
dirt from entering.
8. Sling boom cylinder assembly and remove
plate (6).
2. Sling boom cylinder assembly (2) temporarily,
and remove lock bolt (8).
3. Remove plate (9).

a Check the number, thickness, and posi-
tions of the shims.
4. Sling boom cylinder assembly (2) temporarily.
9. Pull out bottom pin (7). [*2]

a If the bottom pin cannot be pulled out eas-
ily, use the forcing taps (16 x 2).
4 Pin (7): 30 kg
5. Using tool [1], pull out head pin (3), then dis-
connect 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
Installation q Bleeding air

q Carry out installation in the reverse order to Bleed the air.
removal. For details, see Testing and adjusting, "Bleed-
ing air from each part."
[*1]
2 Inside surface of bushing: q Refilling with oil (hydraulic tank)
Molybdenum disulfide lubricant (LM-P) Add oil through oil filler to the specified level.
2 Lubrication after fitting pin: Run the engine to circulate the oil through the
Molybdenum disulfide grease (LM-G) system. Then check the oil level again.
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]
2 Lubrication after fitting pin:
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
Removal and installation of boom 5. Lower boom cylinder assembly onto stand,
cylinder assembly then disconnect hoses (4).
Removal
k Extend the arm and bucket fully, lower the
work equipment completely to the ground
and stop the engine. Operate the control
levers several times to release the remain-
ing pressure in the hydraulic piping.
a Fit plugs in the hoses after disconnecting them,
to prevent dirt or dust from entering.

6. Sling boom cylinder assembly, and remove
2. Remove plate (2). plate, then using forcing screws (Thread dia. =
16 mm, Pitch = 2.0 mm), pull out foot pin (5).
3. Sling boom cylinder assembly, pull out pin (3), [*2]
and disconnect piston rod from boom. [*1]
7. Remove boom cylinder assembly (6).

4. Start engine and retract piston rod fully. 4 Boom cylinder assembly: 550 kg
k Tie the rod with wire to prevent it from com-
ing out.
k After stopping the engine, release the pres-
sure inside the piping.
12 PC600-8
Installation
removal.
[*1]
pin, do not insert your fingers in the pin hole.
[*2]


PC600-8 13
Removal and installation of 5. Remove 3 mounting bolts, then using forcing

bottom dump cylinder assembly screws (Thread dia. = 16 mm, Pitch = 2.0 mm),
pull out pin (4). [*2]
4 Pin: 20 kg
Removal
k Set the bottom of the bucket horizontal, and 6. Lift off bottom dump cylinder assembly (5).
4
retract the rod to a position where the rod
Bottom dump cylinder assembly: 120 kg
connecting pin of the bottom dump cylin-
der can be removed. Then fit a block under
the bucket, lower the work equipment com-
pletely to the ground and stop the engine.
2. 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]
Installation
removal.
[*1]
[*2]
a
Bleed the air from the work equipment circuit.
pressure inside the piping.
4. Remove hoses (3).
14 PC600-8

bucket assembly
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.
1. 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 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
hydraulic circuit."
3. Remove plate (3), then remove connecting pin

(4) of the arm and bucket. [*2]
4 Pin (4): 65 kg
4. Start engine and raise work equipment, swing

work equipment, then remove bucket assem-
bly (5).
4 Bucket assembly: 2,500 kg
PC600-8 15
Installation
removal.
[*1]
Lubricant containing molybdenum
disulfide (LM-G)
[*2]
Lubricant containing molybdenum
disulfide (LM-G)
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
16 PC600-8
Removal and installation of 4. Sling bucket assembly, and remove 3 mount-

bucket assembly ing bolts, then using forcing screws (Thread
dia. = 16 mm, Pitch = 2.0 mm), pull out pin (4).
(Loading shovel specification) 1 [*2]
a Remove the pin on the other side in the
Removal
k
same way.
Set the bottom of the bucket horizontal,
lower the work equipment completely to the 4 Pin: 55 kg
ground and stop the engine. Operate the
control levers several times to release the
remaining pressure in the hydraulic piping.
1. 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.
2. Start the engine and retract the piston rod fully. 5. Lift off bucket assembly (5).
k Bind the piston rod with wires, etc., to
prevent it from coming out. 4 Bucket assembly: 6,000 kg
4 Pin: 40 kg
k After stopping the engine, release the resid-

ual pressure in the piping. For details, see
Testing and adjusting, “Releasing residual
pressure in PPC valve hydraulic circuit”.
3. Disconnect bottom dump cylinder hose (2).
Installation
removal.
[*1] [*2]

After completion of the air bleeding operation,
add engine oil to the hydraulic tank to the
specified level.
PC600-8 17
Removal and installation of arm

assembly
(Backhoe specification)
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
796T-670-1220 Sleeve t 1 Q
791-775-1130 Plate t 1
796-670-1130 Screw t 1
796-870-1110 Adapter t 1
V 1 01643-33080 Washer t 1 6. Start engine, and retract piston rod, then tie
piston rod with wire to prevent it from coming
01803-13034 Nut t 1
out.
Puller k Stop the engine and release the
790-101-4000 t 1
(490 N {50 ton}) remaining pressure in the circuit. For
790-101-1102 Pump t 1 details, see Testing and adjusting,
hydraulic circuit."
Removal
1. Remove bucket assembly. 7. Disconnect 2 bucket cylinder hoses (4).
For detail, see "Removal of bucket assembly."
8. Remove plate (5), then using tool V1, pull out
2. Secure link to arm with wire. boom top pin (6). [*2]
k Extend the arm cylinder piston rod to a a There are shims installed, so check the
point approx. 200 mm before the end of number, thickness, and position, and keep
the arm IN stroke, then lower the arm in a safe place.
4
on to block [1] and stand [2], and set
the work equipment lock lever to the Pin (6): 80 kg
LOCK position. Then, stop the engine.
3. Set block between arm cylinder and boom.
5. 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 Pin (3): 35 kg
5
6
2
3
4
CEP00525
18 PC600-8
9. Start engine, then raise boom and remove arm Installation

assembly (7). q Carry out installation in the reverse order to
4 Arm assembly: 3,200 kg removal.
[*1]
7
[*2]
CEP00526
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 Bleeding air
Bleed the air.
For details, see Testing and adjusting, "Bleed-
q Refilling with oil (hydraulic tank)

Add oil through oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
PC600-8 19
Removal and installation of arm 6. Sling arm assembly, and pull out pin (5). [*1]
assembly a Pull out the pin on the other side in the
same way to a position where the arm can
(Loading shovel specification) 1 be disconnected from the boom.
Removal 4 Pin: 110 kg
1. Remove bucket assembly.
7. Lift off arm assembly (6).
bucket assembly”.
4 Arm assembly: 2,800 kg
2. Lower the tip of the arm assembly to the ground.
3. Sling arm cylinder assembly (1) temporarily

and disconnect the rod side from the arm.
arm cylinder assembly”.
a Secure the arm cylinder assembly to the
boom with lever block [1].
residual pressure in the piping. For
“Releasing residual pressure in PPC
valve hydraulic circuit”.
Installation
removal.
[*1]
q Bleeding air
Bleed the air.
4. Disconnect right and left bottom dump cylinder ing air from each part."
hoses (2).
5. Disconnect right and left bucket cylinder hoses Add oil through oil filler to the specified level.
(3) and (4), 2 pieces on each side. Run the engine to circulate the oil through the
20 PC600-8
Removal and installation of boom 5. Sling boom assembly (10).

assembly
6. Using tool V1, remove boom foot pin (3), then
(Backhoe specification) 1 remove boom assembly (10). [*1]
a There are shims installed, so check the
Special tools
number, thickness, and position, and keep
in a safe place.
Necessity
Symbol
Sketch
4
Q’ty
N/R
Part number Part name Boom foot pin: 150 kg
4 Boom assembly: 4,800 kg
796T-670-1210 Sleeve t 1 Q
791-775-1130 Plate t 1
796-670-1130 Screw t 1
796-870-1110 Adapter t 1
V 1 01643-33080 Washer t 1
01803-13034 Nut t 1
Puller
790-101-4000 t 1
(490 N {50 ton})
790-101-1102 Pump 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 equip-
ment lock lever to LOCK position.
2. Disconnect boom cylinder assembly from

boom.
For details, see "Removal of boom cylinder
assembly."
3. Disconnect front lamp wiring. 10
4. Disconnect bucket cylinder hoses (1) and arm CEP00299
cylinder hoses (2).
PC600-8 21
Installation
removal.
[*1]
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
q Bleeding air
Bleed the air.

22 PC600-8
Removal and installation of boom 5. Disconnect bottom dump cylinder hoses (3),
assembly bucket cylinder hoses (4), and arm cylinder
hoses (5).
(Loading shovel specification) 1 a When the hoses are disconnected, oil may
spurt out, so loosen the hose flanges
Removal
slowly before disconnecting.
arm assembly”.
2. Sling bucket cylinder assembly (1), remove

plate, then pull out pin (2), and remove bucket
cylinder assembly. [*1]
4 Pin: 100 kg
4 Bucket cylinder assembly: 410 kg
a Remove the bucket cylinder on the other
side in the same way.
6. Disconnect head lamp wiring.
7. Using the tool V1, remove boom foot pins (6),

then lift off boom assembly (7). [*2]
4 Boom assembly: 3,880 kg
3. Sling boom, set stand [1] at tip of boom to sup-

port boom.
4. Remove boom cylinder from boom.

boom cylinder assembly”.
a Remove the boom cylinder on the other
side from the boom in the same way.
PC600-8 23
Installation
removal.
[*1] [*2]
q Bleeding air
Bleed the air.

24 PC600-8
Removal and installation of work 5. Sling boom assembly (10).

equipment
6. Using tool V1, remove boom foot pin (3), then
(Backhoe specification) 1 disconnect work equipment assembly. [*1]
a There are shims installed, so check the
Special tools
number, thickness, and position, and keep
in a safe place.
Necessity
Symbol
Sketch
4
Q’ty
N/R
Part number Part name Boom foot pin: 150 kg
4 Work equipment assembly: 13,800 kg
796T-670-1210 Sleeve t 1 Q
791-775-1130 Plate t 1
796-670-1130 Screw t 1
796-870-1110 Adapter t 1
V 1 01643-33080 Washer t 1
01803-13034 Nut t 1
Puller
790-101-4000 t 1
(490 N {50 ton})
790-101-1102 Pump t 1
Removal
For details, see "Removal of arm assembly."
k Lower the boom assembly completely
to the ground, then set the work equip-
ment lock lever to LOCK position.
2. Disconnect boom cylinder assembly from

boom.
For details, see "Removal of boom cylinder
assembly."
3. Disconnect front lamp wiring. 10
4. Disconnect bucket cylinder hoses (1) and arm CEP00299
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.
PC600-8 25
Installation
removal.
[*1]
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
q Bleeding air
Bleed the air.

26 PC600-8
Removal and installation of work 3. Disconnect head lamp wiring.

equipment
4. Set bottom of bucket horizontal, lower work
(Loading shovel specification) 1 equipment completely to ground, then sling
boom assembly (4).
Removal
k Retract the boom cylinder fully, extend the arm
cylinder, set the bottom of the bucket horizon-
tal, 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.
a Release the remaining pressure in the circuit.
For details, see Testing and adjusting, “Releas-
ing pressure in hydraulic circuit”.
1. Disconnect boom cylinder from boom.
For details, see “Removal and installation of 5. Using the tool V1, remove boom foot pins (5),
boom cylinder assembly”. then disconnect work equipment assembly. [*1]
2. Disconnect bottom dump cylinder hose (1), bucket a Check the number and thickness of the
cylinder hoses (2), and arm cylinder hoses (3). shims, and keep in a safe place.
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.
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
Installation
removal.
[*1]
a Adjust the lifting height of the boom assembly
so that the boom foot is at the height of the
mount on the chassis.
q Bleeding air
Bleed the air.

28 PC600-8
PC600-8 29
SEN01068-02

© 2009 KOMATSU
All Rights Reserved
30
SEN01069-01
PC600-8
PC600LC-8

PC600-8 30001 and up

Removal and installation of operator’s cab ..................................................................................................... 2
Removal and installation of operator’s cab glass (stuck glass) ...................................................................... 5
Removal and installation of front window assembly ..................................................................................... 15
PC600-8 1
Removal and installation of 6. Remove air conditioner connector plate (15).

operator’s cab 1
Removal
1. Remove rear covers (1), (2), (3), and (4).
7. Disconnect connectors L03 (16), H03 (17),

H04 (18), and H05 (19).
8. Disconnect upper and lower duct joints (20)

and (21).
9. Remove controller sub-plate (22) and incline it

2. Remove duct (5), cover (6), and plate (7). against the air conditioner.
3. Remove plate (8), duct (9) and the element.

a Remove the duct lock clip.
4. Disconnect connector S13 (10).
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.
2 PC600-8
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 har-
ness.
a Sling the monitor assembly and cab
together.
a When removing the monitor assembly,
remove cover (30) in advance.
PC600-8 3
20. Using lever block [1], lift off operator's cab Installation
assembly (39). q Carry out installation in the reverse order to
4 Operator's cab assembly: 300 kg removal.
Reference
Connection of window washer hoses
1) Hose length from clamp end of part A: Connect

to the hose on the floor side at 150 mm.
2) 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 perpendic-
ularly to it. (See the lower right of the fig-
ure.)
3) Insert each hose end (HE) in joint (J) securely

until it touches joint (J). (See the upper right of
a When starting the engine while the operator's the figure.)
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
4 PC600-8
Removal and installation of operator’s cab glass (stuck glass) 1
a Among the panes of window glass on the 4 (1) : Right side window glass
sides of the operator's cab, 4 panes (1) – (4) (2) : Left side rear window glass
are stuck. (3) : Door lower window glass
In this section, the procedure for replacing the (4) : Front window glass
stuck glass is explained. (5) : Front window assembly
When replacing front window glass (4), remove (Front window glass + Front frame)
front window assembly (5). (It is impossible to (6) : Both-sided adhesive tape
replace only the front window glass while the (16): Center trim seal
front window assembly is installed to the oper-
ator's cab.)
For the procedure for replacing the front win-
dow assembly, see "Removal and installation
of front window assembly."
PC600-8 5
Special tools Installation

1. Using a knife and scraper [5], remove the
Necessity
remaining adhesive and both-sided adhesive
Symbol
Sketch
Q’ty
N/R
Part number Part name tape from the metal sheets (glass sticking sur-
faces) of the operator's cab.
Lifter a Remove the adhesive and both-sided
1 793-498-1210 t 2
Y (Suction cup) adhesive tape to a degree that they will
2 20Y-54-13180 Adapter t 2 not affect adhesion of the new adhesive.
Take care not to scratch the painted sur-
f a c e s . ( I f t h e pa i n t e d s u r f a c e s a r e
Removal scratched, adhesion will be lowered.)
a Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between

broken window glass (7) and operator's cab
(metal sheet) (8).
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (8) and window glass (9) with
white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
a If a seal cutter is not available, widening the the window glass.
cut with a screwdriver, cut the adhesive and a After cleaning the sticking surfaces, leave
both-sided adhesive tape with knife [4]. them for at least 5 minutes to dry.
2. Remove the window glass.
6 PC600-8
3. Apply primer (10). 3) Evenly apply paint primer to the surfaces

a The using limit of primer (10) is 4 months to stick both-sided adhesive tapes and the
after the date of manufacture. Do not use surfaces out of those surfaces on opera-
primer (10) after this limit. tor's cab (8) which will be coated with the
a Use the primer within 2 hours after adhesive.
unpacking it. 2 Paint primer:
a Even if the primer is packed again just SUNSTAR PAINT PRIMER
after it is unpacked, use it within 24 hours 580 SUPER or equivalent
after it is unpacked for the first time. (Dis- a Do not apply the primer more than 2
c 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 times. (If it is applied more than 2
unpacked.) times, its performance will be low-
1) Stir the primers for paint and glass suffi- ered.)
ciently before using them.
a If the primer has been stored in a
refrigerator, leave it at the room tem-
perature for at least half a day before
stirring it. (If the primer is unpacked
just after taken out of the refrigerator,
water will be condensed. Accord-
ingly, 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. a Parts to be coated with primer: Apply
the primer all over dimension (a).
q Dimension to apply primer (a): 25 mm
PC600-8 7
a In addition to the above parts, apply 4) Evenly apply glass primer to the sticking
the primer to right side window glass surfaces of window glass (9).
(1) and door lower window glass (3). 2 Glass primer:
q Range to apply primer additionally for SUNSTAR GLASS PRIMER
right side window glass (1): (b) 580 SUPER or equivalent
q Range to apply primer additionally for a Do not apply the primer more than 2
door lower window glass (3): (c) times. (If it is applied more than 2
a After applying the primer, leave it for times, its performance will be low-
at least 5 minutes (within 8 hours) to ered.)
dry.
a Parts to be coated with primer: Apply

the primer to the sticking surfaces of
window glass (9) and all over dimen-
sion (d) which will be on both-sided
adhesive tape (6) and operator's cab
(8).
a Do not apply the primer to the
boarder about 5 mm wide between
the black part and transparent part of
the glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a Never apply wrong primer. If the
paint primer is applied by mistake,
a Never apply wrong primer. If the glass wipe it off with white gasoline.
primer is applied by mistake, wipe it
off with white gasoline.
8 PC600-8
4. Stick both-sided adhesive tape (6) along the a Stick both-sided adhesive tape (6a)
inside edge of the glass sticking section. additionally for right side window
a Do not remove the release tape of the glass (1).
both-sided adhesive tape on the glass q Positions to stick additional both-
sticking side before sticking the glass. sided adhesive tape for right side win-
a When sticking the both-sided adhesive dow glass:
tape, do not touch the cleaned surface as (f) : 50 mm
much as possible. (g) : 90 mm
a Take care that the both-sided adhesive (h) : 250 mm
tape will not float at each corner of the
window frame.
2) Stick both-sided adhesive tape (6) for left

side rear window glass (2) as shown in the
a When sticking both-sided adhesive tape figure.
(6) around a frame, do not lap its finishing
end over the starting end but make clear-
ance (e) of about 5 mm between them.
1) Stick both-sided adhesive tape (6) for right
side window glass (1) as shown in the fig-
ure.
3) Stick both-sided adhesive tape (6) for door

lower window glass (3) as shown in the
figure.
PC600-8 9
a Stick both-sided adhesive tape (6b) a Stick both-sided adhesive tape (6c) of
additionally for door lower window the lower side of the front window
glass (3). glass along the outside edge of the
a Positions to stick additional both- lower line, differently from other both-
sided adhesive tape for door lower sided adhesive tapes (6). (If it is
window glass: stuck along the inside, it will be seen
(j) : 110 mm through the transparent part of the
(k) : 90 mm glass.)
(m) : 200 mm +
5. Position the new window glass.

4) Stick both-sided adhesive tape (6) for front 1) Check the clearance between the window
window glass (4) as shown in the figure. 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 position-
ing 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
1) Break aluminum seal (13) of the outlet of

adhesive cartridge (12) and install the
nozzle.
a When positioning front window glass

(4), set its horizontal position to the
frame width and set its vertical posi-
tion so that height difference (p) 2) Cut the tip of the adhesive nozzle (14) so
between it and the frame top will be 3 that dimensions (q) and (r) will be as fol-
mm. lows.
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): 3) Set adhesive cartridge (12) to caulking
SUNSTAR PENGUINE gun [7].
SEAL 580 SUPER "S" a An electric caulking gun is more effi-
2 Adhesive (Winter): cient.
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 25°C.
a Never heat the adhesive higher than
30°C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
4) Remove the release tape of the both-

sided adhesive tape on the glass side.
PC600-8 11
5) Apply adhesive (15) to the outside of both-

sided adhesive tape (6) of the operator's
cab.
7. Install the window glass.

1) Install window glass (9), matching it to the
a Apply adhesive (15) to dimensions (s) lines of the positioning tapes drawn in step
and (t) of both-sided adhesive tape 5.
(6) of operator's cab (8). a Since the window glass cannot be
q Dimension (s): 10 mm removed and stuck again, stick it very
q Dimension (t): 15 mm carefully.
a Apply adhesive (15) thicker than a Stick the glass within 5 minutes after
both-sided adhesive tape (6). applying the adhesive.
a Apply the adhesive evenly. 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.
a 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. a You can perform this work efficiently
by pulling window glass (9) from
inside of the operator's cab with suc-
tion cup (Y1).
12 PC600-8
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.
a After installing front window glass (4),

fill the clearances between it and cen-
ter 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 dou-
ble-sided adhesive tape to fit them com-
pletely.
PC600-8 13
9. After installing the window glass, remove the

primer and adhesive from the operator's cab
and window glass.
a Using white gasoline, wipe off the adhe-
sive before it is dried up.
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 20°C and humid-
ity of 60%).
2) After removing the stopper rubbers, sty-
rene foam blocks, and rubber bands, wait
at least 14 hours, at least 24 hours in total,
before operating the machine actually.
14 PC600-8
Removal and installation of front 3. Release the rear locks of the cab.
window assembly 1
4. Lower the front window assembly carefully a
k Lower the work equipment to the ground little. Put out rollers (8) and (9) under the right
and stop the engine. and left sides of the front window through the
a To replace the front window glass, the front portion from which the corner block was
window assembly must be removed from the removed in step 2 (the portion where the rail is
operator's cab. The procedure for removing open) and hold them.
and installing the front window assembly (front
frame and front window glass) is explained 5. Remove rollers (8) and (9) under the right and
below. left sides of the front window.
Removal
1. Raise front window assembly (13) to the ceil-
ing and fix it with the rear locks (right and left).
2. 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
6. Remove left lower pin (10). [*2] 8. Lower front window assembly (13) completely.
a If left lower pin (10) is removed, plate (12) a Do not let the front window assembly
at the end of pull-up assist cable (11) touch the monitor.
comes off.
a Hang plate (12) on the left striker bolt. 9. Twist front window assembly (13) to the right
k The return load of 58.8 N {6 kg} is and left to remove both upper rollers (14) and
applied to the rear of the operator's (15) from the rails, and then remove front win-
cab. Accordingly, take care when dow assembly (13).
removing left lower pin (10) to discon-
nect pull-up assist cable (11).
Installation
7. Put out the bottom of front window assembly q Carry out installation in the reverse order to
(13) through the rail opening portion and lower removal.
it gradually.
[*1]
q Adjust opening and closing of the front window
assembly according to the following proce-
dure.
1. Open and close the front window to check that

it does not interfere with the rails and the roll-
ers are not hitch.
2. 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}
16 PC600-8
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 assem-
bly 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.
4. 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 dif-
ference (a) between it and the rail will be 0
– 1.0 mm.
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
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 win-
dow 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 rub-
bers (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 6) Loosen locknuts (26) of right and left rub-
back 4 – 7 mm by the front window ber stoppers (22) and move right and left
assembly. rubber stoppers (22) back so that the front
a Since the position of limit switch (23) window assembly will not touch the right
cannot be adjusted, the "open" posi- and left rubber stoppers (22) when it is
tion of the front window assembly is "open".
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.
7) Set the rubber stoppers so that limit switch
q After the above check, if the front window
(23) will be pushed back 4 – 7 mm by the
assembly needs to be adjusted, perform
front window assembly (13) (while it is
the following.
"open").
3) Close front window assembly (13).
8) Adjust the working condition of lock (20)
4) Loosen striker plate (24).
and tighten 2 striker plate mounting bolts
(27).
18 PC600-8
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] 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 assem-
bly is "open", it must compress
right and left rubber stoppers 9. Check the latching effort of the front window
(22) by 1.5 – 3.0 mm. assembly.
4] Tighten locknuts (26) of right and left 1) After finishing steps 5 – 8, check that
rubber stoppers (22). 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 opera-
tor'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 Left lower pin:
27 – 34 Nm {2.75 – 3.47 kgm}
PC600-8 19
SEN01069-01

© 2009 KOMATSU
All Rights Reserved
20
SEN01070-02
PC600-8
PC600LC-8

PC600-8 30001 and up

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 1
Removal and installation of air 7. Remove ducts (10) and (11).

conditioner unit assembly 1
Removal
k If you drain the coolant or if you disconnect
the heater hose when the coolant tempera-
ture in the radiator is high, you may be
scalded. In this case, wait until the coolant
temperature lowers and then drain the cool-
ant or disconnect the heater hose.
1. Collect the air conditioner refrigerant (R134a)

from air conditioner circuit in advance. [*1]
a Ask professional traders for collecting and 8. Disconnect connectors D01 (12), D02 (13),
filling operation of refrigerant. S30 (14), R09 (15), R18 (16), R08 (16-1), R10
a Never release the refrigerant to the atmo- (16-2), and K01 (17).
sphere.
k If refrigerant gets in your eyes, you 9. Remove and sling controller (18).
may lose your sight. Accordingly, put
on protective goggles, gloves and 10. Remove plate (19).
working suits with long sleeves while
you are collecting the refrigerant or fill- 11. Disconnect air conditioner unit connectors M27
ing the air conditioner circuit with the (20) and M33 (21).
refrigerant. Collecting and filling work
must be conducted by a qualified per-
son.
q Refrigerant quantity: 1,260 ± 50 g
2. Swing the upper structure by 90°.

6 Coolant: 58 l
4. Remove rear covers (1), (2), (3), and (4).
12. Remove the air conditioner unit undercover.

a Part (A)
5. Remove duct (5), cover (6), and plate (7).
6. Remove plate (8) and duct (9).

a Remove the duct lock clip.
2 PC600-8
13. Remove mounting bolt (24) and connector Installation

(25). [*1] q Carry out installation in the reverse order to
removal.
14. Disconnect heater hoses (22) and (23) and air
conditioner hose (26). [*1] [*1]
a Put tags to the disconnected hoses and a When installing the air conditioner circuit
tubes to prevent a mistake in re-connect- hoses, take care that dirt, water, etc. will
ing them. not enter them.
a When connecting each air conditioner
hose, check that the O-ring is fitted to the
joint.
a Check that each O-ring is free from flaw
and deterioration.
a 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.
15. Remove the 7 mounting bolts and air condi-

tioner unit assembly (27).
a (18): Removed controller.
3 Hose clamp (M6 bolt):

7.84 – 11.8 Nm {0.8 – 1.2 kgm}
3 Hose screw of M16 x 1.5:

11.8 – 14.7 Nm {1.2 – 1.5 kgm}

19.6 – 24.5 Nm {2.0 – 2.5 kgm}

29.3 – 34.3 Nm {3.0 – 3.5 kgm}
q Filling air conditioner circuit with refriger-

ant (R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 1,260 ± 50 g

5 Coolant: 58 l
PC600-8 3
Removal and installation of 5. Disconnect connector (8).

engine controller assembly 1 a Use a hexagonal wrench of 4 mm.
Removal 6. Remove engine controller assembly (9). [*1]

2. Remove controller cover (2).
3. Disconnect connectors CE02 (3) and CE03

(4).
a Use a hexagonal wrench of 4 mm.
4 PC600-8
Installation
removal.
[*1]
When connecting connectors (3), (4), and (8),
check that there is no dust, dirt, etc. in them.
Reference
q Method of replacing O-ring seal of power con-
nector (4)
O-ring seal: 1010-074-0406 (NIHON-DEUT-
SCH LIMITED)
1) Using tweezers [1], hold the claw and

remove cover (6).
2) Using tweezers [1], remove O-ring (7).
PC600-8 5
Removal and Installation of Removal and installation of pump

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

monitor assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove cover (1) and disconnect wiring con-

nector P15 of air conditioner sunlight sensor
(2).
a Raise and remove the cover.
2. Remove the 3 mounting screws and monitor

assembly (3).
a Disconnect monitor panel wiring connec-
tors P01, P02, and P70 before removing
the monitor assembly.
PC600-8 7
SEN01070-02

© 2009 KOMATSU
All Rights Reserved
8
SEN00144-03
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up


Hydraulic diagrams and drawings
Hydraulic circuit diagram (1/4) (Backhoe specification).................................................................................. 3

Hydraulic circuit diagram (2/4) (ATT specification) ......................................................................................... 5
Hydraulic circuit diagram (3/4) (Loading shovel specification) ....................................................................... 7
Hydraulic circuit diagram (4/4) (Loading shovel specification) ....................................................................... 9
PC600-8 1
SEN00144-03 90 Diagrams and drawings
2 PC600-8
Hydraulic circuit diagram (1/4) (Backhoe specification) Hydraulic circuit diagram (1/4)
PC600, 600LC-8
SEN00144-03
PC600-8 3
Hydraulic circuit diagram (2/4) (ATT specification) Hydraulic circuit diagram (2/4)
PC600, 600LC-8
SEN00144-03
PC600-8 5
Hydraulic circuit diagram (3/4) (Loading shovel specification) Hydraulic circuit diagram (3/4)
PC600, 600LC-8
SEN00144-03
PC600-8 7
Hydraulic circuit diagram (4/4) (Loading shovel specification) Hydraulic circuit diagram (4/4)
PC600, 600LC-8
SEN00144-03
PC600-8 9
PC600-8 11
©2010 KOMATSU
All Right Reserved
12
SEN00145-04
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 30001 and up


Electrical diagrams and drawings
Electrical circuit diagram (1/6) ........................................................................................................................ 3

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 1
2 PC600-8
Electrical circuit diagram (1/6)
Electrical circuit diagram (1/6) PC600, 600LC-8
SEN00145-04
PC600-8 3
SEN00145-04
PC600-8 5
SEN00145-04
PC600-8 7
SEN00145-04
PC600-8 9
SEN00145-04
PC600-8 11
SEN00145-04
PC600-8 13
Connector arrangement diagram
PC600, 600LC-8
Connector arrangement diagram
Connector Number Address of Connector Number Address of

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

SM PC600LC 8 30001 UP SEN00128 16 Comprimido

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SEN00128-16

Machine model Serial number

PC600-8 30001 and up

00 Index and foreword

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

Composition of shop manual

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00128-16

00 Index and foreword SEN00129-16

10 Structure, function and maintenance standard SEN00134-08

20 Standard value table SEN00394-04

30 Testing and adjusting SEN00443-04

50 Disassembly and assembly SEN01061-06

90 Diagrams and drawings SEN00143-05

10 Structure, function and maintenance standard

Hydraulic system, Part 2 SEN00139-04

20 Standard value table

30 Testing and adjusting

Reduced cylinder mode operation ................................................................................................ 18

Failure code [CA2271] EGR Valve Pos Sens High Error.............................................................. 58

E-14 Fuel gauge does not display correctly ................................................................................. 27

S-4 Engine stops during operations.............................................................................................. 13

50 Disassembly and assembly

Disassembly and assembly of main control valve assembly ........................................................ 10

90 Diagrams and drawings

PC600, 600LC-8 Hydraulic excavator

Form No. SEN00130-16

Machine model Serial number

PC600-8 30001 and up

00 Index and foreword 1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness