Shop+Manual+PC2000 8

SEN01607-06

HYDRAULIC EXCAVATOR

PC2000-8 SERIAL NUMBERS

20001

and up

SEN01609-06

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

00 Index and foreword

1

Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4

PC2000-8

1

SEN01609-06

00 Index and foreword

Composition of shop manual

1

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

Form Number

Shop Manual, contents binder, binder label and tabs

SEN01607-06

00 Index and foreword Index Foreword and general information

SEN01608-06 SEN01609-06 q SEN01610-02

01 Specification Specification and technical data

SEN01611-01 SEN01612-01 q

10 Structure, function and maintenance standard Engine and cooling system Power train Undercarriage and frame Hydraulic system, Part 1 Hydraulic system, Part 2 Hydraulic system, Part 3 Work equipment Cab and its attachments Electrical system

SEN01613-02 SEN01614-00 SEN01615-00 SEN01616-00 SEN01618-02 q SEN01619-01 SEN01620-01 SEN01621-02 q SEN01622-00 SEN01623-01

20 Standard value table Standard service value table

SEN01624-00 SEN02006-00

30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 Testing and adjusting, Part 3 Testing and adjusting, Part 4

SEN01625-00 SEN02007-00 SEN02008-00 SEN02009-00 SEN02010-00

40 Troubleshooting Failure code table and fuse locations General information on troubleshooting Troubleshooting by failure code, Part 1 Troubleshooting by failure code, Part 2 Troubleshooting by failure code, Part 3 Troubleshooting by failure code, Part 4

SEN01626-00 SEN02011-00 SEN02012-00 SEN02096-00 SEN02097-00 SEN02098-00 SEN02099-00

2

PC2000-8

00 Index and foreword

Troubleshooting by failure code, Part 5 Troubleshooting by failure code, Part 6 Troubleshooting by failure code, Part 7 Troubleshooting of electrical system (E-mode) Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of mechanical system (S-mode)

SEN01609-06

SEN02100-00 SEN02101-00 SEN02102-00 SEN02103-00 SEN02104-00 SEN02105-00

50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system (12V140E-3) Engine (12V140E-3) Power train Undercarriage and frame Hydraulic system Work equipment Cab and its attachments Electrical system

SEN01627-01 SEN02133-00 SEN02134-01 SEN02135-01 SEN02136-00 SEN02137-00 SEN02138-00 SEN02139-00 SEN02140-00 SEN02141-00

90 Diagrams and drawings Hydraulic diagrams and drawings Electrical diagrams and drawings

SEN01628-03 SEN01629-00 SEN01630-03

PC2000-8

3

SEN01609-06

00 Index and foreword

Table of contents

1

00 Index and foreword Index SEN01609-06 Composition of shop manual ................................................................................................... 2 Table of contents...................................................................................................................... 4 Foreword and general information SEN01610-02 Safety notice ............................................................................................................................ 2 How to read the shop manual.................................................................................................. 7 Explanation of terms for maintenance standard ...................................................................... 9 Handling of electric equipment and hydraulic component ....................................................... 11 Handling of connectors newly used for engines ...................................................................... 20 How to read electric wire code................................................................................................. 23 Precautions when carrying out operation ................................................................................ 26 Method of disassembling and connecting push-pull type coupler ........................................... 29 Standard tightening torque table.............................................................................................. 32 Conversion table...................................................................................................................... 36 01 Specification Specification and technical data SEN01612-01 Specification drawings ............................................................................................................. 2 Specifications........................................................................................................................... 6 Weight table ............................................................................................................................. 10 Table of fuel, coolant and lubricants ........................................................................................ 16 10 Structure, function and maintenance standard Engine and cooling system SEN01614-00 Engine and cooling system ......................................................................................................... 2 Radiator and oil cooler............................................................................................................. 2 PTO ......................................................................................................................................... 4 PTO lubrication system............................................................................................................ 6 Power train SEN01615-00 Power train .................................................................................................................................. 2 Power train............................................................................................................................... 2 Swing machinery ..................................................................................................................... 3 Swing circle.............................................................................................................................. 6 Final drive ................................................................................................................................ 8 Sprocket................................................................................................................................... 11 Undercarriage and frame SEN01616-00 Undercarriage and frame ............................................................................................................ 2 Track frame.............................................................................................................................. 2 Idler.......................................................................................................................................... 4 Carrier roller............................................................................................................................. 6 Track roller ............................................................................................................................... 7 Track shoe ............................................................................................................................... 8 HIC system .............................................................................................................................. 13

4

PC2000-8

00 Index and foreword

SEN01609-06

Hydraulic system, Part 1 SEN01618-02 Hydraulic piping drawing ......................................................................................................... 4 Hydraulic tank.......................................................................................................................... 8 Oil cooler ................................................................................................................................. 10 Line oil filter ............................................................................................................................. 12 Pilot oil filter ............................................................................................................................. 13 Return oil filter ......................................................................................................................... 14 Motor drain oil filter .................................................................................................................. 15 Pump drain filter ...................................................................................................................... 16 Accumulator............................................................................................................................. 17 Travel junction valve ................................................................................................................ 19 Solenoid valve ......................................................................................................................... 22 Hydraulic cylinder .................................................................................................................... 30 Greasing system...................................................................................................................... 34 Center swivel joint ................................................................................................................... 44 Hydraulic system, Part 2 SEN01619-01 Hydraulic system, Part 2 ............................................................................................................. 2 Control valve............................................................................................................................ 2 Electronic OLSS system.......................................................................................................... 30 Swing motor............................................................................................................................. 34 Cooling fan motor (For radiator and oil cooler)........................................................................ 42 Cooling fan pump .................................................................................................................... 48 Hydraulic system, Part 3 SEN01620-01 Hydraulic system, Part 3 ............................................................................................................. 2 Travel motor............................................................................................................................. 2 Hydraulic pump........................................................................................................................ 14 PPC valve................................................................................................................................ 32 Variable back pressure valve................................................................................................... 44 Suction selector valve.............................................................................................................. 48 PPC cut-off valve ..................................................................................................................... 52 Work equipment SEN01621-02 Work equipment ...................................................................................................................... 2 Dimensions of work equipment ............................................................................................... 6 Cab and its attachments SEN01622-00 Cab and its attachments.............................................................................................................. 2 Air conditioner piping ............................................................................................................... 2 Cab .......................................................................................................................................... 3 Electrical system SEN01623-01 Electrical system ......................................................................................................................... 2 Engine control.......................................................................................................................... 2 Electrical control system.......................................................................................................... 13 Monitor system ........................................................................................................................ 55 Sensor ..................................................................................................................................... 83 ORBCOMM terminal................................................................................................................ 95

PC2000-8

5

SEN01609-06

00 Index and foreword

20 Standard value table Standard service value table SEN02006-00 Standard service value table ....................................................................................................... 2 Standard service value table for testing, adjusting, and troubleshooting ................................. 2 Standard service value table for chassis ................................................................................. 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN02007-00 Testing and adjusting, Part 1 ....................................................................................................... 3 Tools for testing, adjusting, and troubleshooting...................................................................... 3 Measuring engine speed ......................................................................................................... 6 Testing air boost pressure........................................................................................................ 7 Testing exhaust temperature ................................................................................................... 8 Testing exhaust color ............................................................................................................... 9 Adjusting valve clearance ........................................................................................................ 11 Testing compression pressure ................................................................................................. 13 Testing blow-by pressure ......................................................................................................... 15 Testing engine oil pressure ...................................................................................................... 16 Handling fuel system parts ...................................................................................................... 17 Releasing residual pressure in fuel system ............................................................................. 17 Testing fuel pressure................................................................................................................ 18 Testing leakage from pressure limiter and return rate from injector......................................... 19 Bleeding air from fuel circuit .................................................................................................... 22 Bleeding air from fuel circuit (low-grade fuel specification)...................................................... 26 Testing fuel system for leakage ............................................................................................... 28 Testing and adjusting air conditioner compressor belt tension ................................................ 30 Testing and adjusting, Part 2 SEN02008-00 Testing and adjusting, Part 2 ....................................................................................................... 3 Testing swing circle bearing clearance .................................................................................... 3 Remaining pressure relief from HIC circuit .............................................................................. 4 Gas filling in HIC circuit accumulator ....................................................................................... 4 Bleeding air from HIC circuit and supplying oil to it ................................................................. 6 Testing and adjusting track shoe tension................................................................................. 8 Testing and adjusting work equipment, swing and travel circuit oil pressures......................... 11 Testing and adjusting control circuit oil pressure (output pressure of self pressure reducing valve) ............................................................ 15 Testing and adjusting main pump control signal ...................................................................... 17 Measuring fan speed ............................................................................................................... 20 Measuring fan pump EPC solenoid current ............................................................................. 21 Measuring fan pump EPC solenoid valve output pressure...................................................... 22 Oil pressure measuring points for pump discharge pressure or jet sensor differential pressure ......................................................................................... 24 Measuring PPC valve output pressure .................................................................................... 25 Measuring solenoid valve outlet pressure ............................................................................... 30 Adjusting work equipment and swing PPC valve..................................................................... 32 Testing and adjusting travel deviation...................................................................................... 33 Testing work equipment hydraulic drift cause portion .............................................................. 35 Testing oil leakage ................................................................................................................... 36 Remaining pressure relief from hydraulic circuit...................................................................... 39 Air bleeding from each component .......................................................................................... 40 Air bleeding from PPC circuit................................................................................................... 45 Testing and adjusting auto grease system............................................................................... 47 Adjusting mirrors...................................................................................................................... 50

6

PC2000-8

00 Index and foreword

SEN01609-06

Testing and adjusting, Part 3 SEN02009-00 Testing and adjusting, Part 3....................................................................................................... 2 Special functions of machine monitor ...................................................................................... 2 Handling controller voltage circuit............................................................................................ 57 Testing and adjusting, Part 4 SEN02010-00 Testing and adjusting, Part 4....................................................................................................... 2 VHMS controller initial setting procedure ................................................................................ 2 Precautions for replacing VHMS controller.............................................................................. 19 Preparation work for troubleshooting of electrical system ....................................................... 25 Pm-clinic service...................................................................................................................... 27 Measurement procedure ......................................................................................................... 28 40 Troubleshooting Failure code table and fuse locations SEN02011-00 Failure code table and fuse locations.......................................................................................... 2 Failure code table .................................................................................................................... 2 Before carrying out troubleshooting of electrical system ......................................................... 9 General information on troubleshooting SEN02012-00 General information on troubleshooting ...................................................................................... 2 Points to remember when troubleshooting .............................................................................. 2 Sequence of events in troubleshooting ................................................................................... 3 Checks before troubleshooting................................................................................................ 4 Classification and procedures of troubleshooting.................................................................... 5 Connection table for connector pin numbers ........................................................................... 9 T-adapter box and T-adapter table .......................................................................................... 42 Troubleshooting by failure code, Part 1 SEN02096-00 Troubleshooting by failure code, Part 1....................................................................................... 3 Failure code [0410KA] Fuel LV. Sensor Failure....................................................................... 3 Failure code [0410KB] Fuel LV. Sensor Failure....................................................................... 4 Failure code [6014NX] Hydraulic Oil Filter Clogging (or change of VHMS-LED display from n5 to 51) ............................................................. 5 Failure code [8800ZG] Auto grease abnormally...................................................................... 6 Failure code [7@HAZL] VR1/P1F Relief Press Abnormality ................................................... 7 Failure code [7@HBZL] VL1/P1R Relief Press Abnormality ................................................... 8 Failure code [7@HCZL] VR2/P2F Relief Press Abnormality................................................... 9 Failure code [7@HDZL] VL2/P2R Relief Press Abnormality ................................................... 10 Failure code [AA10NX] Aircleaner Clogging............................................................................ 12 Failure code [AB00KE] Charge Voltage Low ........................................................................... 14 Failure code [aB00KE] Low Upper ALR Charge Voltage (or change of VHMS-LED display from n9 to 11) ............................................................. 16 Failure code [B@BAZG] Eng. Oil Press. Low ......................................................................... 18 Failure code [B@BAZK] Eng. Oil Level Low ........................................................................... 20 Failure code [B@BCNS] Eng. Water Overheat ....................................................................... 22 Failure code [B@BCZK] Eng. Water Lvl Low .......................................................................... 24 Failure code [B@CBNS] PTO Oil Overheat (or change of VHMS-LED display from n5 to 61) ............................................................. 26 Failure code [B@HANS] Hydr. Oil Overheat ........................................................................... 28 Failure code [B@HAZK] Low Hydraulic Oil Level (or change of VHMS-LED display from n5 to 52) ............................................................. 30 Failure code [CA111] ECM Critical Internal Failure ................................................................. 32 Failure code [CB111] ECM Critical Internal Failure ................................................................. 34 Failure code [CA115] Eng. Ne and Bkup Speed Sens Error ................................................... 36 Failure code [CB115] Eng. Ne and Bkup Speed Sens Error ................................................... 37 Failure code [CA122] Chg Air Press Sensor High Error.......................................................... 38 Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 40 Failure code [CA131] Throttle Sensor High Error .................................................................... 42

PC2000-8

7

SEN01609-06

00 Index and foreword

Failure code [CA132] Throttle Sensor Low Error..................................................................... 44 Failure code [CA135] Eng Oil Press Sensor High Error .......................................................... 46 Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................... 48 Failure code [CA144] Coolant Temp Sens High Error ............................................................. 50 Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 52 Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 54 Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 56 Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 58 Failure code [CB187] Sens Supply 2 Volt Low Error ............................................................... 58 Failure code [CA212] Eng Oil Temp Sensor High Error........................................................... 60 Failure code [CA213] Eng Oil Temp Sensor Low Error ........................................................... 62 Troubleshooting by failure code, Part 2 SEN02097-00 Troubleshooting by failure code, Part 2....................................................................................... 4 Failure code [CA221] Ambient Press Sens High Error ............................................................ 4 Failure code [CA222] Ambient Press Sens Low Error............................................................. 6 Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 8 Failure code [CB227] Sens Supply 2 Volt High Error .............................................................. 10 Failure code [CA234] Eng Over Speed.................................................................................... 12 Failure code [CA238] Ne Speed Sens Supply Volt Error ......................................................... 14 Failure code [CB238] Ne Speed Sens Supply Volt Error ......................................................... 16 Failure code [CA263] Fuel Temp Sensor High Error ............................................................... 18 Failure code [CB263] Fuel Temp Sensor High Error ............................................................... 20 Failure code [CA265] Fuel Temp Sensor Low Error ................................................................ 21 Failure code [CB265] Fuel Temp Sensor Low Error ................................................................ 21 Failure code [CA271] IMV/PCV1 Short Error........................................................................... 22 Failure code [CB271] IMV/PCV1 Short Error........................................................................... 24 Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 26 Failure code [CB272] IMV/PCV1 Open Error .......................................................................... 28 Failure code [CA273] PCV2 Short Error .................................................................................. 30 Failure code [CB273] PCV2 Short Error .................................................................................. 32 Failure code [CA274] PCV2 Open Error.................................................................................. 34 Failure code [CB274] PCV2 Open Error.................................................................................. 36 Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................ 38 Failure code [CA323] Inj #5(L#5) Open/Short Error ................................................................ 40 Failure code [CA324] Inj #3(L#3) Open/Short Error ................................................................ 42 Failure code [CA325] Inj #6(L#6) Open/Short Error ................................................................ 44 Failure code [CA331] Inj #2(L#2) Open/Short Error ................................................................ 46 Failure code [CA332] Inj #4(L#4) Open/Short Error ................................................................ 48 Failure code [CA342] Calibration Code Incompatibility ........................................................... 50 Failure code [CB342] Calibration Code Incompatibility ........................................................... 50 Failure code [CA351] Injectors Drive Circuit Error................................................................... 52 Failure code [CB351] Injectors Drive Circuit Error................................................................... 54 Failure code [CA352] Sens Supply 1 Volt Low Error ............................................................... 56 Failure code [CB352] Sens Supply 1 Volt Low Error ............................................................... 56 Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 58 Failure code [CB386] Sens Supply 1 Volt High Error .............................................................. 60 Failure code [CA441] Battery Voltage Low Error ..................................................................... 62 Failure code [CB441] Battery Voltage Low Error ..................................................................... 62 Failure code [CA442] Battery Voltage High Error .................................................................... 63 Failure code [CB442] Battery Voltage High Error .................................................................... 63 Failure code [CA449] Rail Press Very High Error .................................................................... 64 Failure code [CB449] Rail Press Very High Error .................................................................... 64 Troubleshooting by failure code, Part 3 SEN02098-00 Troubleshooting by failure code, Part 3....................................................................................... 4 Failure code [CA451] Rail Press Sensor High Error................................................................ 4 Failure code [CB451] Rail Press Sensor High Error................................................................ 6 Failure code [CA452] Rail Press Sensor Low Error................................................................. 8

8

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00 Index and foreword

SEN01609-06

Failure code [CB452] Rail Press Sensor Low Error ................................................................ 8 Failure code [CA553] Rail Press High Error ............................................................................ 9 Failure code [CB553] Rail Press High Error ............................................................................ 10 Failure code [CA554] Rail Press Sensor In Range Error ........................................................ 11 Failure code [CB554] Rail Press Sensor In Range Error ........................................................ 11 Failure code [CA559] Rail Press Low Error............................................................................. 12 Failure code [CB559] Rail Press Low Error............................................................................. 16 Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 20 Failure code [CB689] Eng Ne Speed Sensor Error ................................................................. 22 Failure code [CA691] Intake Air Temp Sens High Error .......................................................... 24 Failure code [CA692] Intake Air Temp Sens Low Error ........................................................... 26 Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 27 Failure code [CB731] Eng Bkup Speed Sens Phase Error...................................................... 27 Failure code [CA757] All Persistent Data Lost Error ............................................................... 28 Failure code [CB757] All Persistent Data Lost Error ............................................................... 28 Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 30 Failure code [CB778] Eng Bkup Speed Sensor Error.............................................................. 32 Failure code [CA781] CEN Communication Error ................................................................... 34 Failure code [CB781] CEN Communication Error ................................................................... 36 Failure code [CA1117] Persistent Data Lost Error ................................................................... 37 Failure code [CB1117] Persistent Data Lost Error ................................................................... 37 Failure code [CA1257] Harness Key Error .............................................................................. 38 Failure code [CB1257] Harness Key Error .............................................................................. 39 Failure code [CB1548] Inj #7(R#1) Open/Short Error.............................................................. 40 Failure code [CB1549] Inj #8(R#2) Open/Short Error.............................................................. 42 Failure code [CB1551] Inj #10(R#4) Open/Short Error............................................................ 44 Failure code [CB1552] Inj #11(R#5) Open/Short Error ............................................................ 46 Failure code [CB1553] Inj #12(R#6) Open/Short Error............................................................ 48 Failure code [CB1622] Inj #9(R#3) Open/Short Error.............................................................. 50 Failure code [CA1633] KOMNET Data link Time out Error...................................................... 52 Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 54 Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 56 Failure code [CA2249] Rail Press Very Low Error................................................................... 57 Failure code [CB2249] Rail Press Very Low Error................................................................... 57 Failure code [CA2555] Grid Heater Relay Volt Low Error ....................................................... 58 Failure code [CA2556] Grid Heater Relay Volt High Error....................................................... 60 Troubleshooting by failure code, Part 4 SEN02099-00 Troubleshooting by failure code, Part 4....................................................................................... 4 Failure code [D110KB] Battery Relay Drive S/C...................................................................... 4 Failure code [D163KB] Flash Light Relay S/C......................................................................... 6 Failure code [D195KA] Step Light Relay Disc ......................................................................... 8 Failure code [D195KY] Step Light Relay S/C .......................................................................... 10 Failure code [D1E9KB] Wiper Drive Relay 1 S/C .................................................................... 12 Failure code [D1EAKB] Wiper Drive Relay 2 S/C.................................................................... 14 Failure code [D1EBKB] Lower Wiper Brake Relay Short Circuit ............................................. 16 Failure code [D1ECKB] Upper Wiper Brake Relay Short Circuit............................................. 18 Failure code [DA22KK] Pump 1 Solenoid Power Low Error.................................................... 20 Failure code [dA22KK] Pump 2 Solenoid Power Low Error .................................................... 22 Failure code [DA25KP] Pump 1 Sens Supply Vol Low Error................................................... 24 Failure code [dA25KP] Pump 2 Sens Supply Vol Low Error ................................................... 26 Failure code [DA26KP] 5V Sensor 2 Power Abnormality ........................................................ 28 Failure code [DA29KQ] Pump 1 Model Select Abnormality .................................................... 30 Failure code [dA29KQ] Pump 2 Model Select Abnormality ..................................................... 32 Failure code [DA2RMC] CAN Discon (Pump 1 Con Detected) ............................................... 34 Failure code [dA2RMC] CAN Discon (Pump 2 Con Detected) ................................................ 36 Failure code [DA2TMC] Pump Comm. ECM Child Abnormality .............................................. 38 Failure code [DBB0KK] VHMS Source Voltage Error (or change of VHMS-LED display from n9 to 01) ............................................................. 40 PC2000-8

9

SEN01609-06

00 Index and foreword

Failure code [DBB0KQ] VHMS Connector Mismatch (or change of VHMS-LED display from nF to 11) ............................................................. 42 Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMS-LED display from n9 to 04) ............................................................. 44 Failure code [DBB6KP] VHMS 24V source sys Error (or change of VHMS-LED display from n9 to 02) ............................................................. 46 Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02) ............................................................. 48 Failure code [DGE5KX] Ambient Air Temp Sensor Failure (or change of VHMS-LED display from n4 to 01) ............................................................. 50 Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C .............................................................. 52 Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMS-LED display from n5 to 01) ............................................................. 54 Troubleshooting by failure code, Part 5 SEN02100-00 Troubleshooting by failure code, Part 5....................................................................................... 4 Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 12) ............................................................. 4 Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 22) ............................................................. 6 Failure code [DGT5KB] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 11) ............................................................. 8 Failure code [dGT5KB] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 21) ............................................................. 10 Failure code [DGT6KA] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 24) ............................................................. 12 Failure code [dGT6KA] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26) ............................................................. 14 Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 23) ............................................................. 16 Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26) ............................................................. 18 Failure code [DH25KX] VR1/P1F J/S Dif Press Sensor Abnormality ...................................... 20 Failure code [DH26KX] VL1/P1R J/S Dif Press Sensor Abnormality ...................................... 22 Failure code [DH27KX] VR2/P2F J/S Dif Press Sensor Abnormality ...................................... 24 Failure code [DH28KX] VL2/P2R J/S Dif Press Sensor Abnormality ...................................... 26 Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 32) ............................................................. 28 Failure code [DHE5KY] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 31) ............................................................. 30 Failure code [DHH2KA] Hydraulic oil filter Sensor Failure (or change of VHMS-LED display from n5 to 53) ............................................................. 32 Failure code [DHPEKX] VR1/P1F Pump P. Sensor Abnormality ............................................. 34 Failure code [DHPFKX] VL1/P1R Pump P. Sensor Abnormality ............................................. 36 Failure code [DHPGKX] VR2/P2F Pump P. Sensor Abnormality ............................................ 38 Failure code [DHPHKX] VL2/P2R Pump P. Sensor Abnormality ............................................. 40 Failure code [DHPSKX] Auto Grease Press Sensor Abnormality ........................................... 42 Failure code [DHPTKX] Fan(RAD) Pump P. Sensor Open Circuit........................................... 44 Failure code [DHPUKX] Fan(O/C) Pump P. Sensor Open Circuit ........................................... 46 Failure code [DHS3KX] Arm Dig PPC Press Sensor Abnormality........................................... 48 Failure code [DHS4KX] Bucket Curl PPC Press Sensor Abnormality ..................................... 50 Failure code [DHS8KX] Boom Raise PPC Press Sensor Abnormality .................................... 52 Failure code [DHS9KX] Boom Lower PPC Press Sensor Abnormality ................................... 54 Failure code [DHSAKX] Swing Right PPC Press Sensor Abnormality .................................... 56 Failure code [DHSBKX] Swing Left PPC Press Sensor Abnormality ...................................... 58 Failure code [DHSCKX] Arm Dump PPC Press Sensor Abnormality...................................... 60 Failure code [DHSDKX] Bucket Dump PPC Press Sensor Abnormality ................................. 62

10

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00 Index and foreword

SEN01609-06

Troubleshooting by failure code, Part 6 SEN02101-00 Troubleshooting by failure code, Part 6....................................................................................... 3 Failure code [DUM3KB] Auto Grease Caution LED Short Circuit ........................................... 3 Failure code [DUM4KB] FAN Reverse LED Short Circuit........................................................ 4 Failure code [DV20KB] Travel Alarm S/C................................................................................ 5 Failure code [DW41KA] Swing Priority Sol Open Circuit......................................................... 7 Failure code [DW41KB] Swing Priority Sol Short Circuit ......................................................... 9 Failure code [DW45KA] Swing Brake Sol. Disc....................................................................... 11 Failure code [DW45KB] Swing Brake Sol. S/C........................................................................ 14 Failure code [DW91KA] Straight-Travel Sol. Disc.................................................................... 16 Failure code [DW91KB] Straight-Travel Sol. S/C..................................................................... 18 Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc. ...................................................... 20 Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C ........................................................ 21 Failure code [DW7BKA] Fan Motor (RAD) Reverse Sol Open Circuit..................................... 22 Failure code [DW7BKB] Fan Reverse Sol. S/C....................................................................... 24 Failure code [DW7HKA] Fan Motor(O/C) Reverse Sol Open Circuit....................................... 26 Failure code [DW7HKB] Fan Motor(O/C) Reverse Sol Short Circuit....................................... 28 Failure code [DWA3KA] Arm throttle Valve/L Sol Open Circuit ............................................... 30 Failure code [DWA3KB] Arm throttle Valve/L Sol Short Circuit ............................................... 32 Failure code [DWA4KA] Arm throttle Valve/R Sol Open Circuit............................................... 34 Failure code [DWA4KB] Arm throttle Valve/R Sol Short Circuit............................................... 36 Failure code [DWA5KA] Auto Grease Sol Open Circuit .......................................................... 38 Failure code [DWA5KB] Auto Grease Sol Short Circuit........................................................... 40 Failure code [DWA6KA] Boom throttle Valve Sol Open Circuit ............................................... 41 Failure code [DWA6KB] Boom throttle Valve Sol Short Circuit................................................ 43 Failure code [DWK0KA] 2-stage Relief Sol. Disc. ................................................................... 45 Failure code [DWK0KB] 2-stage Relief Sol. S/C ..................................................................... 47 Failure code [DWK2KA] Back Press Comp Valve Sol Open Circuit ........................................ 48 Failure code [DWK2KB] Back Press Comp Valve Sol Short Circuit ........................................ 49 Troubleshooting by failure code, Part 7 SEN02102-00 Troubleshooting by failure code, Part 7....................................................................................... 3 Failure code [DWN5KA] Fan(RAD) Pump EPC Sol Open Circuit ........................................... 3 Failure code [DWN5KB] Fan(RAD) Pump EPC Sol Short Circuit ........................................... 5 Failure code [DWNCKA] Fan(O/C) Pump EPC Sol Open Circuit............................................ 6 Failure code [DWNCKB] Fan(O/C) Pump EPC Sol Short Circuit ............................................ 7 Failure code [DXAAKA] P1F EPC Sol Disc ............................................................................. 8 Failure code [DXAAKB] P1F EPC Sol S/C .............................................................................. 10 Failure code [DXABKA] P1R Pump EPC Sol. Disc. ................................................................ 12 Failure code [DXABKB] P1R Pump EPC Sol. S/C .................................................................. 14 Failure code [DXACKA] P2F Pump EPC Sol. Disc. ................................................................ 16 Failure code [DXACKB] P2F Pump EPC Sol. S/C .................................................................. 18 Failure code [DXADKA] P2R Pump EPC Sol. Disc. ................................................................ 20 Failure code [DXADKB] P2R Pump EPC Sol. S/C .................................................................. 22 Failure code [DY2CKB] Washer Drive S/C.............................................................................. 24 Failure code [DY20MA] Low Wiper Working Abnormality ....................................................... 26 Failure code [DY2FMA] Upper Wiper Working Abnormality .................................................... 29 Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38) ............................................................. 32 Failure code [F@BYNR] Very High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 62) ............................................................. 34 Failure code [f@BYNR] Very High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 72) ............................................................. 36 Failure code [F@BYNS] High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 61) ............................................................. 38 Failure code [f@BYNS] High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 71) ............................................................. 40 Failure code [F@BZNR] Very High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 82) ............................................................. 42 PC2000-8

11

SEN01609-06

00 Index and foreword

Failure code [f@BZNR] Very High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 92) ............................................................. 44 Failure code [F@BZNS] High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 81) ............................................................. 46 Failure code [f@BZNS] High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 91) ............................................................. 48 Failure code [LA10ZL] RAD system fan pump relief pressure high error ................................ 50 Failure code [LA20ZL] O/C system pump relief pressure high error ....................................... 51 Troubleshooting of electrical system (E-mode) SEN02103-00 Troubleshooting of electrical system (E-mode) ........................................................................... 4 Contents of troubleshooting table ............................................................................................ 6 E-1 When starting switch is turned ON, machine monitor displays nothing ............................ 8 E-2 When starting switch turned ON (before starting engine), basic check item lights up ...... 10 E-3 Engine does not start (Engine does not turn).................................................................... 12 E-4 Auto-decelerator does not operate.................................................................................... 16 E-5 Automatic warm-up system does not operate................................................................... 17 E-6 Preheater does not work ................................................................................................... 18 E-7 Whole work equipment, swing operation and machine travel operation are disabled ...... 20 E-8 Machine push-up function does not work.......................................................................... 22 E-9 Boom shockless function cannot be released................................................................... 24 E-10 Machine monitor does not display some items ............................................................... 26 E-11 Contents of display by machine monitor are different from applicable machine ............. 27 E-12 Fuel level monitor lights up in red while engine is running.............................................. 28 E-13 Hydraulic oil temperature gauge does not indicate normally .......................................... 29 E-14 Fuel level gauge does not indicate normally ................................................................... 30 E-15 Swing lock monitor does not indicate normally ............................................................... 32 E-16 Machine monitor display anything even when operated on monitor switch section........ 34 E-17 Wiper does not work ....................................................................................................... 35 E-18 Monitoring function does not display "Travel" normally................................................... 42 E-19 Travel alarm does not sound........................................................................................... 44 E-20 All of room lamp, headlamp and working lamp do not light up........................................ 45 E-21 Air conditioner does not work.......................................................................................... 50 E-22 Step light does not light up or goes off ............................................................................ 52 Troubleshooting of hydraulic and mechanical system (H-mode) SEN02104-00 Troubleshooting of hydraulic and mechanical system (H-mode)................................................. 3 Before troubleshooting for hydraulic and mechanical systems................................................ 3 Table of failure modes and causes .......................................................................................... 8 Information in troubleshooting table......................................................................................... 10 H-1 Speed or power of whole work equipment, travel, and swing is low ................................. 11 H-2 Engine speed lowers remarkably or engine stalls............................................................. 13 H-3 Work equipment, swing, and travel mechanism do not move........................................... 14 H-4 Abnormal noise comes from around hydraulic pump........................................................ 16 H-5 Speed or power of boom is low......................................................................................... 17 H-6 Speed or power of arm is low............................................................................................ 19 H-7 Speed or power of bucket is low ....................................................................................... 20 H-8 Boom does not move ........................................................................................................ 21 H-9 Arm does not move........................................................................................................... 21 H-10 Bucket does not move .................................................................................................... 21 H-11 Hydraulic drift of work equipment is large. ...................................................................... 22 H-12 Time lag of work equipment is large ............................................................................... 23 H-13 Heavy lift function does not work or is not reset. ............................................................ 24 H-14 Machine push-up function does not work or is not reset................................................. 24 H-15 Boom shockless function does not work or is not reset .................................................. 24 H-16 Machine gradually deviates during traveling................................................................... 26 H-17 Machine deviates excessively when started to travel ..................................................... 29 H-18 Machine deviates excessively during multiple operations .............................................. 30 H-19 Traveling speed or power is low...................................................................................... 30

12

PC2000-8

00 Index and foreword

SEN01609-06

H-20 Travel system does not move (only one side) ................................................................ 31 H-21 Upper structure does not swing ...................................................................................... 32 H-22 Swing speed or acceleration is low................................................................................. 34 H-23 In compound operation of work equipment, swing speed or acceleration is low ............ 36 H-24 Upper structure overruns remarkably when it stops swinging ........................................ 37 H-25 Large shock is made when upper structure stops swinging ........................................... 38 H-26 Large abnormal sound comes from when upper structure stops swinging..................... 39 H-27 Hydraulic drift of work equipment is large in swing operation ......................................... 40 H-28 Fan rotation is abnormal (large noise or vibration of fans, or fan overheating) .............. 41 Troubleshooting of mechanical system (S-mode) SEN02105-00 Troubleshooting of mechanical system (S-mode) ....................................................................... 3 Method of using troubleshooting charts................................................................................... 3 S-1 Starting performance is poor ............................................................................................. 6 S-2 Engine does not start ........................................................................................................ 7 S-3 Engine does not pick up smoothly .................................................................................... 10 S-4 Engine stops during operations ........................................................................................ 11 S-5 Engine does not rotate smoothly ...................................................................................... 12 S-6 Engine lacks output (or lacks power) ................................................................................ 13 S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 15 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 16 S-9 Oil becomes contaminated quickly ................................................................................... 17 S-10 Fuel consumption is excessive ....................................................................................... 18 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 19 S-12 Oil pressure drops........................................................................................................... 20 S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 21 S-14 Coolant temperature becomes too high (overheating).................................................... 22 S-15 Abnormal noise is made ................................................................................................. 23 S-16 Vibration is excessive ..................................................................................................... 24 50 Disassembly and assembly General information on disassembly and assembly SEN02133-00 General information on disassembly and assembly.................................................................... 2 How to read this manual.......................................................................................................... 2 Coating materials list ............................................................................................................... 4 Special tool list......................................................................................................................... 7 Sketches of special tools ......................................................................................................... 10 Engine and cooling system (12V140E-3) SEN02134-01 Engine and cooling system (12V140E-3).................................................................................... 2 Removal and installation of power container assembly........................................................... 2 Removal and installation of engine, PTO and hydraulic pump assembly................................ 7 Removal and installation of radiator assembly ........................................................................ 19 Removal and installation of aftercooler assembly ................................................................... 20 Removal and installation of hydraulic oil cooler assembly ...................................................... 22 Removal and installation of fuel cooler assembly.................................................................... 23 Removal and installation of cooling assembly ......................................................................... 24 Removal and installation of fan motor assembly ..................................................................... 28 Removal and installation of fuel tank assembly....................................................................... 29 Engine (12V140E-3) SEN02135-01 Engine (12V140E-3).................................................................................................................... 2 Removal and installation of fuel supply pump assembly ......................................................... 2 Removal and installation of cylinder head assembly ............................................................... 5 Removal and installation of fuel injector .................................................................................. 19 Removal and installation of engine front seal .......................................................................... 30 Removal and installation of engine rear seal........................................................................... 33

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13

SEN01609-06

00 Index and foreword

Power train SEN02136-00 Power train .................................................................................................................................. 2 Removal and installation of PTO assembly ............................................................................. 2 Disassembly and assembly of PTO assembly......................................................................... 3 Removal and installation of swing motor and swing machinery assembly .............................. 7 Disassembly and assembly of swing machinery assembly ..................................................... 9 Removal and installation of swing circle assembly .................................................................. 19 Removal and installation of final drive assembly ..................................................................... 20 Disassembly and assembly of final drive assembly................................................................. 22 Undercarriage and frame SEN02137-00 Undercarriage and frame ............................................................................................................ 2 Removal and installation of track shoe assembly.................................................................... 2 Removal and installation of idler assembly.............................................................................. 4 Disassembly and assembly of idler assembly ......................................................................... 5 Disassembly and assembly of idler adjust cylinder assembly ................................................. 7 Removal and installation of idler cushion cylinder assembly ................................................... 8 Disassembly and assembly of idler cushion cylinder assembly .............................................. 9 Removal and installation of track roller assembly.................................................................... 10 Disassembly and assembly of track roller assembly ............................................................... 11 Removal and installation of carrier roller assembly ................................................................. 13 Disassembly and assembly of carrier roller assembly............................................................. 14 Removal and installation of revolving frame assembly ............................................................ 18 Removal and installation of counterweight assembly .............................................................. 21 Hydraulic system SEN02138-00 Hydraulic system ......................................................................................................................... 2 Removal and installation of hydraulic tank assembly .............................................................. 2 Removal and installation of hydraulic pump assembly ............................................................ 5 Removal and installation of hydraulic pump input shaft oil seal .............................................. 10 Removal and installation of control valve assembly ................................................................ 11 Disassembly and assembly of control valve assembly............................................................ 18 Removal and installation of center swivel joint assembly ........................................................ 22 Disassembly and assembly of center swivel joint assembly.................................................... 23 Removal and installation of swing motor assembly ................................................................. 24 Removal and installation of travel motor assembly ................................................................. 25 Disassembly and assembly of work equipment PPC valve assembly..................................... 26 Disassembly and assembly of travel PPC valve assembly ..................................................... 28 Disassembly and assembly of hydraulic cylinder assembly .................................................... 29 Work equipment SEN02139-00 Work equipment .......................................................................................................................... 2 Removal and installation of bucket cylinder assembly ............................................................ 2 Removal and installation of bucket assembly .......................................................................... 4 Removal and installation of arm cylinder ................................................................................. 6 Removal and installation of arm assembly .............................................................................. 8 Removal and installation of boom cylinder assembly .............................................................. 10 Removal and installation of boom assembly ........................................................................... 12 Cab and its attachments SEN02140-00 Cab and its attachments.............................................................................................................. 2 Removal and installation of operator cab assembly ................................................................ 2 Removal and installation of operator cab glass (adhesion glass)............................................ 5 Removal and installation of operator cab (assembly-type) ...................................................... 12 Removal and installation of cab base assembly...................................................................... 13 Electrical system SEN02141-00 Electrical system ......................................................................................................................... 2 Removal and installation of air conditioner unit assembly ....................................................... 2 Removal and installation of monitor assembly ........................................................................ 6 Removal and installation of engine controller assembly.......................................................... 7

14

PC2000-8

00 Index and foreword

SEN01609-06

Removal and installation of pump controller assembly ........................................................... Removal and installation of VHMS controller assembly .......................................................... Removal and installation of Orbcomm terminal assembly for VHMS ......................................

8 9 9

90 Diagrams and drawings Hydraulic diagrams and drawings SEN01629-00 Hydraulic diagrams and drawings ............................................................................................... 3 Hydraulic circuit diagram ......................................................................................................... 3 Electrical diagrams and drawings SEN01630-03 Electrical diagrams and drawingss.............................................................................................. 3 Electrical circuit diagram (1/2) ................................................................................................. 3 Electrical circuit diagram (2/2) ................................................................................................. 5 Connector arrangement diagram............................................................................................. 7

PC2000-8

15

SEN01609-06

PC2000-8 Hydraulic excavator Form No. SEN01609-06

© 2007 KOMATSU All Rights Reserved Printed in Japan 07-07 (01)

16

SEN01610-02

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

00 Index and foreword

1

Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling 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

PC2000-8

1

SEN01610-02

Safety notice

00 Index and foreword

1

(Rev. 2007/03)

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

2

General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, ha ng UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7)

8)

If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out w e ld in g w o r k, a lw a y s w e a r w e ld i n g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition.

Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5

Prohibition of operation and handling by unlicensed workers

6 Safety check before starting work 7

Wearing protective goggles (for cleaning or grinding work)

8

Wearing shielding goggles and protectors (for welding work)

9 Good physical condition and preparation 10

2.

Precautions against work which you are not used to or you are used to too much

Preparations for work 1) Before adding oil or making any repairs, pa rk th e ma ch in e o n h a rd an d le v e l ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

PC2000-8

00 Index and foreword

3)

4)

3.

When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h in e . N e v e r j u m p o n o r o f f t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping th e en g in e ( me as ur ing o il p re ss ur e, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires.

PC2000-8

SEN01610-02

8)

9)

10)

11)

12)

13)

14)

15)

16)

When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damag ed tu bes a re da ng erou s, so be extremely careful when installing tubes for high pressure circuits. In addition, check that connecting parts are correctly installed. When assembling or installing parts, alwa ys tigh te n the m to the sp ecified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r l y c a r e fu l t o c h e c k th a t t h e y a r e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tra cks of track-type ma chines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

3

SEN01610-02

4.

4

Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. W hen h oisting a loa d with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.

00 Index and foreword

8)

When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not g ras p th em bu t p res s th em fr om above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

PC2000-8

00 Index and foreword

If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

SEN01610-02

13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

q

5.

6.

Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.

PC2000-8

7.

Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.

Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

a

The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

5

SEN01610-02

8.

Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k Collect the air conditioner refrigerant (R134a) from the air c onditioner circuit in advance. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant and put on protective goggles. 2)

Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigeran t ( R1 34 a ) ( DEN SO : ND -O IL8 , ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings.

a

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

a

For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".

6

00 Index and foreword

PC2000-8

00 Index and foreword

How to read the shop manual q q q

1.

SEN01610-02

1

Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.

2.

Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.

PC2000-8

7

SEN01610-02

3.

4.

00 Index and foreword

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.

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

a

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing work.

4

Weight

Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

3

Tightening torque

2

Coat

5

Oil, coolant

6

Drain

Special safety precautions are necessary when performing work.

Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.

5.

Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

8

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Explanation of terms for maintenance standard

1

The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1.

Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q

Example: Standard size 120

Tolerance –0.022 –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 indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them

q

Example: Standard size 60

PC2000-8

Tolerance Shaft Hole –0.030 +0.046 –0.076 +0

9

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2.

3.

4.

Standard clearance and standard value q The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value. Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.

00 Index and foreword

5.

Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q

6.

Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q

Repair limit and allowable value The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit must be replaced or repaired. q The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the “allowable value”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement. q

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Handling of electric equipment and hydraulic component

SEN01610-02

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

Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)

Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

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12

3)

Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

4)

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

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 surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the co nn ec tor, be c ar efu l n ot t o u se excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

00 Index and foreword

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3.

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Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q

When removing from clips 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 stoppers. 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 connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

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2)

14

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Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

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3)

Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks

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SEN01610-02

q

Disconnection

q

Connection (Example of incomplete setting of (a))

15

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4)

16

00 Index and foreword

Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk th at oil in t he a ir ma y c au se defective contact, so remove all o il a n d w a t e r fr o m t h e c o m pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n t a c t restorer and reassemble.

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4.

Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.

5.

Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.

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17

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

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 performance 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 ope ning 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 cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

18

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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 p ossib le o f the old hydra ulic oil must b e 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 equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7.

Cleaning operations After repairing the hydraulic equipment (pump, c on tr ol v alve , e tc. ) o r w h en r un n in g th e machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.

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SEN01610-02

19

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00 Index and foreword

Handling of connectors newly used for engines a

1.

Mainly, following engines are object for following connectors. q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (107, 114 engines) Ne speed sensor of flywheel housing: NE (107 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)

2.

1

Pull lock type (PACKARD-2) 107 – 170, 12V140 engine q Various temperature sensors Example) Intake air temp er atur e se nso r in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.

q

Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.

20

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3.

SEN01610-02

Push lock type 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03)

q

Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q

q

114 engine

q

107, 114 engine Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)

3)

While pressing lock (D), pull out connector (4) in the direction of the arrow.

107 engine

a

2)

If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

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q

4)

125 – 170, 12V140 engine While pressing lock (E) of the connector, pullout connector (5) in the direction of the arrow. Example) Fuel pressure in common rail: PFUEL etc. (AMP-3)

00 Index and foreword

4.

Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.

q

1)

Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.

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) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)

Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.

22

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How to read electric wire code a

1

The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX

0.85

L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)

1.

Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile

Symbol AV

AVS

Heat-resistant low-voltAEX age wire for automobile

PC2000-8

Material Conductor Insulator Conductor

Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance Heat-resistant crosslinked polyethylene

Insulator

Using temperature range (°C)

Example of use General wiring (Nominal No. 5 and above)

–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place

23

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2.

00 Index and foreword

Dimensions

(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) AVS CovAV er D AEX

d (approx.) Standard Standard Standard

8

15

20

30

40

50

60

85

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7 – 5.5 5.3

4.8 – 7.0 7.0

6.0 – 8.2 8.2

8.0 – 10.8 10.8

8.6 – 11.4 11.4

9.8 – 13.0 13.0

10.4 – 13.6 13.6

12.0 – 16.0 16.0

13.6 – 17.6 17.6

108/0.80 127/0.80 169/0.80

100 217/0.80

“f” of nominal No. denotes flexible”.

24

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3.

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Color codes table

(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White.

4.

Types of circuits and color codes

(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit

Others

PC2000-8

AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch

AEX

WG

–

–

–

–

–

–

–

–

–

–

R B R D Y G L

–

–

– –

–

–

–

–

–

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

YW GL

– –

Gr Br – –

25

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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. q q q q q q q q q q

a

Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)

26

Sleeve nut (elbow end)

07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234

02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234

Split flange type hoses and tubes Nominal number 04 05

3)

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

If the part is not under hydraulic pressure, the following corks can be used. Nominal number

Part Number

06 08 10 12 14 16 18 20 22 24

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430

Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30

27

07049-02734

27

22.5

34

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2. q q q q q q q q q q q q q

a

a 3.

SEN01610-02

Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.

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4)

5)

28

00 Index and foreword

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

PC2000-8

00 Index and foreword

SEN01610-02

Method of disassembling and connecting push-pull type coupler k k

1

Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.

Type 1 1.

Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.

2.

Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

PC2000-8

29

SEN01610-02

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Type 2 1.

2.

Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)

Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

q

30

PC2000-8

00 Index and foreword

SEN01610-02

Type 3 1.

2.

Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)

Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)

q

PC2000-8

31

SEN01610-02

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Standard tightening torque table 1.

Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) a

The following table corresponds to the bolts in Fig. A.

Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a

a Fig. A

Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Tightening torque Nm kgm 11.8 – 14.7 1.2 – 1.5 27 – 34 2.8 – 3.5 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 153 – 190 15.5 – 19.5 235 – 285 23.5 – 29.5 320 – 400 33.0 – 41.0 455 – 565 46.5 – 58.0 610 – 765 62.5 – 78.0 785 – 980 80.0 – 100.0 1,150 – 1,440 118 – 147 1,520 – 1,910 155 – 195 1,960 – 2,450 200 – 250 2,450 – 3,040 250 – 310 2,890 – 3,630 295 – 370

The following table corresponds to the bolts in Fig. B.

Thread diameter of bolt mm 6 8 10 12

32

1

Width across flats mm 10 13 14 27

Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

a Fig. B

PC2000-8

00 Index and foreword

2.

Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt mm 10 12 16

3.

Width across flats mm 14 17 22

Tightening torque Nm kgm 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 235 – 285 23.5 – 29.5

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.

Nominal No. 02 03,04 05,06 10,12 14

4.

SEN01610-02

Thread diameter mm 14 20 24 33 42

Width across flats mm Varies depending on type of connector.

Tightening torque Nm Range 35 – 63 { 3.5 – 6.5} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 363 – 480 {37.0 – 49.0} 746 – 1,010 {76.0 – 103}

{kgm} Target 44 { 4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}

Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

PC2000-8

Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52

Width across flats Tightening torque Nm {kgm} mm Range Target 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

33

SEN01610-02

5.

00 Index and foreword

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}

Nominal No. of hose

Width across flats

02

19

03 04 05 06 (10) (12) (14)

6.

22 24 27 32 36 41 46 55

Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}

Target

44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

mm 6 8 10 12 14

– 14 – 18 22 24 30 33 36 42

Tightening torque Bolts and nuts Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —

kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —

Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14

34

Thread size (mm)

Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –

Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Thread size

7.

Taper seal

Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

PC2000-8

00 Index and foreword

8.

SEN01610-02

Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Thread size inch 1/16 1/8 1/4 3/8 1/2 3/4 1

PC2000-8

Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9

kgm 0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92

35

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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 horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.

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

(A)

36

(B)

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

7 0.276 0.669 1.063 1.457 1.850

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

PC2000-8

00 Index and foreword

SEN01610-02

Millimeters to inches

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

5 0.197 0.591 0.984 1.378 1.772

6 0.236 0.630 1.024 1.417 1.811

1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

Kilogram to pound

0 10 20 30 40

0 0 22.05 44.09 66.14 88.18

1 2.20 24.25 46.30 68.34 90.39

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

4 8.82 30.86 51.91 74.96 97.00

5 11.02 33.07 55.12 77.16 99.21

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

Liters to U.S. Gallons

0 10 20 30 40

0 1 0 0.264 2.642 2.906 5.283 5.548 7.925 8.189 10.567 10.831

2 0.528 3.170 5.812 8.454 11.095

3 0.793 3.434 6.076 8.718 11.359

4 1.057 3.698 6.340 8.982 11.624

5 1.321 3.963 6.604 9.246 11.888

1 l = 0.2642 U.S.Gal 6 7 8 9 1.585 1.849 2.113 2.378 4.227 4.491 4.755 5.019 6.869 7.133 7.397 7.661 9.510 9.774 10.039 10.303 12.152 12.416 12.680 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

13.737 16.379 19.020 21.662 24.304

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

14.795 17.435 20.077 22.719 25.361

PC2000-8

13.473 16.115 18.756 21.398 24.040

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

37

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Liters to U.K. Gallons

0 10 20 30 40

0 0 2.200 4.399 6.599 8.799

1 0.220 2.420 4.619 6.819 9.019

2 0.440 2.640 4.839 7.039 9.239

3 0.660 2.860 5.059 7.259 9.459

4 0.880 3.080 5.279 7.479 9.679

5 1.100 3.300 5.499 7.699 9.899

50 60 70 80 90

10.998 13.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

kgm to ft.lb

0 10 20 30 40

0 0 72.3 144.7 217.0 289.3

1 7.2 79.6 151.9 224.2 296.6

2 14.5 86.8 159.1 231.5 303.8

3 21.7 94.0 166.4 238.7 311.0

4 28.9 101.3 173.6 245.9 318.3

5 36.2 108.5 180.8 253.2 325.5

6 43.4 115.7 188.1 260.4 332.7

1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

38

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1106.6 1113.9 1121.1 1171.7 1179.0 1186.2 1193.4 1244.1 1251.3 1258.5 1265.8 1316.4 1323.6 1330.9 1338.1 1388.7 1396.0 1403.2 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4

PC2000-8

00 Index and foreword

SEN01610-02

kg/cm2 to lb/in2

0 10 20 30 40

0 0 142.2 284.5 426.7 568.9

1 14.2 156.5 298.7 440.9 583.2

2 28.4 170.7 312.9 455.1 597.4

3 42.7 184.9 327.1 469.4 611.6

4 56.9 199.1 341.4 483.6 625.8

5 71.1 213.4 355.6 497.8 640.1

6 85.3 227.6 369.8 512.0 654.3

1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1,138 1,280

725.4 867.6 1,010 1,152 1,294

739.6 881.8 1,024 1,166 1,309

753.8 896.1 1,038 1,181 1,323

768.1 910.3 1,053 1,195 1,337

782.3 924.5 1,067 1,209 1,351

796.5 938.7 1,081 1,223 1,365

810.7 953.0 1,095 1,237 1,380

825.0 967.2 1,109 1,252 1,394

839.2 981.4 1,124 1,266 1,408

100 110 120 130 140

1,422 1,565 1,707 1,849 1,991

1,437 1,579 1,721 1,863 2,005

1,451 1,593 1,735 1,877 2,020

1,465 1,607 1,749 1,892 2,034

1,479 1,621 1,764 1,906 2,048

1,493 1,636 1,778 1,920 2,062

1,508 1,650 1,792 1,934 2,077

1,522 1,664 1,806 1,949 2,091

1,536 1,678 1,821 1,963 2,105

1,550 1,693 1,835 1,977 2,119

150 160 170 180 190

2,134 2,276 2,418 2,560 2,702

2,148 2,290 2,432 2,574 2,717

2,162 2,304 2,446 2,589 2,731

2,176 2,318 2,460 2,603 2,745

2,190 2,333 2,475 2,617 2,759

2,205 2,347 2,489 2,631 2,773

2,219 2,361 2,503 2,646 2,788

2,233 2,375 2,518 2,660 2,802

2,247 2,389 2,532 2,674 2,816

2,262 2,404 2,546 2,688 2,830

200 210 220 230 240

2,845 2,987 3,129 3,271 3,414

2,859 3,001 3,143 3,286 3,428

2,873 3,015 3,158 3,300 3,442

2,887 3,030 3,172 3,314 3,456

2,901 3,044 3,186 3,328 3,470

2,916 3,058 3,200 3,343 3,485

2,930 3,072 3,214 3,357 3,499

2,944 3,086 3,229 3,371 3,513

2,958 3,101 3,243 3,385 3,527

2,973 3,115 3,257 3,399 3,542

PC2000-8

39

SEN01610-02

00 Index and foreword

Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

°C

1°C = 33.8°F °F

°F

°C

°F

°C

°F

°C

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

177.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

40

PC2000-8

00 Index and foreword

PC2000-8

SEN01610-02

41

SEN01610-02

PC2000-8 Hydraulic excavator Form No. SEN01610-02

© 2007 KOMATSU All Rights Reserved Printed in Japan 05-07 (01)

42

SEN01612-01

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

01 Specification

1

Specification and technical data Specification drawings .................................................................................................................................... 2 Specifications .................................................................................................................................................. 6 Weight table .................................................................................................................................................. 10 Table of fuel, coolant and lubricants.............................................................................................................. 16

PC2000-8

1

SEN01612-01

01 Specification

Specification drawings

1

Backhoe specification

Item

1

Unit

PC2000-8

A Overall length

mm

17,030

B Overall height

mm

7,135

C Overall width

mm

With slide ladder

Without slide ladder

7,550

7,235

D Track shoe width

mm

810

E Height of machine cab

mm

5,970

F Height of operator’s cab

mm

7,030

G Tail swing radius

mm

5,980

H Track overall length

mm

7,445

J Length of track on ground

mm

5,780

K Min. ground clearance

mm

825

2

PC2000-8

01 Specification

SEN01612-01

Working range drawing

Item

Unit

PC2000-8

A Max. digging height

mm

13,410

B Max. dumping height

mm

8,650

C Max. digging depth

mm

9,235

D Max. vertical wall depth

mm

2,710

E Max. reach at ground level

mm

15,305

F Max. digging reach

mm

15,780

mm

7,500

G

Min. swing radius of work equipment

PC2000-8

3

SEN01612-01

01 Specification

Loading shovel specification

Item

1

Unit

PC2000-8

A Overall length

mm

13,075

B Overall height

mm

8,180

C Overall width

mm

7,550

D Track shoe width

mm

810

E Height of machine cab

mm

5,970

F Height of operator’s cab

mm

7,030

G Tail swing radius

mm

5,980

H Track overall length

mm

7,445

J Length of track on ground

mm

5,780

K Min. ground clearance

mm

825

4

PC2000-8

01 Specification

SEN01612-01

Working range drawing

Item

Unit

PC2000-8

A Max. digging height

mm

14,450

B Max. dumping height

mm

9,665

C Max. digging depth

mm

3,190

D Min. reach at ground level

mm

7,090

E Max. reach at ground level

mm

11,940

F Max. digging reach

mm

13,170

mm

7,500

G

Min. swing radius of work equipment

PC2000-8

5

SEN01612-01

01 Specification

Specifications

1

Backhoe specification Machine model

PC2000-8

Serial number Bucket capacity

Working range

12.0

kg

200,000

Max. digging depth

mm

9,235

Max. vertical wall depth

mm

2,710

Max. digging reach

mm

15,780

mm

15,305

Max. digging height

mm

13,410

Max. dumping height

mm

8,650

kN {kg}

697 {71,100}

Swing speed

rpm

4.8

Swing max. slope angle

deg.

9.0

Travel speed

km/h

2.7

Gradeability

deg.

Max. digging force

33

Ground pressure (standard shoe)

kPa {kg/cm }

190 {1.94}

With work equipment

mm

17,030

Upper structure only

mm

8,500

Lower crawler only (equipped with standard shoe)

mm

7,440

With work equipment

mm

7,135

Upper structure only

mm

5,170

Lower crawler only (equipped with standard shoe)

mm

2,840

Overall width

Dimensions

6

m

Max. reach at ground level

Overall height Overall length

Performance

Weight of machine

20001 and up 3

2

With slide ladder

Without slide ladder

7,550

7,235

With work equipment

mm

Upper structure only

mm

Lower crawler only (equipped with standard shoe)

mm

5,650 (with step)

Overall width of crawler

mm

5,410

Ground clearance of upper structure

mm

2,095

Min. ground clearance

mm

825

Tail swing radius

mm

5,980

Min. swing radius of work equipment

mm

7,500

Height of work equipment at min. swing radius

mm

11,880

Length of track on ground

mm

5,780

Track gauge

mm

4,600

Height of machine cab Standard shoe width

mm mm

5,970 810

PC2000-8

01 Specification

SEN01612-01

Machine model

PC2000-8

Serial number

20001 and up

Model

SAA12V140E-3

Type

4-cycle, water-cooled, V type, direct injection, with turbocharger and aftercooler (air cooled)

No. of cylinders – bore × stroke

mm

12 – 140 × 165

l {cc}

30.48 {30,480}

kW/rpm {HP/rpm}

728/1,800 {976/1,800}

Nm/rpm {kgm/rpm}

4,510/1,350 {460/1,350}

High idle

rpm

1,980 ± 50

Low idle

rpm

825 ± 25

g/kWh {g/HPh}

207 {154}

Performance

Engine

Piston displacement Flywheel horsepower Max. torque

Min. fuel consumption

Starting motor

24 V, 11 kW × 2

Alternator

24 V, 50 A × 2

Battery

12 V, 170 Ah × 4

Undercarriage

Radiator fan type

Aluminum wave 4-row

Carrier roller

3 on each side

Track roller

8 on each side

Track shoe

Assembly-type double grouser, 49 on each side

Hydraulic pump

Type

Delivery l/min

Hydraulic Control motor valve

Hydraulic system

Set pressure

Main pump: variable displacement tandem piston type 2 (HPV375 + 375) Fan pump: variable displacement tandem piston type 1 (HPV95 + 95) PTO lubrication pump: gear type 1 (SBL (1) 21) Main pump P1: 629 + 629, P2: 518 + 518 Fan pump: 160 + 160 PTO lubrication pump: 35 Main pump: 29.6 {300}, Fan pump: 24.5 {250}

MPa {kg/cm2}

Type × No.

5-spool + 5-spool type × 2

Control method

Hydraulic type

Travel motor

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

Swing motor

Piston type (with safety valve, shaft brake): 2 (KMF230)

Hydraulic cylinder

Boom Cylinder type

Arm

Bucket

Double-acting piston

Inside diameter of cylinder

mm

300

250

200

Outside diameter of piston rod

mm

200

160

140

Stroke

mm

2,647

2,134

2,170

Max. distance between pins

mm

6,480

5,267

5,420

Min. distance between pins

mm

3,833

3,133

3,250

Hydraulic tank

Box-shaped, with breather

Hydraulic filter

Pump outlet, tank return side

Hydraulic cooler

PC2000-8

Air cooled

7

SEN01612-01

01 Specification

Machine model

PC2000-8

Serial number

20001 and up

Bucket capacity

m3

11.0

Weight of machine

kg

195,000

Max. digging depth

mm

3,190

Max. vertical wall depth

mm

—

Max. digging reach

mm

13,170

Max. reach at ground level

mm

11,940

Max. digging height

mm

14,450

Max. dumping height

mm

9,665

kN {kg}

755 {77,000}

Swing speed

rpm

4.8

Swing max. slope angle

deg.

9.0

Travel speed

km/h

2.7

Gradeability

deg.

35

kPa {kg/cm2}

186 {1.90} [810 mm]

Overall length (for transport)

mm

13,075

Overall width

mm

7,550

Overall width of track

mm

5,410

Overall height (for transport)

mm

8,180

Overall height to top of machine

mm

7,030

Ground clearance of upper structure

mm

2,095

Min. ground clearance

mm

825

Tail swing radius

mm

5,980

Min. swing radius of work equipment

mm

7,500

Height of work equipment at min. swing radius

mm

10,920

Length of track on ground

mm

5,780

Track gauge

mm

4,600

Height of machine cab

mm

5,970

Working ranges

Performance

Loading shovel specification

Max. digging force

Dimensions

Ground pressure [standard shoe width]

8

PC2000-8

01 Specification

SEN01612-01

Machine model

PC2000-8

Serial number

20001 and up

Model

SAA12V140E-3

Type

4-cycle, water-cooled, V type, direct injection, with turbocharger and aftercooler (air cooled)

No. of cylinders – bore × stroke

mm

12 – 140 × 165

l {cc}

30.48 {30,480}

Flywheel horsepower

kW/rpm {HP/rpm}

728/1,800 {976/1,800}

Max. torque

Nm/rpm {kgm/rpm}

4,510/1,350 {460/1,350}

High idle

rpm

1,980 ± 50

Low idle

rpm

825 ± 25

g/kWh {g/HPh}

207 {154}

Performance

Engine

Piston displacement

Min. fuel consumption

Starting motor

24 V, 11 kW × 2

Alternator

24 V, 50 A × 2

Battery

12 V, 170 Ah × 4

Undercarriage

Radiator fan type

Aluminum wave 4-row

Carrier roller

3 on each side

Track roller

8 on each side

Track shoe

Assembly-type double grouser, 49 on each side

Hydraulic pump

Type

Delivery l/min

Hydraulic Control motor valve

Hydraulic system

Set pressure

Main pump: variable displacement tandem piston type 2 (HPV375 + 375) Fan pump: variable displacement tandem piston type 1 (HPV95 + 95) PTO lubrication pump: gear type 1 (SBL (1) 21) Main pump P1: 629 + 629, P2: 518 + 518 Fan pump: 160 + 160 PTO lubrication pump: 35 Main pump: 29.6 {300}, Fan pump: 24.5 {250}

MPa {kg/cm2}

Type × No.

5-spool + 5-spool type × 2 Hydraulic type

Control method Travel motor

Piston type (with brake valve, shaft brake): 2 (KMF340) Piston type (with safety valve, shaft brake): 2 (KMF230)

Swing motor

Hydraulic cylinder

Boom Cylinder type

Arm

Bucket

Bottom dump

Double-acting piston

Inside diameter of cylinder

mm

280

200

200

180

Outside diameter of piston rod

mm

180

150

140

100

Stroke

mm

2,110

1,830

1,870

600

Max. distance between pins

mm

5,680

4,910

5,020

1,990

Min. distance between pins

mm

3,570

3,080

3,150

1,390

Hydraulic tank

Box-shaped, with breather

Hydraulic filter

Pump outlet, tank return side

Hydraulic cooler

PC2000-8

Air cooled

9

SEN01612-01

Weight table k

01 Specification

1

This weight table is a guide for use when transporting or handling components.

Backhoe specification Unit: kg Machine model Serial number Power container assembly q Engine body q Engine mount bracket, engine oil drain q Air cleaner, muffler, tail pipe q PTO q PTO lubrication piping, PTO drain q Radiator, radiator drain q Oil cooler q Fuel piping q Harness q Main pump (F) q Second pump (R) q Fan pump q Delivery line q Oil cooler line q Pump drain line, pump drain filter q PPC delivery line, pilot filter q Air conditioner compressor, air conditioner piping, heater piping q Engine hood, cooling duct, power container exterior q Power container base frame q Power container partition q Underguard Operator’s cab assembly q Harness q VHMS controller, pump controller, ORBCOMM controller, PHMS controller, power distribution q Horn q PPC return line, safety lock, accumulator q Junction joint q PPC travel control line q PPC work equipment control line, boom shockless q Operator’s seat q Sub seat q Seat belt q Operator’s cab body, wiper, left rearview mirror q Floor mat q Air conditioner q Fire extinguisher q First aid box

10

PC2000-8 20001 and up 16,238 3,375 364 488 1,092 30 1,249 1,124 55 58 490 490 220 212 57 83 27 40 3,789 2,668 142 185 4,135 50 20 5 42 17 3 14 50 11 1 1,540 16 95 4 5

PC2000-8

01 Specification

SEN01612-01

Unit: kg Machine model Serial number q Cab mount (viscous mount) q Work equipment PPC valve (LH and RH), control stand (LH and RH), left gauge panel q Travel PPC valve, travel lever, travel pedal q Cab base, cab round step, emergency refuge ladder Left deck (with battery) with power assist ladder without power assist ladder Right deck (incl. counterweight handrail) Fuel tank Fuel piping Harness Travel alarm Grease piping, injector Hydraulic tank, return oil filter, oil level sensor Main valve, valve bracket Suction line Delivery line, in-line filter Oil cooler line Return line (excl. return filter) PPC drain line Boom line Arm line Bucket line Travel line Straight travel line Swing line Solenoid valve Solenoid valve line Shuttle valve line PPC control line PPC main line PPC delivery line Revolving frame Boom foot pin, boom cylinder bottom pin Air conditioner piping, heater piping, electronic controller, receiver dryer Cab rear floor, revolving frame front step, center maintenance floor, drum can cover Right rearview mirror Counterweight Swing machinery Swing motor Swivel joint Pump, drum can bracket, oil piping, grease reel line

PC2000-8

PC2000-8 20001 and up 108 130 22 2,002 2,097 1,674 1,085 2,112 26 40 3 62 1,884 1,732 290 128 127 111 34 195 171 93 91 11 49 22 8 51 8 38 26 19,355 475 70 511 6 24,000 2,136 210 290 309

11

SEN01612-01

01 Specification

Unit: kg Machine model Serial number Track frame assembly q Swing circle q Travel piping q Idler cushion oil pressure part q Travel final drive q Idler q Idler cushion cylinder part q Track roller q Carrier roller q Track Standard triple shoe (810 mm) Wide triple shoe (1,010 mm) q Center frame, grease bus q Crawler frame q Center cover (if equipped) q Travel motor cover q Travel motor guard q Track frame step q Track roller guard Single type Divided welding type (if equipped) Boom Hose between machine and boom foot Arm cylinder hose Boom cylinder Boom cylinder hose Arm cylinder Arm Hose between boom and arm Bucket cylinder Link Bucket Bucket body (incl. tooth, shroud) Wear kit (if equipped)

12

PC2000-8 20001 and up 68,051 3,633 139 332 6,514 2,462 946 5,586 762 17,020 21,040 13,562 14,331 646 515 937 81 1,231 2,328 18,389 118 74 4,790 73 2,470 8,699 97 1,752 2,030 9,737 2,508

PC2000-8

01 Specification k

SEN01612-01

This weight table is a guide for use when transporting or handling components.

Loading shovel specification Unit: kg Machine model Serial number Power container assembly q Engine body q Engine mount bracket, engine oil drain q Air cleaner, muffler, tail pipe q PTO q PTO lubrication piping, PTO drain q Radiator, radiator drain q Oil cooler q Fuel piping q Harness q Main pump (F) q Second pump (R) q Fan pump q Delivery line q Oil cooler line q Pump drain line, pump drain filter q PPC delivery line, pilot filter q Air conditioner compressor, air conditioner piping, heater piping q Engine hood, cooling duct, power container exterior q Power container base frame q Power container partition q Underguard Operator’s cab assembly q Harness q VHMS controller, pump controller, ORBCOMM controller, PHMS controller, power distribution q Horn q PPC return line, safety lock, accumulator q Junction joint q PPC travel control line q PPC work equipment control line, boom shockless q Operator’s seat q Sub seat q Seat belt q Operator’s cab body, wiper, left rearview mirror q Floor mat q Air conditioner q Fire extinguisher q First aid box

PC2000-8

PC2000-8 20001 and up 16,238 3,375 364 488 1,092 30 1,249 1,124 55 58 490 490 220 212 57 83 27 40 3,789 2,668 142 185 4,135 50 20 5 42 17 3 14 50 11 1 1,540 16 95 4 5

13

SEN01612-01

01 Specification

Unit: kg Machine model Serial number q Cab mount (viscous mount) q Work equipment PPC valve (LH and RH), control stand (LH and RH), left gauge panel q Travel PPC valve, travel lever, travel pedal q Cab base, cab round step, emergency refuge ladder Left deck (with battery) with power assist ladder Right deck (incl. counterweight handrail) Fuel tank Fuel piping Harness Travel alarm Grease piping, injector Hydraulic tank, return oil filter, oil level sensor Main valve, valve bracket Suction line Delivery line, in-line filter Oil cooler line Return line (excl. return filter) PPC drain line Boom line Arm line Bucket line Bottom dump line Travel line Straight travel line Swing line Solenoid valve Solenoid valve line Shuttle valve line PPC control line PPC main line PPC delivery line PPC bottom dump line Revolving frame Boom foot pin, boom cylinder bottom pin Air conditioner piping, heater piping, electronic controller, receiver dryer Cab rear floor, revolving frame front step, center maintenance floor, drum can cover Right rearview mirror Counterweight Swing machinery Swing motor Swivel joint Pump, drum can bracket, oil piping, grease reel line

14

PC2000-8 20001 and up 108 130 22 2,002 2,097 1,085 2,112 26 40 3 62 1,884 1,732 290 128 127 111 34 195 136 93 26 91 11 49 31 8 51 8 38 26 10 19,355 475 70 511 6 24,000 2,136 210 290 309

PC2000-8

01 Specification

SEN01612-01

Unit: kg Machine model Serial number Track frame assembly q Swing circle q Travel piping q Idler cushion oil pressure part q Travel final drive q Idler q Idler cushion cylinder part q Track roller q Carrier roller q Track Standard triple shoe (810 mm) Wide triple shoe (1,010 mm) q Center frame, grease bus q Crawler frame q Center cover (if equipped) q Travel motor cover q Travel motor guard q Track frame step q Track roller guard Single type Divided welding type (if equipped) Boom assembly (Excluding piping) Arm assembly (Excluding piping) Bucket assembly Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly Bottom dump cylinder assembly Front and rear bucket connecting pin Bottom dump cylinder rod pin Bottom dump cylinder bottom pin Boom top pin Boom foot pin Boom cylinder rod pin Boom cylinder bottom pin Arm top pin Arm cylinder rod pin Arm cylinder bottom pin Bucket cylinder rod pin Bucket cylinder bottom pin

PC2000-8

PC2000-8 20001 and up 68,051 3,633 139 332 6,514 2,462 946 5,586 762 17,020 21,040 13,562 14,331 646 515 937 81 1,231 2,328 13,200 6,850 14,315 2,330 × 2 1,100 × 2 1,496 × 2 309 × 2 41 × 2 41 × 2 26 × 2 99 × 2 110 × 2 61 × 2 87 × 2 106 × 2 28 × 2 28 × 2 51 × 2 68 × 2

15

SEN01612-01

01 Specification

Table of fuel, coolant and lubricants a

1

For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.

Unit: l Swing Final drive Engine oil PTO case machinery case pan case

Hydraulic system

Fuel tank

Cooling system

Grease

Specified capacity (l)

128

36

(Each of front and rear) 30

(Each of right and left) 85

2400

3400

180

200

Refill capacity (l)

120

36

(Each of front and rear) 30

(Each of right and left) 85

1300

—

—

200

16

PC2000-8

01 Specification

PC2000-8

SEN01612-01

17

SEN01612-01

PC2000-8 Hydraulic excavator Form No. SEN01612-01

© 2007 KOMATSU All Rights Reserved Printed in Japan 07-07 (01)

18

SEN01614-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

10 Structure, function and maintenance standard

1

Engine and cooling system Engine and cooling system ............................................................................................................................. 2 Radiator and oil cooler ......................................................................................................................... 2 PTO ...................................................................................................................................................... 4 PTO lubrication system ........................................................................................................................ 6

PC2000-8

1

SEN01614-00

10 Structure, function and maintenance standard

Engine and cooling system Radiator and oil cooler

2

1

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

SEN01614-00

Reservoir tank Aftercooler outlet tube Aftercooler inlet tube Radiator inlet hose Radiator Radiator bypass tube Fan pump Aftercooler Fan drive motor (radiator side) Fan guard Fan (radiator side) Engine return hose

Specifications 1. Fan (Radiator side) Outside diameter:1,450 mm No. of vanes: 6 Rotating speed: Variable (Standard. spec.: Max. 840 rpm) (+55°C spec: Max. 1,100 rpm) 2. Radiator Core type: Aluminum wave 4-row, 3.5/2P Fin pitch: 3.5 mm Releasing pressure for pressure valve: 0.05 MPa {0.5 kg/cm2} Releasing pressure for vacuum valve: –0.005 MPa {–0.05 kg/cm2} 3. Aftercooler Core type: Aluminum wave 4.0/2P Fin pitch: 4.0 mm

PC2000-8

3

SEN01614-00

10 Structure, function and maintenance standard

PTO

4

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8.

Drive gear (No. of teeth: 57) Coupling Main shaft Connection plate PTO case Driven gear (No. of teeth: 72, 60) Driven gear (No. of teeth: 56) Breather

A. B. C. D.

Center of No. 1 pump (HPV375 + 375) shaft Center of No. 2 pump (HPV375 + 375) shaft Center of fan pump (HPV95 + 95) shaft Center of input shaft

SEN01614-00

Specifications Lubricating oil : 36 l Reduction ratio : Input shaft: 1.0 No. 1 pump (HPV375 + 375): 60/57 = 1.053 No. 2 pump (HPV375 + 375): 72/57 = 1.263 Fan pump (HPV95 + 95): 56/57 = 0.982 Unit: mm No.

Check Item

Criteria

Remedy

Standard size

Repair limit

0.09 – 0.26

—

Backlash between driven gear and hydraulic pump

0.14 – 0.29

—

Backlash between driven gear and fan pump shaft

0.14 – 0.29

—

9

Backlash between main shaft and drive gear coupling

10 11

PC2000-8

Replace

Adjust

5

SEN01614-00

10 Structure, function and maintenance standard

PTO lubrication system

1. 2. 3. 4.

PTO case PTO oil reservoir Gear pump (SAL(1)020) PTO oil filter

Hydraulic circuit diagram

Outline The lubricating oil sucked by gear pump (3) from PTO oil reservoir (2) passes through PTO oil filter (4) to PTO case (1), is divided in PTO case to lubricate and cool the gears.

6

PC2000-8

SEN01614-00

PC2000-8 Hydraulic excavator Form No. SEN01614-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 09-06 (01)

8

SEN01615-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

10 Structure, function and maintenance standard

1

Power train Power train...................................................................................................................................................... 2 Power train ........................................................................................................................................... 2 Swing machinery.................................................................................................................................. 4 Swing circle .......................................................................................................................................... 6 Final drive............................................................................................................................................. 8 Sprocket ............................................................................................................................................. 10

PC2000-8

1

SEN01615-00

10 Structure, function and maintenance standard

Power train Power train

2

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

SEN01615-00

Idler Center swivel joint Swing motor (KMF230) 5-spool control valve (L1) 5-spool control valve (L2) 5-spool control valve (R1) 5-spool control valve (R2) Final drive, sprocket Travel motor (KMF340) Engine (SAA12V140E) PTO P1 pump (HPV375+375) P2 pump (HPV375+375) PF pump (HPV95+95+SAL (1) 020) Swing brake solenoid valve Swing machinery Swing circle

PC2000-8

3

SEN01615-00

10 Structure, function and maintenance standard

Swing machinery

4

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

SEN01615-00

Swing pinion (No. of teeth: 16) Cover Case Coupling No. 2 planetary gear (No. of teeth: 32) No. 2 ring gear (No. of teeth: 83) No. 1 ring gear (No. of teeth: 190) No. 1 planetary gear (No. of teeth: 77) Cover Dipstick Swing motor No. 1 sun gear (No. of teeth: 35) No. 1 planetary carrier No. 2 sun gear (No. of teeth: 17) No. 2 planetary carrier Drain plug

Specification Reduction ratio: (35 + 190)/35 × (17 + 83)/17 = 37.815 Unit: mm No.

Check Item

Criteria

Remedy

Standard clearance

Clearance limit

0.177 – 0.282

—

0.14 – 0.39

—

0.20 – 0.57

—

Backlash between No. 1 20 planetary carrier and No. 2 sun gear

0.41 – 0.72

—

21

Backlash between No. 2 sun gear and No. 2 planetary gear

0.15 – 0.38

—

22

Backlash between No. 2 planetary gear and ring gear

0.23 – 0.67

—

23

Backlash between No. 2 planetary gear and coupling

0.06 – 0.24

—

24

Backlash between coupling and swing pinion

0.09 – 0.25

—

25

Backlash between swing pinion and swing circle

0.18 – 1.58

—

26

Clearance between plate and coupling

0.50 – 1.00

—

27

Clearance between No. 1 sun gear and ring

2.22 – 4.68

—

28

Wear of swing pinion oil seal contact surface

Standard size

Repair limit

–0

—

Backlash between swing motor 17 shaft and No. 1 sun gear Backlash between No. 1 sun 18 gear and No. 1 planetary gear 19

Backlash between No. 1 planetary gear and ring gear

PC2000-8

180 –0.115

Replace

Repair hard chrome plating or replace

5

SEN01615-00

10 Structure, function and maintenance standard

Swing circle

1. 2. 3. 4. No. 5

Swing circle inner race (No. of teeth: 131) Swing circle outer race (Upper side) Roller Swing circle outer race (Lower side) Check Item Clearance of bearing in axial direction (when mounted on machine)

a. b.

Inner race soft zone “S” position Outer race soft zone “S” position

Unit: mm Remedy

Criteria Standard clearance

Clearance limit

0.5 – 1.5

2.0

Replace

Specifications Reduction ratio: 131/16 = 8.1875 Amount of grease: 80 l (G2-LI)

6

PC2000-8

SEN01615-00

10 Structure, function and maintenance standard

Final drive

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

8

No. 2 planetary carrier No. 2 ring gear (No. of teeth: 69) Housing Floating seal Sprocket Hub Housing No. 1 ring gear (No. of teeth: 80) No. 1 planetary gear (No. of teeth: 33) Drive gear (No. of teeth: 12) Travel motor case Travel motor No.1 sun gear (No. of teeth 13) Driven gear (No. of teeth: 67) Case No. 1 planetary carrier No. 2 planetary gear (No. of teeth: 26) No. 2 sun gear (No. of teeth: 15)

Specifications Reduction ratio: –67/12 × (13 + 80)/31 × (15 + 69)/15 = –223.677 Amount of final drive oil: 85 l (each) (TO30)

PC2000-8

10 Structure, function and maintenance standard

No. 19 20 21 22 23 24 25 26 27

Check Item Backlash between drive gear and driven gear Backlash between No. 1 sun gear and driven gear Backlash between No. 1 sun gear and No. 1 planetary gear Backlash between No. 1 sun gear and No. 2 planetary carrier Backlash between No. 2 planetary gear and No. 2 sun gear Backlash of housing Backlash between housing and No. 2 ring gear Clearance between housing and hub Standard shim thickness of cover mounting part

PC2000-8

SEN01615-00

Unit: mm Remedy

Criteria Standard clearance 0.21 – 0.73

Clearance limit —

0.085 – 0.207

—

0.25 – 0.46

—

0.089 – 0.293

—

0.24 – 0.62

—

0.067 – 0.258

—

0.276 – 0.808

—

10

— 2

Replace

Adjust

9

SEN01615-00

10 Structure, function and maintenance standard

Sprocket

No.

Check Item

1

Wear of tooth tip

2 3 4

Thickness of tooth root Width of tooth Wear of tooth shape

10

Criteria Standard size Repair limit 482.7 470.7 40 34 140 130 Repair limit: 6 (measure with sprocket tooth shape)

Unit: mm Remedy Build-up welding or replace

PC2000-8

10 Structure, function and maintenance standard

a

SEN01615-00

The above drawing is reduced to 41%. Enlarge it to 244% to return it to the full scale and make a copy on an OHP sheet.

PC2000-8

11

SEN01615-00

PC2000-8 Hydraulic excavator Form No. SEN01615-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 09-06 (01)

12

SEN01616-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

10 Structure, function and maintenance standard

1

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

PC2000-8

1

SEN01616-00

10 Structure, function and maintenance standard

Undercarriage and frame Track frame

1. 2. 3. 4. 5.

No.

11

12

2

1 1

6. 7. 8. 9. 10.

Idler Track frame Carrier roller Center frame Final drive

Check Item Top-to-bottom width of idler guide

Left-to-right width of idler guide

Track frame Idler support Track frame Idler support

Track roller Track shoe Idler cushion Roller guard Accumulator Unit: mm Remedy

Standard size

Criteria Tolerance

Repair limit

253

±2

233

250

± 0.5

215

Replace

420

±2

430

Rebuild

416

+1.0 +0

408

Replace

Rebuild

PC2000-8

10 Structure, function and maintenance standard

Specification Item Width of shoe Type Link pitch Number of shoes

PC2000-8

SEN01616-00

810 mm shoe

1,010 mm shoe

810 mm Double grouser 317.5 mm 49

1,010 mm Triple grouser 317.5 mm 49

3

SEN01616-00

Idler

4

10 Structure, function and maintenance standard

1

PC2000-8

10 Structure, function and maintenance standard

SEN01616-00

Unit: mm No.

Check item

Repair limit

1,072

—

1,030

1,018

—

—

Height of tread

21

27

Overall width

311

—

Width of tread

85

—

Outside diameter of protruding part

2

Outside diameter of tread surface

3

Thickness of tread

4 5 6

8

9

Remedy

Standard size

1

7

Criteria

Clearance between shaft and bushing

Interference between idler and bushing

Play of axial direction

PC2000-8

Standard size 165 Standard size 175

Tolerance Shaft

Hole

–0.060 –0.120

+0.37 –0.23

Tolerance

Rebuild or replace

Standard clearance

Clearance limit

0.29 – 0.49

— Interference limit —

Shaft

Hole

Standard interference

+0.134 +0.086

–0.123 –0.175

0.209 – 0.309

Standard clearance

Clearance limit

0.65 – 1.07

—

Replace bushing

5

SEN01616-00

10 Structure, function and maintenance standard

Carrier roller

1

Unit: mm No. 1

Check item

Criteria

Outside diameter of flange

Standard size

Repair limit

275

—

2

Outside diameter of tread

240

220

3

Width of tread

85

—

4

Thickness of tread

47

37

5

Width of flange

25

—

Standard size 6

Clearance between shaft and bushing

7

Standard clearance

Clearance limit —

–0.060 –0.120

+0.360 +0.220

0.280 – 0.480

Inside

125

–0.060 –0.150

+0.390 +0.145

0.205 – 0.540

Interference between Outside roller and bushing

Play of roller in axial direction

Hole

95

Inside 8

Tolerance

Rebuild or replace

Shaft

Outside

Standard size

6

Remedy

Tolerance

Standard Interference Replace bushing interference limit

Shaft

Hole

102.5

+0.087 +0.057

+0.035 +0.035

0.022 – 0.087

135

+0.180 +0.080

+0.053 –0.010

0.027 – 0.190

Standard clearance

Clearance limit

0.40 – 0.76

—

—

PC2000-8

10 Structure, function and maintenance standard

SEN01616-00

Track roller

1

Unit: mm No.

Check item

Criteria

Remedy

Standard size

Repair limit

400

—

Outside diameter of tread surface

340

328

3

Thickness of tread

92.5

86.5

4

Overall width

394

—

5

Width of tread

85

—

6

Width of flange

41.5

—

7

Clearance between shaft and bushing

1

Outside diameter of flange

2

8

9

Interference between roller and bushing

Play of axial direction

PC2000-8

Standard size 145 Standard size 155

Tolerance

Rebuild or replace

Shaft

Hole

Standard clearance

Clearance limit

–0.060 –0.120

+0.482 +0.361

0.421 – 0.602

—

0.042 – 0.130

—

Tolerance Shaft

Hole

+0.115 +0.067

+0.025 –0.015

Replace Standard Interference bushing interference limit

Standard clearance

Clearance limit

0.29 – 0.68

—

Replace

7

SEN01616-00

10 Structure, function and maintenance standard

Track shoe

a

8

1

P portion shows the link of bushing press fitting end.

PC2000-8

10 Structure, function and maintenance standard

SEN01616-00

Unit: mm No. 1

2

Check item

Criteria

Link pitch

Bushing outside diameter

Standard size

Repair limit

317.8

320.8 When turned

Standard size 116

Normal load

Heavy load

—

111

Standard size

Repair limit

22.5

17.5

Link height

195

182

Thickness of link metal (bushing press-fitting portion)

49.5

36.5

3

Thickness of bushing metal

4 5 6 7

274 Shoe bolt pitch

Reverse or replace

Adjust or replace Rebuild or replace

Replace

96

8

33

9

Inside width

148

10 Link

Overall width

83

11

Tread width

78

12 Protrusion of pin 14 Overall length of pin 16 Thickness of spacer

Press-fitting force

*19

10.75 353

15 Overall length of bushing 17

Repair or replace

2.9

13 Protrusion of regular bushing

18

Remedy

247.4

Adjust or replace

— Bushing

235 – 647 kN {24 – 66 ton}

Regular pin

470 – 1176 kN {48 – 120 ton}

Master pin

235 – 686 kN {24 – 70 ton}

—

*Dry type track link

PC2000-8

9

SEN01616-00

10 Structure, function and maintenance standard

Unit: mm No.

Check item a. Regular link

Criteria Tightening torque (Nm {kgm})

Additional tightening angle (deg.)

686.5 ± 68.6 {70 ± 7}

120 ± 10

20 Shoe bolt b. Master link

Interference between bushing 21 and link

22

23

*24

*25

Interference between regular pin and link Clearance between regular pin and bushing

Interference between master pin and link

Clearance between master pin and bushing

Remedy

Tightening torque (Nm {kgm})

Additional tightening angle (deg.)

Lower limit torque (Nm {kgm})

—

—

— Standard size

Tolerance

Standard interference

Shaft

Hole

113

+0.652 +0.522

+0.087 +0.087

0.435 – 0.652

70

+0.496 +0.396

–0.126 –0.200

0.522 – 0.696

Standard size 70 Standard size 70 Standard size 69.8

Tolerance Shaft

Hole

+0.496 +0.396

+1.236 +0.736

Tolerance Shaft

Hole

+0.216 +0.176

–0.126 –0.200

Tolerance Shaft

Hole

+0.050 –0.050

+1.436 +0.936

Retighten

Standard clearance 0.240 – 0.840

Adjust or replace

Standard interference 0.302 – 0.416 Standard clearance 0.886 – 1.486

*Dry type track link

10

PC2000-8

10 Structure, function and maintenance standard

SEN01616-00

Double shoe

Unit: mm No.

Check Item

1

Height of shoe

2

Height of grouser

3

Thickness

4 5

Criteria Standard size

Repair limit

108

87

23

2 8 50

Length at tip

6

PC2000-8

Remedy

Rebuild or replace

44 —

11

SEN01616-00

10 Structure, function and maintenance standard

Triple grouser shoe

Unit: mm No.

Check item

1

Height of shoe

2

Height of grouser

3

Thickness

4 5 6

12

Criteria Standard size

Repair limit

127

109

20

2 8 44

Length at tip

Remedy

Rebuild or replace

35 35

PC2000-8

10 Structure, function and maintenance standard

SEN01616-00

HIC system

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

1

Idler Yoke Plunger A Plunger B Cylinder Stop valve Relief-check valve Accumulator Check valve Stop valve Pressure reducing valve Check valve Right travel motor Center swivel joint Control valve (R.H.) Line oil filter Hydraulic pump (front)

Operation q The space between yoke (2) and plunger (3) is filled with grease. The space between plunger (4) and cylinder (5) is filled with hydraulic oil at the constant pressure of 17.7 MPa {180 kg/cm2}. This hydraulic oil is connected through reliefcheck valve (7) to accumulator (8). q If idler (1) is moved back by external force, plunger (4) is pressed and the pressure in cylinder (5) increases. If this pressure increases above the set pressure, relief-check valve (7) opens and the oil flows into accumulator (8). q The volume of the nitrogen gas in the accumulator is reduced by the quantity of the oil pushed by plunger (4). Since the gas pressure increases as a result, the cushion force increases according to movement of plunger (4).

PC2000-8

q

If idler (1) returns forward, the oil is returned by the gas pressure in the accumulator through the check valve of the relief-check valve to cylinder (5). The cushion force decreases and the system returns to the original condition according to the forward movement of the idler.

13

SEN01616-00

10 Structure, function and maintenance standard

Accumulator (HIC system)

1. 2. 3. 4.

Valve Body Bladder Check valve

Specification Capacity: 32, 500 cc Actuation pressure: 29.4 MPa {300 kg/cm2}

14

PC2000-8

SEN01616-00

PC2000-8 Hydraulic excavator Form No. SEN01616-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 09-06 (01)

16

SEN01618-02

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

10 Structure, function and maintenance standard

1

Hydraulic system, Part 1 Hydraulic piping drawing................................................................................................................................. 4 Hydraulic tank ................................................................................................................................................. 8 Oil cooler....................................................................................................................................................... 10 Line oil filter................................................................................................................................................... 12 Pilot oil filter................................................................................................................................................... 13 Return oil filter............................................................................................................................................... 14 Motor drain oil filter ....................................................................................................................................... 15 Pump drain filter............................................................................................................................................ 16 Accumulator .................................................................................................................................................. 17 Travel junction valve ..................................................................................................................................... 19 Solenoid valve............................................................................................................................................... 22 Hydraulic cylinder.......................................................................................................................................... 30 Greasing system ........................................................................................................................................... 34

PC2000-8

1

SEN01618-02

10 Structure, function and maintenance standard

Center swivel joint ......................................................................................................................................... 44

2

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01618-02

3

SEN01618-02

Hydraulic piping drawing

10 Structure, function and maintenance standard

1

Backhoe specification 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.

4

Bucket cylinder Arm cylinder Boom cylinder Line oil filter L1 control valve (5-spool) L2 control valve (5-spool) R1 control valve (5-spool) R2 control valve (5-spool) No. 1 pump (HPV375 + 375) No. 2 pump (HPV375 + 375) Fan pump (HPV95 + 95 + SAL (1) 020) Swing motor Center swivel joint Travel motor Oil cooler Pump drain filter Pilot oil filter 8-spool solenoid valve assembly 18A. Back pressure compensation valve selector solenoid valve 18B. Swing priority solenoid valve (right) 18C. 2-stage main relief solenoid valve 18D. Arm throttle solenoid valve (L1) 18E. Arm throttle solenoid valve (R2) 18F. Boom throttle solenoid valve (R1) 18G. Straight-travel solenoid valve 18H. Machine push-up solenoid valve Swing holding brake solenoid valve Bucket high cancel solenoid valve Motor drain oil filter Pilot selector valve (L1) Pilot selector valve (R1) Pilot selector valve (R2) PPC cut-off valve Travel shuttle valve Travel junction valve Variable back pressure compensation valve Hydraulic tank Return oil filter Fan motor (Oil cooler) Fan motor (Radiator) Grease pump HIC cylinder Lock valve PPC accumulator Boom damper valve Work equipment PPC valve (LH) Work equipment PPC valve (RH) Travel PPC valve Accumulator (for oil cooler pressure)

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01618-02

5

SEN01618-02

10 Structure, function and maintenance standard

Loading shovel specification 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.

44.

6

Bucket cylinder Arm cylinder Boom cylinder Line oil filter L1 control valve (5-spool) L2 control valve (5-spool) R1 control valve (5-spool) R2 control valve (5-spool) No. 1 pump (HPV375 + 375) No. 2 pump (HPV375 + 375) Fan pump (HPV95 + 95 + SAL (1) 020) Swing motor Center swivel joint Travel motor Oil cooler Pump drain filter Pilot oil filter 8-spool solenoid valve assembly 18A. Back pressure compensation valve selector solenoid valve 18B. Swing priority solenoid valve (right) 18C. 2-stage main relief solenoid valve 18D. Arm throttle solenoid valve (L1) 18E. Arm throttle solenoid valve (R2) 18F. Boom throttle solenoid valve (R1) 18G. Straight-travel solenoid valve 18H. Machine push-up solenoid valve Swing holding brake solenoid valve Bucket high cancel solenoid valve Motor drain oil filter Pilot selector valve (L1) Pilot selector valve (R1) Pilot selector valve (R2) PPC cut-off valve Travel shuttle valve Travel junction valve Variable back pressure compensation valve Hydraulic tank Return oil filter Fan motor (Oil cooler) Fan motor (Radiator) Grease pump HIC cylinder Lock valve PPC accumulator Boom damper valve Work equipment PPC valve (LH) Work equipment PPC valve (RH) Travel PPC valve Accumulator (for oil cooler pressure) Bottom dump cylinder 4-spool solenoid valve assembly 43A. Bottom dump OPEN (L1) 43B. Bottom dump OPEN (L2) 43C. Bottom dump CLOSE (L1) 43D. Bottom dump CLOSE (L2) Bottom dump priority solenoid valve PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01618-02

7

SEN01618-02

Hydraulic tank

8

10 Structure, function and maintenance standard

1

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8. 9.

SEN01618-02

Suction strainer proximity switch Breather Hydraulic tank Suction strainer Oil filler cap Strainer Hydraulic oil level sensor Hydraulic oil temperature sensor Hydraulic oil low temperature sensor

Specifications Tank capacity: 1,910 l Quantity of oil in tank: 1,215 l Breather Relief cracking pressure: 0.07 ± 0.01 MPa {0.7 ± 0.1 kg/cm2} Suction cracking pressure: Max. 0.002 MPa {0.02 kg/cm2} Adjustment method for suction strainer proximity switch

PC2000-8

9

SEN01618-02

Oil cooler

10

10 Structure, function and maintenance standard

1

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7.

SEN01618-02

Fuel cooler Oil cooler Fan pump Drain filter Hydraulic motor for fan drive (oil cooler side) Fan guard Fan (oil cooler side)

Specifications 1. Fan (Oil cooler side) Outside diameter:1,450 mm No. of vanes: 6 Rotating speed: Variable (Standard. spec.: Max. 760 rpm) (+55°C spec: Max. 1,100 rpm) 2. Oil cooler Core type: PF 4-6, 3.0P Fin pitch: 3.0 mm 3.

Fuel cooler Core type: Fin pitch:

PC2000-8

CF 40-1, 4.5/2P 4.5 mm

11

SEN01618-02

Line oil filter

1. 2. 3.

Element Case Cover

A: B:

From hydraulic pump To control valve

12

10 Structure, function and maintenance standard

1

Outline There are 4 line oil filters installed to the discharge side of the hydraulic pump. They protect the circuit and equipment by removing all dirt and dust from the oil.

PC2000-8

10 Structure, function and maintenance standard

Pilot oil filter

1. 2. 3.

SEN01618-02

1

Bracket Cartridge Safety valve

PC2000-8

13

SEN01618-02

Return oil filter

1. 2. 3. 4. 5. 6.

Cover Spring Bypass valve Bypass valve spring Element Housing

A: B:

From control valve To hydraulic tank

14

10 Structure, function and maintenance standard

1

Outline q There are 3 return oil filters installed to the side face of the hydraulic tank. They remove the dirt and dust in the return oil. q Bypass valve set pressure: 0.15 ± 0.03 MPa {1.5 ± 0.3 kg/cm2}

PC2000-8

10 Structure, function and maintenance standard

SEN01618-02

Motor drain oil filter

1. 2. 3. 4.

Bracket Bypass valve Cartridge Element

PC2000-8

1

Outline This filter is installed between the swing motor, travel motor, and hydraulic tank. It acts to remove the dirt and foreign matter in the oil coming from the drain port of each motor. q Bypass valve set pressure: 0.1 MPa {1.0 kg/cm2} q

15

SEN01618-02

Pump drain filter

1. 2. 3. 4.

16

Head Bypass valve Cartridge Element

10 Structure, function and maintenance standard

1

Outline The pump drain filter is installed between the hydraulic pump, fan pump and hydraulic tank. It removes dirt and foreign matter from the oil flowing in from each pump drain port. q Bypass valve set pressure: 147 ± 29 kPa {1.5 ± 0.3 kg/cm2} q

PC2000-8

10 Structure, function and maintenance standard

SEN01618-02

Accumulator

1

PPC accumulator

1. 2. 3. 4. 5. 6. 7.

Cap Nut Cap Body Bladder Port Nut

PC2000-8

Specifications Gas capacity: 5,100 cc Gas pressure: 1.18 MPa {12 kg/cm2}

17

SEN01618-02

10 Structure, function and maintenance standard

Accumulator (for oil cooler pressure)

1. 2. 3. 4. 5. 6. 7.

Accumulator Oil cooler Hydraulic tank Control valve Cooler check valve Variable back pressure valve Return filter

System diagram

Outline The accumulator is installed in the oil cooler hydraulic circuit to cut the peak hydraulic pressure of the oil cooler and secure the durability and reliability. 1. 2. 3. 4. 5. 6. 7.

Body Bladder Poppet Film Holder Port Plug

Specifications Volume of gas: 500 cm3 Charge pressure: 0.098 MPa {1 kg/cm2}

18

PC2000-8

10 Structure, function and maintenance standard

SEN01618-02

Travel junction valve

1. 2. 3. 4.

Valve body Spool Retainer Spring

1

Specifications Spool change pressure: 0.2 ± 0.05 MPa {2 ± 0.5 kg/cm2} Outline The travel junction valve is used for the travel circuit. q When the machine travels straight, the travel junction valve connects the travel circuits to prevent travel deviation caused by the difference between the oil flow rates in the right and left motors. q

PC2000-8

19

SEN01618-02

10 Structure, function and maintenance standard

System diagram

1. 2. 3. 4. 5. 6. 7.

20

Travel PPC valve Control valve Shuttle valve Travel junction valve Swivel joint RH travel motor LH travel motor

a. b. c. d.

LH travel reverse LH travel forward RH travel reverse RH travel forward

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01618-02

21

SEN01618-02

Solenoid valve 1.

22

10 Structure, function and maintenance standard

1

For back pressure compensation, 2-stage main relief, arm throttle, swing priority, straight travel, and machine push-up

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Back pressure compensation valve selector solenoid valve Swing priority solenoid valve 2-stage main relief solenoid valve Arm throttle solenoid valve (L1) Arm throttle solenoid valve (R2) Boom throttle solenoid valve (R1) Straight-travel solenoid valve Machine push-up solenoid valve Connector Movable core Coil Spool Block Spring

A1: To back pressure compensation valve A2: To PPC cutoff valve (CV2) A3: To main relief valve A4: To pilot valve (PV1) A5: To pilot valve (PV3) A6: To pilot valve (PV2) A7: To PPC cutoff valves (CV1), (CV2) A8: To main valves (L1), (R1) P1: From pump T: To hydraulic tank ACC: Plug

SEN01618-02

Operation When solenoid is de-energized q Since the signal current does not flow from the controller to solenoid, coil (11) is de-energized. For this reason, spool (12) is pushed to the left by spring (14). q By this operation, the pass from port (P) to port (A) is closed and the pressurized oil from the main pump does not flow into the actuator. q At this time, the oil from the actuator is drained through ports (A) and (T) into the tank.

When solenoid is energized The signal current flows from the controller to solenoid, and coil (11) is energized. Accordingly, spool (12) is pressed against to the right side. q By this operation, the pressurized oil from the main pump flows through port (P) and spool (4) to port (A), then flows into the actuator. q At the same time, port (T) closes and stops the oil from flowing to the tank. q

PC2000-8

23

SEN01618-02

2.

24

10 Structure, function and maintenance standard

For swing holding brake and lock valve

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Swing holding brake solenoid valve Connector Coil Movable core Body Plug Spring Spool Body Plug Spring Spool

T: A:

To tank To front and rear swing motors (for swing holding brake) To PPC valve (for safety lock) From control pump

P:

SEN01618-02

Operation When solenoid is de-energized q While the signal current is not flowing in from the controller, coil (3) is de-energized. Accordingly, spool (12) is pushed up by spring (11) and spool (8) is pushed to the left by spring (7). q Since port (P) is closed at this time, the oil from the control pump does not flow to the actuator. q The oil from the actuator flows through ports (A) and (T) to the tank. When solenoid is energized q If the signal current flows in from the controller and coil (3) is energized, spool (12) is pushed down. q Accordingly, the oil from the control pump flows through port (P) to port (A) and spool (8) is pushed to the right. q If spool (8) is pushed to the right, the oil from the control pump flows through ports (P) and (A) to the actuator. q Since port (T) is closed at this time, the oil does not flow to the tank.

PC2000-8

25

SEN01618-02

10 Structure, function and maintenance standard

3.

For bucket high cancel, for bottom dump priority (If equipped)

1. 2. 3. 4. 5. 6. 7.

Connector Movable core Solenoid Spool Body Spring Plug

Operation When solenoid is de-energized q While the signal current is not flowing in from the controller, solenoid (3) is de-energized and spool (4) is set in the neutral position by spring (6). q At this time, port (P) and port (A) are connected and the oil from the PPC valve flows to the control valve.

26

When solenoid is energized q If the signal current flows in from the controller, solenoid (3) is energized and movable core (2) is pushed to the right. Accordingly, spool (4) is pushed to the right. q If spool (4) is pushed to the right, port (P) is closed and the oil from the PPC valve does not flow to the control valve. q Since port (A) and port (T) are connected at this time, the oil from the control valve flows to the tank.

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01618-02

27

SEN01618-02

4.

28

10 Structure, function and maintenance standard

For bottom dump spool drive (Loading shovel specification)

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Bottom dump solenoid valve open (L1) Bottom dump solenoid valve open (L2) Bottom dump solenoid valve close (L1) Bottom dump solenoid valve close (L2) Connector Movable core Coil Spool Block Spring

A1: To main valve (L1) A2: To main valve (L2) A3: To main valve (L1) A4: To main valve (L2) P1: From pump T: To hydraulic tank ACC: Plug

SEN01618-02

Operation When solenoid is de-energized q Since the signal current does not flow from the controller to solenoid, coil (11) is de-energized. For this reason, spool (12) is pushed to the left by spring (14). q By this operation, the pass from port (P) to port (A) is closed and the pressurized oil from the main pump does not flow into the actuator. q At this time, the oil from the actuator is drained through ports (A) and (T) into the tank.

When solenoid is energized The signal current flows from the controller to solenoid, and coil (11) is energized. Accordingly, spool (12) is pressed against to the right side. q By this operation, the pressurized oil from the main pump flows through port (P) and spool (4) to port (A), then flows into the actuator. q At the same time, port (T) closes and stops the oil from flowing to the tank. q

PC2000-8

29

SEN01618-02

Hydraulic cylinder

10 Structure, function and maintenance standard

1

Backhoe specification Boom cylinder

Arm cylinder

Bucket cylinder

30

PC2000-8

10 Structure, function and maintenance standard

SEN01618-02

Unit: mm No.

Check item

Criteria Name of cylinder

1

2

3

Clearance between piston rod and bushing

Clearance between piston rod support shaft and bushing

Clearance between cylinder bottom support shaft and bushing

PC2000-8

Standard size

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

+0.257 +0.039

0.089 – 0.379

—

Boom

200

–0.050 –0.122

Arm

160

–0.043 –0.105

+0.228 +0.046

0.089 – 0.334

—

Bucket

140

–0.043 –0.106

+0.035 +0.005

0.048 – 0.141

—

Boom

180

–0.043 –0.106

+0.025 +0.025

0.043 – 0.131

1.0

Arm

140

–0.043 –0.106

+0.025 +0.025

0.043 – 0.131

1.0

Bucket

140

–0.043 –0.106

+0.245 +0.145

0.188 – 0.351

1.0

Boom

180

–0.043 –0.106

+0.025 +0.025

0.043 – 0.131

1.0

Arm

140

–0.043 –0.106

+0.025 +0.025

0.043 – 0.131

1.0

Bucket

120

–0.036 –0.090

+0.457 +0.370

0.406 – 0.547

1.0

Replace bushing

Replace pin, bushing

31

SEN01618-02

10 Structure, function and maintenance standard

Loading shovel specification Boom cylinder

Arm cylinder

Bucket cylinder

32

PC2000-8

10 Structure, function and maintenance standard

SEN01618-02

Bottom dump cylinder

Unit: mm No.

1

2

3

Check item

Clearance between piston rod and bushing

Clearance between piston rod support shaft and bushing

Clearance between cylinder bottom support shaft and bushing

PC2000-8

Criteria Tolerance

Remedy

Name of cylinder

Standard size

Shaft

Hole

Standard clearance

Clearance limit

Boom

180

—

—

—

—

Arm

150

—

—

—

—

Bucket

160

—

—

—

—

Bottom dump

100

—

—

—

—

Boom

150

—

—

—

—

Arm

120

—

—

—

—

Bucket

120.6

—

—

—

—

Bottom dump

100

—

—

—

—

Boom

180

—

—

—

—

Arm

120

—

—

—

—

Bucket

140.6

—

—

—

—

Bottom dump

100.5

—

—

—

—

Replace bushing

Replace pin, bushing

33

SEN01618-02

Greasing system

34

10 Structure, function and maintenance standard

1

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01618-02

35

SEN01618-02

10 Structure, function and maintenance standard

Injector distribution valve line Backhoe specification Grease point

Delivery

1

Front link + Bucket pin

1.30 cc/rev × 2

2

Front link + wrist pin

1.30 cc/rev × 4

3

Arm B boss

1.30 cc/rev × 4

4

Arm A boss + Bucket pin

1.30 cc/rev × 4

5

Arm C boss + Bucket top pin

6

Bucket cylinder bottom pin

0.97 cc/rev × 2

7

Arm cylinder head pin

1.30 cc/rev × 2

8

Boom foot pin

0.97 cc/rev × 4

9

Boom cylinder head pin

1.30 cc/rev × 2

Arm

1.30 cc/rev × 2

Boom

0.72 cc/rev × 2

10

Arm cylinder bottom pin

1.30 cc/rev × 2

11

Boom cylinder bottom pin

0.13 cc/rev × 2

12

Swing circle

1.30 cc/rev × 10

36

PC2000-8

10 Structure, function and maintenance standard

SEN01618-02

Outline q Auto grease function If the grease mode selector switch is in the auto grease position, the controller operates the grease pump at constant time intervals and the icon of the grease pump operating at the set pressure is displayed on the monitor. q Manual grease function If the grease mode selector switch is in the manual grease position, the controller operates the grease pump continuously. q Grease level warning function If the grease level lowers, the low-level switch signal is inputted to the controller and warning is displayed on the monitor and the grease warning lamp blinks. q Auto grease intervals

PC2000-8

Auto grease interval

Time from stop of pump to start

SMR 100 hours or less

5 minutes

Above SMR 100 hours

10 minutes

37

SEN01618-02

10 Structure, function and maintenance standard

Components Grease pump

1. 2. 3. 4. 5. 6. 7.

Vent valve Pump Follower plate Tube Cover Grease tank Pressure gauge

A. B. C.

Oil inlet port Grease chamber Grease feed port (if equipped: with refill function) Grease drain port (if equipped: with refill function) Pump drain port

D. T.

Outline q In the auto grease system, this hydraulic pump supplies the grease from grease chamber (B). q This pump is double-action type, that is, it discharges grease in both upward and downward strokes. q This pump is operated automatically by the oil pressure switch and controller. a When the grease is supplied, if pressure gauge (7) indicates 4.9 – 19.6 MPa {50 – 200 kg/cm2}, the operation is normal. a If the pressure gauge indicates below 4.9 MPa {50 kg/cm2}, grease tank is empty. a If the grease tank or vent valve is broken, the caution lamp lights up and the contents of the trouble are displayed on the machine monitor. Grease delivery (Max.): 28 l/min Set pressure (reducing valve): 2.3 ± 1.0 MPa {23.5 ± 1 kg/cm2} Grease tank capacity: Approx. 180 kg

38

PC2000-8

10 Structure, function and maintenance standard

Auto grease indicator q If the grease mode selector switch is set in “AUTO”, “AUTO” indicator (1) is displayed on the normal screen of the monitor.

SEN01618-02

Grease gun q Use the grease gun to grease the parts which are not greased by the auto grease system (trunnion at the front of the engine and tracks) and the local parts which are greased by the auto grease system.

Manual grease indicator q If the grease mode selector switch is set in “MANUAL”, “MANUAL” indicator (2) is displayed on the normal screen of the monitor.

PC2000-8

39

SEN01618-02

10 Structure, function and maintenance standard

Hose reel q The hose reel is used to store the grease gun hose. It is the auto winder type.

40

PC2000-8

10 Structure, function and maintenance standard

SEN01618-02

Injector distribution valve

1. 2. 3. 4. 5. 6.

Adjustment screw Injector body Injector piston Piston spring Slide valve Manifold

Delivery: 0.13 – 1.31 cc/rev

PC2000-8

41

SEN01618-02

Operation q Stage 1 The grease pressurized by the pump pushes up slide valve (5) and connects manifold (6) and passage (P).

42

10 Structure, function and maintenance standard

q

Stage 2 The grease flowing through passage (P) pushes down injection piston (3) and discharges the grease in discharge chamber (D) to oil hole (h).

PC2000-8

10 Structure, function and maintenance standard

q

Stage 3 Injector piston (3) lowers to slide valve (5) and then pushes it down to disconnect manifold (6) and passage (P).

PC2000-8

SEN01618-02

q

Stage 4 If slide valve (5) is pushed down, passage (P) is connected to discharge chamber (D) by valve port (q) and the grease in measuring chamber (M) is sent to discharge chamber (D) for the next supply. The operation cycle is completed at this point.

43

SEN01618-02

10 Structure, function and maintenance standard

Center swivel joint

1. 2. 3. 4. 5.

1

Cover Body Slipper seal Oil seal Shaft

A1 : From R.H. travel control valve port A5 A2 : To R.H. travel motor port PA B1 : From R.H. travel control valve port B5

B2 : To R.H. travel motor port PB C1 : From L.H. travel control valve port A5 C2 : To L.H. travel motor port PB D1 : From L.H. travel control valve port B5 D2 : To L.H. travel motor port PA P1 : To hydraulic tank P2 : From L.H. and R.H. travel motor port T T1 : To hydraulic tank T2 : From L.H. and R.H. travel motor port T Unit: mm

No. 6

44

Check item Clearance between rotor and shaft

Criteria

Remedy

Standard size

Standard clearance

Clearance limit

110

0.056 – 0.105

0.111

Replace

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01618-02

45

SEN01618-02

PC2000-8 Hydraulic excavator Form No. SEN01618-02

© 2007 KOMATSU All Rights Reserved Printed in Japan 07-07 (01)

46

SEN01619-01

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

10 Structure, function and maintenance standard

1

Hydraulic system, Part 2 Hydraulic system, Part 2 ................................................................................................................................. 2 Control valve ........................................................................................................................................ 2 Electronic OLSS system .................................................................................................................... 30 Swing motor ....................................................................................................................................... 34 Cooling fan motor (For radiator and oil cooler) .................................................................................. 42 Cooling fan pump ............................................................................................................................... 48

PC2000-8

1

SEN01619-01

10 Structure, function and maintenance standard

Hydraulic system, Part 2

1

Control valve

1

L.H. 10-spool valve

2

PC2000-8

10 Structure, function and maintenance standard

A1 : A2 : A3 : A4 : A5 : B1 : B2 : B3 : B4 : B5 : CN-P27: CN-P28: NCA1 : NCA2 : NCB1 : NCB2 : P1 : P2 : PA11 : PA21 : PA31 : PA41 : PA51 : PB11 : PB21 : PB31 : PB41 : PB51 : PA12 : PA22 : PA32 : PA42 : PA52 : PB12 : PB22 : PB32 : PB42 : PB52 : PC1 : PP1 : PP2 : PS1 : T : TC1 : TS : 1. 2.

SEN01619-01

To arm cylinder head To boom cylinder head To bucket cylinder head – To L.H. travel motor [Port (PB)] To arm cylinder bottom To boom cylinder bottom To bucket cylinder bottom – To L.H. travel motor [Port (PA)] To controller To controller Pressure pick-up port (Jet sensor upstream pressure) Pressure pick-up port (Jet sensor upstream pressure) Pressure pick-up port (Jet sensor downstream pressure) Pressure pick-up port (Jet sensor downstream pressure) From P1 rear pump From P2 rear pump From PPC valve (Arm IN) From PPC valve (Boom RAISE) From PPC valve (Bucket CURL) – From PPC valve (L.H. travel reverse) From PPC valve (Arm OUT) From PPC valve (Boom LOWER) From PPC valve (Bucket DUMP) – From PPC valve (L.H. travel forward) From PPC valve (Arm IN) From PPC valve (Boom RAISE) From PPC valve (Bucket CURL) – From PPC valve (L.H. travel reverse) From PPC valve (Arm OUT) Drain From PPC valve (Bucket DUMP) – From PPC valve (L.H. travel forward) From boom priority selector valve From solenoid valve (Main relief valve) From solenoid valve (Main relief valve) From solenoid valve (Machine push-up) To tank (Main drain) Drain To swing motor [Port (S)]

L1 valve L2 valve

PC2000-8

3

SEN01619-01

10 Structure, function and maintenance standard

Sectional view

4

PC2000-8

10 Structure, function and maintenance standard

SEN01619-01

L1 valve

PC2000-8

5

SEN01619-01

10 Structure, function and maintenance standard

Sectional view

6

PC2000-8

10 Structure, function and maintenance standard

A11 : A21: A31: A41: A51: B11 : B21: B31: B41: B51: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

SEN01619-01

To arm cylinder head To boom cylinder head To bucket cylinder head – To L.H. travel motor [Port (PB)] To arm cylinder bottom To boom cylinder bottom To bucket cylinder bottom – To L.H. travel motor [Port (PA)]

Main relief valve Spool (Arm Lo) Spool (Boom Lo) Spool (Bucket Hi) – Spool (L.H. travel Hi) Valve body Jet sensor and orifice Jet sensor and relief valve Jet sensor and differential pressure sensor Orifice check valve Check valve Piston Check valve Check valve Unit: mm

No.

Check item

Criteria Standard size

Remedy Repair limit

Free length × outside diameter

Installed length

Installed load

Free length

Installed load

69.9 × 57

63

431 N {44 kg}

—

345 N {35.2 kg}

17 Spool return spring

74.5 × 38.1

71.5

541 N {55.2 kg}

—

433 N {44.2 kg}

18 Check valve spring

65.28 × 14

46

18.8 N {1.92 kg}

—

15.1 N {1.54 kg}

19 Check valve spring

78.2 × 26.6

52

18.8 N {1.92 kg}

—

15.1 N {1.54 kg}

20 Check valve spring

20.8 × 12.2

13.5

12.7 N {1.3 kg}

—

10.2 N {1.04 kg}

16 Spool return spring

PC2000-8

If damaged or deformed, replace spring

7

SEN01619-01

8

10 Structure, function and maintenance standard

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8.

SEN01619-01

Arm Lo valve Boom Lo valve Bucket Hi valve – L.H. travel Hi valve Safety-suction valve 2-stage safety-suction valve Suction valve

PC2000-8

9

SEN01619-01

10 Structure, function and maintenance standard

L2 valve

10

PC2000-8

10 Structure, function and maintenance standard

SEN01619-01

Sectional view

PC2000-8

11

SEN01619-01

10 Structure, function and maintenance standard

A12 : To arm cylinder head A22 : To boom cylinder head A32 : To bucket cylinder head A42 : – A52 : To L.H. travel motor [Port (PB)] B12 : To arm cylinder bottom B22 : To boom cylinder bottom B32 : To bucket cylinder bottom B42 : – B52 : To L.H. travel motor [Port (PA)] 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Main relief valve Spool (Arm Hi) Spool (Boom Hi) Spool (Bucket Lo) Spool (–) Spool (L.H. travel Lo) Valve body Jet sensor and relief valve Jet sensor and orifice Jet sensor and differential pressure sensor Check valve Check valve Unit: mm

No.

Check item

Criteria Standard size

Remedy Repair limit

Free length × outside diameter

Installed length

Installed load

Free length

Installed load

69.9 × 57

63

431 N {44 kg}

—

345 N {35.2 kg}

14 Spool return spring

74.5 × 38.1

71.5

541 N {55.2 kg}

—

433 N {44.2 kg}

15 Check valve spring

78.2 × 26.6

52

18.8 N {1.92 kg}

—

15.1 N {1.54 kg}

16 Check valve spring

20.8 × 12.2

13.5

12.7 N {1.3 kg}

—

10.2 N {1.04 kg}

13 Spool return spring

12

If damaged or deformed, replace spring

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01619-01

13

SEN01619-01

14

10 Structure, function and maintenance standard

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7.

SEN01619-01

Arm Hi valve Boom Hi valve Bucket Lo valve – L.H. travel Lo valve Safety-suction valve Suction valve

PC2000-8

15

SEN01619-01

10 Structure, function and maintenance standard

R.H. 10-spool valve

16

PC2000-8

10 Structure, function and maintenance standard

SEN01619-01

A1 : To arm cylinder head A2 : To boom cylinder head A3 : To bucket cylinder head A4 : To swing motor [Port (MB)] A5 : To R.H. travel motor [Port (PA)] B1 : To arm cylinder bottom B2 : To boom cylinder bottom B3 : To bucket cylinder bottom B4 : To swing motor [Port (MA)] B5 : To R.H. travel motor [Port (PB)] CN-P36: To controller CN-P37: To controller NCA1 : Pressure pick-up port (Jet sensor upstream pressure) NCA2 : Pressure pick-up port (Jet sensor upstream pressure) NCB1 : Pressure pick-up port (Jet sensor downstream pressure) NCB2 : Pressure pick-up port (Jet sensor downstream pressure) P1 : From P1 front pump P2 : From P2 front pump PA11 : From PPC valve (Arm IN) PA21 : From PPC valve (Boom RAISE) PA31 : From PPC valve (Bucket CURL) PA41 : From PPC valve (Right swing) PA51 : From PPC valve (R.H. travel reverse) PB11 : From PPC valve (Arm OUT) PB21 : Drain PB31 : From PPC valve (Bucket DUMP) PB41 : From PPC valve (Left swing) PB51 : From PPC valve (R.H. travel forward) PA12 : From PPC valve (Arm IN) PA22 : From PPC valve (Boom RAISE) PA32 : From PPC valve (Bucket CURL) PA42 : – PA52 : From PPC valve (R.H. travel reverse) PB12 : From PPC valve (Arm OUT) PB22 : From PPC valve (Boom LOWER) PB32 : From PPC valve (Bucket DUMP) PB42 : – PB52 : From PPC valve (R.H. travel forward) PC1 : From swing priority selector valve PC2 : From boom priority selector valve PP1 : From solenoid valve (Main relief valve) PP2 : From solenoid valve (Main relief valve) PS2 : From solenoid valve (Machine push-up) T : To tank (Main drain) TC1 : Drain TC2 : Drain TS : To swing motor [Port (S)] 1. 2.

R1 valve R2 valve

PC2000-8

17

SEN01619-01

10 Structure, function and maintenance standard

Sectional view

18

PC2000-8

10 Structure, function and maintenance standard

SEN01619-01

R1 valve

PC2000-8

19

SEN01619-01

10 Structure, function and maintenance standard

Sectional view

20

PC2000-8

10 Structure, function and maintenance standard

A11 : A21: A31: A41: A51: B11 : B21: B31: B41: B51: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

SEN01619-01

To arm cylinder head To boom cylinder head To bucket cylinder head To swing motor [Port (MB)] To R.H. travel motor [Port (PA)] To arm cylinder bottom To boom cylinder bottom To bucket cylinder bottom To swing motor [Port (MA)] To R.H. travel motor [Port (PB)]

Main relief valve Spool (Arm Lo) Spool (Boom Hi) Spool (Bucket Lo) Spool (Swing) Spool (R.H. travel Hi) Valve body Jet sensor and orifice Jet sensor and relief valve Jet sensor and differential pressure sensor Orifice check valve Check valve Piston Check valve Check valve Unit: mm

No.

Check item

Criteria Standard size

Remedy Repair limit

Free length × outside diameter

Installed length

Installed load

Free length

Installed load

69.9 × 57

63

431 N {44 kg}

—

345 N {35.2 kg}

17 Spool return spring

74.5 × 38.1

71.5

541 N {55.2 kg}

—

433 N {44.2 kg}

18 Check valve spring

65.28 × 14

46

18.8 N {1.92 kg}

—

15.1 N {1.54 kg}

19 Check valve spring

78.2 × 26.6

52

18.8 N {1.92 kg}

—

15.1 N {1.54 kg}

20 Check valve spring

20.8 × 12.2

13.5

12.7 N {1.3 kg}

—

10.2 N {1.04 kg}

16 Spool return spring

PC2000-8

If damaged or deformed, replace spring

21

SEN01619-01

22

10 Structure, function and maintenance standard

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7.

SEN01619-01

Arm Lo valve Boom Hi valve Bucket Lo valve Swing valve R.H. travel Hi valve Safety-suction valve Suction valve

PC2000-8

23

SEN01619-01

10 Structure, function and maintenance standard

R2 valve

24

PC2000-8

10 Structure, function and maintenance standard

SEN01619-01

Sectional view

PC2000-8

25

SEN01619-01

10 Structure, function and maintenance standard

A12 : To arm cylinder head A22 : To boom cylinder head A32 : To bucket cylinder head A42 : To swing motor [Port (MB)] A52 : To R.H. travel motor [Port (PA)] B12 : To arm cylinder bottom B22 : To boom cylinder bottom B32 : To bucket cylinder bottom B42 : To swing motor [Port (MA)] B52 : To R.H. travel motor [Port (PB)] 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Main relief valve Spool (Arm Hi) Spool (Boom Lo) Spool (Bucket Hi) – Spool (R.H. travel Lo) Valve body Jet sensor and relief valve Jet sensor and orifice Jet sensor and differential pressure sensor Orifice check valve Check valve Piston Check valve Check valve Unit: mm

No.

Check item

Criteria Standard size

Remedy Repair limit

Free length × outside diameter

Installed length

Installed load

Free length

Installed load

69.9 × 57

63

431 N {44 kg}

—

345 N {35.2 kg}

17 Spool return spring

74.5 × 38.1

71.5

541 N {55.2 kg}

—

433 N {44.2 kg}

18 Check valve spring

65.28 × 14

46

18.8 N {1.92 kg}

—

15.1 N {1.54 kg}

19 Check valve spring

78.2 × 26.6

52

18.8 N {1.92 kg}

—

15.1 N {1.54 kg}

20 Check valve spring

20.8 × 12.2

13.5

12.7 N {1.3 kg}

—

10.2 N {1.04 kg}

16 Spool return spring

26

If damaged or deformed, replace spring

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01619-01

27

SEN01619-01

28

10 Structure, function and maintenance standard

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8.

SEN01619-01

Arm Hi valve Boom Lo valve Bucket Hi valve – R.H. travel Lo valve Safety-suction valve 2-stage safety-suction valve Suction valve

PC2000-8

29

SEN01619-01

Electronic OLSS system

30

10 Structure, function and maintenance standard

1

PC2000-8

10 Structure, function and maintenance standard

Function q The electronic OLSS system converts signals from the jet sensor to electronic signals by use of the differential pressure sensor to enable EPC valve to directly control the swash plate of the variable displacement pump. q Conventional OLSS used to control the flow rate by conducting the signal pressures from TVC valve, CO valve and NC valve to the pump servo piston. q The electronic OLSS system controls TVC, CO and NC digitally. And sensing the lever signals, jet sensor signals, pump discharge pressure and engine speed, this system controls the flow rate to ensure more efficient use of the engine horsepower than available from the hydraulic control. q As the spool stroke of the control valve increases, carry-over flow rate (QC) decreases, decreasing the differential pressure (PT – PD) output from the jet sensor.

SEN01619-01

q q

q q

q

q

Voltage is output as output differential pressure (PT – PD) is conducted to the differential pressure sensor. The figure shows the relation between the in pu t an d ou tpu t sign als, ind icatin g th at decrease in output differential pressure (PT – PD) results in increasing output voltage (E).

PC2000-8

Output voltage (E) from the differential pressure sensor is conducted to the controller. Current (IEPC) being conducted from the controller to EPC valve increases output voltage (PI) of EPC. As the result, pump delivery (Q) increases. The figure shows the relationship between the control valve spool stroke and pump delivery (Q). Pump delivery (Q) increases roughly in proportion to increase in the control valve spool stroke.

Features q Favorable fuel consumption results in the fine control mode because the pump delivers the only necessary flow rate, the reducing power loss. q Favorable fuel consumption also results when the lever is set to the neutral position since the flow rate is kept at minimum and, thus, the power loss is reduced. q Startability of the pump increases significantly since the pump driving torque at startup is small. q Small spool stroke of the control valve enhances the fine steering control since it decreases the pump delivery. q This system saves power loss since it allows setting a different speed on individual work equipment basis. q Adding the digitized modulation enhances the operability.

31

SEN01619-01

10 Structure, function and maintenance standard

Arm and boom throttle valves

Function q When the sections with a high operating pressure and a low operating pressure are operated si mu ltaneou sl y in the compound operation, the throttle valve brings balance to the flow rate to respective work equipment by preventing the operating pressure from flowing more to the low-pressure side.

32

Operating condition table Operating condition (*: throttling side)

No.

Section

1

Arm throttle valve (L1 valve)

Arm Arm Arm Arm

2

Arm throttle valve (R2 valve)

Arm IN* + Boom RAISE Arm OUT* + Boom Raise

3

Boom throttle valve (R1 valve)

IN* + Boom RAISE IN* + Bucket DUMP IN* + Bucket CURL OUT* + Boom RAISE

Swing + Boom RAISE*

PC2000-8

10 Structure, function and maintenance standard

SEN01619-01

Operation q As the output pressure to respective PPC valves is generated according to a combination listed in the operating condition table, the solenoid valve outputs the pilot pressure responding to the signal from the controller and, as the result, the selector valve is switched. When the signal from the controller is present q The selector valve is switched by the pilot pressure from the solenoid valve and the pump pressure is introduced at the result. q Piston (4) is pushed down due to the area difference between (φd1) and (φd2). q Stroke of orifice check valve (1) is disabled by piston (4). q The pressurized oil from the pump flows through orifice (a) of orifice check valve (1), retracting spring (3) and pushing up check valve (2) in the process. Then it flows through orifice (b) to the cylinder port. q Flow of the pressurized oil to the cylinder port is restricted by orifices (a) and (b). When the signal from the controller is absent q Port (PC) is drained. Thus, piston (4) does not operate. q As long as piston (4) remains inactive, the pressurized oil from the pump flows to the cylinder port by retracting spring (3) and pushing up orifice check valve (1) and check valve (2). q In this case, flow of the pressurized oil to the cylinder port is not restricted.

PC2000-8

33

SEN01619-01

10 Structure, function and maintenance standard

Swing motor

1

Type: KMF230AB-5

B MA MB S T

: From swing holding brake solenoid valve : From control valve : From control valve : From control valve : To tank

1. 2.

Plate Safety valve

34

Specifications Type : Theoretical displacement : Safety valve set pressure : Rated speed : Brake release pressure :

KMF230AB-5 229.4 cm3/rev 27.9 MPa {290 kg/cm2} 1,315 rpm 1.9 MPa {19 kg/cm2}

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01619-01

35

SEN01619-01

36

10 Structure, function and maintenance standard

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

SEN01619-01

Brake spring Drive shaft Spacer Case Disc Plate Brake piston Housing Piston Cylinder block Valve plate Center shaft Center spring Check valve Shuttle valve Unit: mm

No.

Check item

Criteria Standard size

16 Check valve spring

17 Shuttle valve spring

PC2000-8

Remedy Repair limit

Free length × outside diameter

Installed length

Installed load

Free length

Installed load

66.5 × 25.6

45.0

6.96 N {0.71 kg}

—

5.59 N {0.57 kg}

24.5 × 11.6

14.5

7.45 N {0.76 kg}

—

5.98 N {0.61 kg}

If damaged or deformed, replace spring

37

SEN01619-01

10 Structure, function and maintenance standard

Swing holding brake 1.

When solenoid valve is de-energized

Operation q As the swing holding brake is de-energized, the pressurized oil from the self pressure reducing valve is shut off. q Port (B) is connected to tank circuit (T). q Brake piston (7) is pushed down by brake spring (1). q Disc (5) and plate (6) are pushed together, and the brake is applied.

38

2.

When solenoid valve is energized

Operation q As the swing brake solenoid valve is energized, the valve is switched. q The pressurized oil from the self pressure reducing valve is conducted brake chamber (a) through port (B). q After entering chamber (a), the pressurized oil compresses brake spring (1) and pushes brake piston (7) up. q Disc (5) is separated from plate (6), releasing the brake.

PC2000-8

10 Structure, function and maintenance standard

SEN01619-01

Relief valve Outline q The relief valve consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). Function q When the machine is in the swing holding mode, control valve (6) closes the motor outlet circuit, but the motor rotation is continued by inertial force. q The motor output, therefore, is abnormally increased, resulting in damaging the motor. q In order to prevent the motor damages, the relief valve relieves the abnormally high pressure to port (S) from the motor outlet side (high-pressure side) of the motor. Operation

1.

When starting swing

q

When the swing control lever is operated to the right-swing, the pressurized oil from the pump is supplied to port (MA) through control valve (6). The pressure on port (MA) rises, the starting torque is generated in the motor, and the motor starts to rotate. The pressurized oil from the outlet port of the motor passes from port (MB) through control valve (6) and returns to the tank.

q

q

PC2000-8

39

SEN01619-01

2.

When swing is stopped

q

When the swing control lever is returned to neutral, the supply of pressurized oil from the pump to port (MA) is stopped. The pressurized oil from the motor outlet can't return to the tank since the returning circuit to the tank is closed from control valve (6). Thus, pressure on port (MB) increases. Rotation resistance is generated on the motor and hence the brake starts working. The pressure on port (MB) pushes shuttle valve (4) as it goes higher than that on port (MA). The pressure on chamber (C) is increased to th e s e t p re ss u r e o f r e li e f v a lv e (1 ) a n d becomes the same as that of port (MB). A high braking torque works on the motor, thereby stopping the motor. When relief valve (1) is being actuated, the relieved pressurized oil and the pressurized oil from port (S) are fed to port (MA) through check valve (3). Above prevents cavitation on port (MA).

q

q q

q

q q

q

40

10 Structure, function and maintenance standard

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01619-01

41

SEN01619-01

Cooling fan motor (For radiator and oil cooler)

10 Structure, function and maintenance standard

1

Type: LMF110

P : From fan pump T : From cooler to tank TC : To tank Specifications Type: LMF110 Capacity: 110.7 cm3/rev Rated speed: 1,050 rpm Rated flow rate: 116.2 l/min Check valve clacking pressure: 78.5 kPa {0.8 kg/cm2} Safety valve cracking pressure: 24.5 MPa {250 kg/cm2}

42

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7.

SEN01619-01

8. 9. 10. 11. 12. 13.

Output shaft Case Thrust plate Shoe Piston Cylinder block Valve plate

End cover Center spring Suction valve Pilot valve Reversible valve spool Safety valve

Unit: mm No.

Check item

Criteria Standard size

14 Spool return spring

15 Suction valve spring

PC2000-8

Remedy Repair limit

Free length × outside diameter

Installed length

Installed load

Free length

Installed load

62.66 × 19.8

53.5

146 N {14.9 kg}

—

117 N {11.9 kg}

16.4 × 8.9

11.5

13.7 N {1.4 kg}

—

11.0 N {1.12 kg}

If damaged or deformed, replace spring

43

SEN01619-01

1.

10 Structure, function and maintenance standard

Hydraulic motor

Function q This hydraulic motor is called a swash platetype axial piston motor. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion. Principle of operation q The oil sent from the hydraulic pump flows through valve plate (7) into cylinder block (5). This oil can flow on only one side of the (Y-Y) line connecting the top dead center and bottom dead center of the stroke of piston (4). q The hydraulic oil conducted to one side of cylinder block (5) pushes respective pistons (4) to generate force (F1) [F1 = P × xD2/4]. q This force is applied to thrust plate (2). Since thrust plate (2) is fixed to the angle of (a°) to output shaft (1), the force is divided into components (F2) and (F3). q The radial component (F3) generates torque [T = F3 × ri] against the (Y–Y) line connecting the top dead center and bottom dead center. q The combined force of all torque [T = Σ (F3 × ri)] rotates cylinder block (5) through the piston. q Since this cylinder block (5) is splined to the output shaft, the output shaft revolves to transmit the torque.

44

PC2000-8

10 Structure, function and maintenance standard

2.

Suction valve

Function q If the fan pump stops, the pressurized oil does not flow into the motor. Since the motor continues revolution because of the force of inertia, however, the pressure on the outlet side of the motor rises. q When the oil stops flowing in from inlet port (P), suction valve (1) sucks in the oil on the outlet side and supplies it to port (MA) where there is not sufficient oil to prevent cavitation. Operation 1) q

SEN01619-01

2) q

q

When the 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) any more. As the hydraulic oil is not supplied to the (MA) side of the motor, the motor speed lowers gradually to stop. If the motor shaft is revolved by the force of inertia while the oil flow in the port (P) is reducing, the oil in port (T) on the outlet side is sent by suction valve (1) to the (MA) side to prevent cavitation.

When pump is started When the hydraulic oil from the pump is supplied to port (P) and the pressure on the (MA) side rises and starting torque is generated in the motor, the motor starts revolution. The oil on the outlet (MB) side of the motor returns through port (T) to the tank.

PC2000-8

45

SEN01619-01

3.

Operation of reversible valve

1)

When the ON-OFF solenoid is de-energized If ON-OFF solenoid (1) is “de-energized”, the pressurized oil from the pump is blocked by ON-OFF selector valve (2), and port (C) opens for the tank circuit. Spool (3) is pushed to the right by spring (4). Motor port (MA) opens and pressurized oil flows in to revolve the motor in forward (clockwise).

q

q q

46

10 Structure, function and maintenance standard

2) q

q q

When ON-OFF solenoid is energized If ON-OFF solenoid (1) is “energized”, ONOFF selector valve (2) changes to let the pressured oil from the pump flow through port (C) into spool chamber (D). The pressurized oil in chamber (D) pushes valve spool (3) to the left against spring (4). Motor port (MB) opens and pressurized oil flows in to revolve the motor in reverse (counterclockwise).

PC2000-8

10 Structure, function and maintenance standard

4.

SEN01619-01

Safety valve

Function q When the engine is started, the pressure in port (P) of the fan motor is heightened in some cases. q Safety valve (1) is installed to protect the fan system circuit. Operation q If the pressure in port (P) exceeds the cracking pressure of safety valve (1), valve (2) of safety valve (1) opens to relieve the oil into port (T). q By this operation, generation of abnormal pressure in port (P) is prevented.

PC2000-8

47

SEN01619-01

Cooling fan pump

10 Structure, function and maintenance standard

1

Type: HPV95+95+SBL (1) 21

48

PC2000-8

10 Structure, function and maintenance standard

SEN01619-01

Outline q The pump unit is composed of 2 variablecapacity swash plate-type piston pumps, PC valves, EPC valves and a single gear pump. IMF : IMR : PAF : PAG : PAR : PBF : PBR : PD1F : PD1R : PD2F : PD2R : PENF : PENR: PEPC : PFC : PMF : PMR : PPF PPR PRC PRF PRR PS PSG 1. 2. 3. 4. 5. 6.

: : : : : : :

Front side swash plate control current Rear side swash plate control current Front pump discharge port Gear pump discharge port Rear pump discharge port Pump pressure output port Pump pressure output port Case drain port Air bleeder Drain plug Drain plug Control pressure pick-up port Control pressure pick-up port EPC basic pressure port Front pump discharge pressure pick-up port EPC output pressure pick-up port for front side swash plate control EPC output pressure pick-up port for rear side swash plate control Front pump pressure sensor installation port Pump pressure sensor installation port Rear pump discharge pressure pick-up port Pilot pressure input port Pilot pressure input port Pump suction port Gear pump suction port

Front pump Rear pump Gear pump PC valve EPC valve Sequence valve

PC2000-8

49

SEN01619-01

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

50

10 Structure, function and maintenance standard

Front shaft Cradle Front case Rocker cam Shoe Piston Cylinder block Valve plate End cap Rear shaft Rear case Servo piston PC valve

PC2000-8

10 Structure, function and maintenance standard

SEN01619-01

Function q The engine speed and torque are transmitted to the shaft of this pump. Then, this pump converts the speed and torque into oil pressure and discharges pressurized oil according to the load. q It is possible to change the delivery by changing the swash plate angle.

q

Structure q Cylinder block (7) is supported to shaft (1) by spline (14). q Shaft (1) is supported by front and rear bearings (15). q The end of piston (6) has a spherical hollow and is combined with shoe (5). q Piston (6) and shoe (5) form a spherical bearing. q Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular movement.

q

PC2000-8

q

q

q

Rocker cam (4) conducts high pressure oil to cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8).

51

SEN01619-01

Operation of pump q Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). q When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and the axial direction of cylinder block (7) changes. q Angle (a) is called the swash plate angle.

q

q

q q

q

52

10 Structure, function and maintenance standard

q

q

As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)

With center line (X) of rocker cam (4) at swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). A single piston (6) sucks and discharges the oil by amount (F) – (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suctioned.

PC2000-8

10 Structure, function and maintenance standard

SEN01619-01

Control of delivery q If swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and pump delivery (Q) increases. q Servo piston (12) is used for changing swash plate angle (a). q Servo piston (12) carries out linear reciprocal movement according to the signal pressure from the PC and LS valves. q This linear movement is transmitted to rocker cam (4) through slider (13). q Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while continuing revolving movement. q Space of the pressure receiving area of servo piston (12) are not identical on the left side and right side. Main pump discharge pressure (self pressure) (PP) is always brought to the pressure chamber of the small diameter piston side. q Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. q The relationship in the size of pressure (PP) at the small diameter piston end and pressure (PEN) at the large diameter piston end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).

PC2000-8

53

SEN01619-01

1.

10 Structure, function and maintenance standard

PC valve

PA PDP PM PPL

: : : :

Pump port Drain port EPC pressure input port Control pressure output port (To servo piston large diameter end)

1. 2. 3. 4. 5. 6. 7. 8.

Plug Servo piston assembly Pin Spool Retainer Seat Cover Wiring

Function q The PC valve controls the pump delivery (Q) according to the EPC valve output pressure (PM). q If the EPC valve output pressure (PM) rises, the PC valve increases the pump delivery (Q). q If the EPC valve output pressure (PM) lowers, the PC valve decreases the pump delivery (Q).

54

PC2000-8

10 Structure, function and maintenance standard

SEN01619-01

1) Action of EPC valve solenoid (1)

Operation q PC mode selector current (IM) from the pump controller is conducted to EPC valve solenoid (1). q PC mode selector current (IM) works on EPC valve to have it generate the signal pressure in order to change piston (2) pushing force. q Spool (3) stops at a position where the force of spring (4) is balanced with the force applied to piston (2) according to the EPC valve signal pressure. q The pressure [port (C) pressure] output from PC valve is changed depending on the above position. q The level of PC mode selector current (IM) is determined by the engine oil temperature, hydraulic oil temperature, engine speed, and set value of the hydraulic fan. q The spring set force of spring (4) varies as servo piston (9) expands and compresses spring (4).

PC2000-8

55

SEN01619-01

10 Structure, function and maintenance standard

2) When PC mode selector current is decreased (When EPC output pressure lowers)

q q

q q

q q

q

56

Port (C) of PC valve is connected to the large diameter end of servo piston (9). Pump discharge pressure (PA) is applied to the small diameter end of servo piston (9) and port (B). When EPC output pressure (PM) is decreased, spool (3) moves to the left. Ports (C) is connected to port (D) and the pressure applied to the large diameter end of the piston becomes drain pressure (PT) and servo piston (9) moves to the left. The pump delivery will be set to the increasing trend. Accompanied with move of servo piston (9), spring (4) will be expanded and the spring force becomes weaker. As the spring force is weakened, spool (3) moves to the right, the connecting between port (C) and port (D) is shut off and the pump discharge pressure ports (B) and (C) are connected.

q

q

q

The pressure on port (C) rises and the pressure on the large diameter end of the piston also rises. Thus, the leftward move of servo piston (9) is stopped. The stop position of servo piston (9) (= pump delivery) is determined by the position where the pressing force generated by the EPC valve output pressure is balanced with the force of spring (4). When the stop position of servo piston (9) (= pump delivery) is at a middle position between the maximum and minimum pump delivery positions, the pressure on the large diameter end of the piston is about a half of pump discharge pressure (PA). When the former is at the maximum pump delivery position, the latter becomes drain pressure (PT).

PC2000-8

10 Structure, function and maintenance standard

SEN01619-01

3) When PC mode selector current is increased (When EPC output pressure rises)

Operation q When EPC output pressure (PM) is increased, spool (3) moves to the right. q If ports (C) is connected to port (B), the pressure on the large diameter end of the piston rises and servo piston (9) moves to the right. q The pump delivery is decreased. q As servo piston (9) moves, spring (4) is compressed and its force is increased. q If the spring force is increased, spool (3) moves to the left, port (C) is disconnected from port (B), and draining port (D) is connected to port (C). q If the pressure in port (C) lowers, the pressure on the large diameter end of the piston lowers and consequently servo piston (9) stops moving to the right. q The stop position of servo piston (9) (= pump delivery) is determined by the position where the pressing force generated by the EPC valve output pressure is balanced with the force of spring (4).

PC2000-8

q

When the stop position of servo piston (9) (= pump delivery) is at a middle position between the maximum and minimum pump delivery positions, the pressure on the large diameter end of the piston is about a half of pump discharge pressure (PA). When the former is at the minimum pump delivery position, the latter becomes pump discharge pressure (PA).

57

SEN01619-01

q

58

10 Structure, function and maintenance standard

The relationship between PC mode selector current (IM) and pump delivery (Q) becomes as shown below.

PC2000-8

10 Structure, function and maintenance standard

2.

EPC valve

C: P: T:

To PC valve From pilot relief valve To tank

1. 2. 3. 4. 5. 6. 7.

Connector Coil Body Spring Spool Rod Plunger

PC2000-8

SEN01619-01

59

SEN01619-01

Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the PC valve.

10 Structure, function and maintenance standard

Operation 1) q q q q

60

When signal current is 0 (Coil is de-energized) When there is no signal current flowing from the controller to coil (2), coil (2) is de-energized. Spool (5) is pushed to the left by spring (4). Port (P) is closed and the pressurized oil from the pilot relief valve does not flow to the PC valve. The pressurized oil from the PC valve is drained to the tank through port (C) and port (T).

PC2000-8

10 Structure, function and maintenance standard

2) q

q q

q q q

q

When signal current is very small (coil is energized) When a very small signal current flows to coil (2), coil (2) is energized, and a propulsion force is generated on the right side of plunger (7). Rod (6) pushes spool (5) to the right, and pressurized oil flows from port (P) to port (C). Pressures on port (C) increases and the force to act on spool (5) surface and the spring load on spring (4) become larger than the propulsion force of plunger (7). Spool (5) is pushed to the left, and port (P) is shut off from port (C). Port (C) and port (T) are connected. Spool (5) moves so that the propulsion force of plunger (7) may be in balance with pressure of port (C) + spring load of spring (4). The circuit pressure between the EPC valve and PC valve is controlled in proportion to the size of the signal current.

PC2000-8

SEN01619-01

3) q q

q q

q

When signal current is maximum (coil is energized) As the signal current flows to coil (2), coil (2) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (7) is also at its maximum. Spool (5) is pushed toward the right side by rod (6). The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit pressure across the EPC valve and PC valve to the maximum level. Since port (T) is closed, pressurized oil does not flow to the tank.

61

SEN01619-01

PC2000-8 Hydraulic excavator Form No. SEN01619-01

© 2007 KOMATSU All Rights Reserved Printed in Japan 05-07 (01)

62

SEN01620-01

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

10 Structure, function and maintenance standard

1

Hydraulic system, Part 3 Hydraulic system, Part 3 ................................................................................................................................. 2 Travel motor ......................................................................................................................................... 2 Hydraulic pump .................................................................................................................................. 14 PPC valve .......................................................................................................................................... 32 Variable back pressure valve ............................................................................................................. 44 Suction selector valve ........................................................................................................................ 48 PPC cut-off valve ............................................................................................................................... 52

PC2000-8

1

SEN01620-01

10 Structure, function and maintenance standard

Hydraulic system, Part 3

1

Travel motor

1

Type: KMF340-5

B : Pressure pick-up port MA : Pressure pick-up port MB : Pressure pick-up port PA : From control valve PB : From control valve PAI : Pressure pick-up port PBI : Pressure pick-up port T : To tank

2

Specifications Type : KMF340-5 Theoretical displacement : 337.2 cm3/rev Rated pressure : 32.8 MPa {335 kg/cm2} Rated speed : 2,461 rpm Brake release pressure : 1.31 MPa {13.4 kg/cm 2}

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01620-01

3

SEN01620-01

4

10 Structure, function and maintenance standard

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

SEN01620-01

Output shaft Motor case Piston Cylinder block Valve plate Housing Plate Disc Oil seal Counterbalance valve spool Retainer Brake spring Brake piston Safety valve Check valve Unit: mm

No.

Check item

Criteria Standard size

16 Check valve spring

17 Spool return spring

PC2000-8

Remedy Repair limit

Free length × outside diameter

Installed length

Installed load

Free length

Installed load

66.5 × 25.6

45

6.96 N {0.71 kg}

—

6.57 N {0.67 kg}

63 × 44.5

61.5

520 N {53 kg}

—

—

If damaged or deformed, replace spring

5

SEN01620-01

10 Structure, function and maintenance standard

Operation of parking brake 1) When starting travel

q

q

q

6

As the travel lever is operated, pressurized oil from the pump actuates counterbalance valve spool (10) to open the parking brake circuit. The pressurized oil flows to chamber (e) of brake piston (13), compressing brake spring (12) and pushing brake piston (13) to the right. Pressing force so far allied to plate (7) and disc (8) is eliminated. Thus, plate (7) disengages from disc (8), releasing the brake.

PC2000-8

10 Structure, function and maintenance standard

SEN01620-01

2) When travel is stopped

q

q

q

q q

When the travel lever is set to the neutral position, and counterbalance valve spool (10) returns to the neutral position, closing the parking brake circuit. The pressurized oil in chamber (e) of brake piston (13) keeps flowing through the throttle of slow return valve (18) until counterbalance valve spool (10) returns to the neutral. As counterbalance valve spool (10) returned to the neutral, the oil is drained from the throttle (f) of brake piston (13) to the case. Brake piston (13) is pressed by spring (12) to the left. Plate (7) and disc (8) are compressed to each other, actuating the brake.

PC2000-8

q q

Returning brake piston (13) reduces flow of the pressurized oil with slow return valve (18). The specified time lag actuates the brake after the machine has been stopped.

7

SEN01620-01

10 Structure, function and maintenance standard

Brake valve q

q

1)

The brake valve is consisted of check valves (1) and (2), counterbalance valve (3) and safety valve (4). Functions and operations of respective components shall conform to the following. Counterbalance valve and check valve

Function q When traveling downhill, the machine travel speed tend s to ge t faster than the moto r (engine) speed because of the downward force generated from its own weight. q If the machine travels with the engine at low speed, the motor may rotate without load, causing the machine to run away; resulting in a very dangerous situation. q These valves are used to prevent above by controlling the machine to travel according to the engine speed (pump delivery).

Operation when pressurized oil is supplied Operating the travel lever conducts the pressurized oil from the control valve to port (PA). q The pressurized oil pushes open check valve (1) and flows through motor inlet port (MA) to motor outlet port (MB). q Since the motor outlet side is closed by check valve (2) and spool (3), the pressure on the supply side rises. q

q

q

8

The pressurized oil on the supply side flows to chamber (S1) through orifices (E1) and (E2) of spool (3). As the pressure in chamber (S1) rises above the spoo l se lector p ressu re, spoo l (3 ) is pushed to the right.

PC2000-8

10 Structure, function and maintenance standard

q

Port (MB) and port (PB) are connected, opening the motor outlet port side and starting the motor rotating.

PC2000-8

SEN01620-01

Operation of brake during travelling downhill q If indication of the machine runaway is sensed while travelling downhill, the motor will be caused to rotate without load to decrease the inlet side oil pressure. q Pressure in chamber (S1) is released through orifices (E1) and (E2). q When the pressure in chamber (S1) drops below the spool selector pressure, spool (3) is returned to the left, in the direction of the arrow by spring (6), and outlet port (MB) is throttled. q The pressure at the outlet port side rises, generating rotation resistance on the motor to prevent the machine from running away. q The spool moves to a position where the pressure on the outlet port (MB) can be balanced against the machine's own weight and the inlet port pressure. q Oil flow from the outlet circuit is reduced to ensure the travel speed corresponded to the pump delivery.

9

SEN01620-01

2)

10 Structure, function and maintenance standard

Safety valve (bidirectional 2-stage set safety valve)

Function q As long as the machine travel is stopped (or it is travelling downhill), the counterbalance valve closes the inlet and outlet circuits of the motor. q Since the motor is rotated by inertial force, pressure in the motor outlet port side is abnormally increased, potentially resulting in damages on the motor and piping. q The safety valve releases this abnormal pressure to the inlet port side of the motor in order to prevent damages to the equipment.

q

q

As the pressure goes above the set pressure, [Difference in areas of circles (D1) and (D2) × Pressure] compresses spring (2). Poppet (1) is moved leftward and the pressurized oil flows into chamber (MA) of the opposite circuit.

Bidirectional action (1) When pressure in chamber (MB) has become high (when rotating clockwise) q As long as the machine travel is stopped (or it is travelling downhill), the check valve of counterbalance valve closes chamber (MB) of the outlet port circuit. q The motor tries to continue rotation resorting to inertial force, thus pressure on the outlet port (MB) is increased.

10

PC2000-8

10 Structure, function and maintenance standard

(2) When pressure in chamber (MA) has become high (when rotating counterclockwise) q As long as the machine travel is stopped (or it is travelling downhill), the check valve of counterbalance valve closes chamber (MA) of the outlet port circuit. q The motor tries to continue rotation resorting to inertial force, thus pressure on the outlet port (MA) is increased.

q

q

SEN01620-01

Operation of mechanism for varying set pressure (1) When starting travel (high-pressure setting) q As the travel lever is operated, the pressurized oil from the pump moves spool (10) to the right. q Above opens the pilot circuit to the safety valve, conducting the pressurized oil to chamber (J) through chamber (G) and passage (H). q Piston (3) is pushed rightward, spring (2) is compressed and the set load is increased. q High pressure is turned on the safety valve, providing a large tractional force to the valve.

As the pressure goes above the set pressure, [Difference in areas of circles (D1) and (D3) × Pressure] compresses spring (2). Poppet (1) is moved leftward and the pressurized oil flows into chamber (MB) of the opposite circuit.

PC2000-8

11

SEN01620-01

10 Structure, function and maintenance standard

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

Safety valve set pressure High pressure set: 40.2 MPa {410 kg/cm2} (At start and during travel) Low pressure set: 27.5 MPa {280 kg/cm2} (When stopped)

12

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01620-01

13

SEN01620-01

Hydraulic pump

10 Structure, function and maintenance standard

1

Type: HPV375+375

14

PC2000-8

10 Structure, function and maintenance standard

SEN01620-01

Outline q The pump unit is composed of 2 variablecapacity swash plate-type piston pumps, VC valves, EPC valves and self pressure reducing valves. CE1 : CE2 : CH1 : CH2 : CP1 : CP2 : CPR: CS1 : CS2 : E1 : E2 : P1 : P2 : PF : PR3 : PR4 : PR5 : S : T1 : T2 : T3 : T4 : T5 : T6 : T7 : T8 : T9 : T10 : T11 : 1. 2. 3. 4. 5. 6.

Front EPC output pressure pick-up port Rear EPC output pressure pick-up port Front EPC basic pressure pick-up port Rear EPC basic pressure pick-up port Front pump discharge pressure pick-up port Rear pump discharge pressure pick-up port Pilot basic pressure pick-up port Front control pressure pick-up port Rear control pressure pick-up port Front EPC command current Rear EPC command current Discharge port Discharge port Self pressure reducing valve basic pressure port Pilot basic pressure input port (succeeding to the inline filter attached to the machine) Pilot basic pressure output port (preceding the inline filter attached to the machine) Pilot basic pressure pick-up port Suction port Drain port Drain plug Drain plug Drain plug Drain plug Air bleeder Drain branch piping port Drain plug Drain plug Drain plug Drain plug

Front pump Rear pump VC valve EPC valve Self pressure reducing valve Filter

PC2000-8

15

SEN01620-01

16

10 Structure, function and maintenance standard

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

SEN01620-01

Front shaft Cradle Front case Rocker cam Shoe Piston Cylinder block Servo piston Valve plate End cap Rear case Rear shaft Bevel gear Impeller pump Impeller shaft Impeller pinion

PC2000-8

17

SEN01620-01

10 Structure, function and maintenance standard

Function q The engine speed and torque are transmitted to the shaft of this pump. Then, this pump converts the speed and torque into oil pressure and discharges pressurized oil according to the load. q It is possible to change the delivery by changing the swash plate angle.

q

Structure q Cylinder block (7) is supported to shaft (1) by spline (17). q Shaft (1) is supported by front and rear bearings (18). q The end of piston (6) has a spherical hollow and is combined with shoe (5). q Piston (6) and shoe (5) form a spherical bearing. q Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular movement.

q

18

q

q

q

q

q

Rocker cam (4) brings high pressure oil at cylinder surface with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressurized oil to valve plate (9) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The pressurized oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (9). Impeller pump (14) and impeller pinion (16) are united by impeller shaft (15) and connected to shaft (1) through bevel gear (13). They rotate along with the shaft. Thus, they help supplying the sucked pressurized oil to cylinder block (7) and also help sucking it there by use of centrifugal force.

PC2000-8

10 Structure, function and maintenance standard

Operation of pump q Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). q When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and t h e a x ia l d ir e c ti o n o f c yl in d e r b lo c k ( 7 ) changes. q Angle (a) is called the swash plate angle.

q

q

q q

q

SEN01620-01

q

q

As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)

With center line (X) of rocker cam (4) at swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). A single piston (6) sucks and discharges the oil by the amount (F) – (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suctioned.

PC2000-8

19

SEN01620-01

10 Structure, function and maintenance standard

Control of delivery

q

q q

q q

q

q

20

If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) b e c o m e s la r g e r a n d p u m p d e li v e r y ( Q ) increases. Swash plate angle (a) is changed with servo piston (8). Servo piston (8) moves in a reciprocal movement according to the signal pressure from the pump controller. This linear motion is transmitted to rocker cam (4) through rod (19). Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while continuing revolving movement. With servo piston (8), the area receiving the pressure is different on the left and the right. The pump discharge pressure (self pressure) (PH) is constantly led to the pressure chamber of the small diameter piston end. The pressure chamber of the large diameter piston end is supplied with the VC valve output pressure (PS).

q

The relationship in the size of pressure (PH) at the small diameter piston end and pressure (PS) at the large diameter piston end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (8).

PC2000-8

10 Structure, function and maintenance standard

SEN01620-01

Pump controller System diagram

PC2000-8

21

SEN01620-01

10 Structure, function and maintenance standard

Pump control signal

22

PC2000-8

10 Structure, function and maintenance standard

SEN01620-01

Servo valve

CE CH CS PA PH PR PS T

: : : : : : : :

Control pressure pick-up port Servo actuator pressure pick-up port Servo actuator pressure pick-up port Main pump pressure port Servo actuator port Servo basic pressure port Pump control pressure output port Drain port

PC2000-8

1. 2. 3. 4. 5.

VC valve EPC valve Spool Sleeve Spring

23

SEN01620-01

1.

VC valve

Outline q VC valve controls servo piston (4) position (pump delivery) responding to the EPC valve output pressure (controller command current). Operation q Sleeve (2) moves to and stops at a position where the EPC valve output pressure and the force of spring (1) are balanced. q The large diameter end pressure is changed by the changes of the opening area on the notches (A) and (B) between sleeve (2) and spool (3) plus by the switching of the connection port. As the result, servo piston (4) is moved.

24

10 Structure, function and maintenance standard

Move of servo piston to the maximum side q As the EPC valve output pressure increases, sleeve (2) compresses spring (1) to move upward. q As long as the swash plate angle is set to maximum, the large diameter end pressure (PS) functions as the drain pressure. [The servo piston is pushed toward the maximum side by the small diameter end pressure (PH).] q Move of servo piston (4) toward the maximum side is stopped at a position where it contacts against the MAX adjustment screw (5).

PC2000-8

10 Structure, function and maintenance standard

Move of servo piston to the minimum side q As the EPC valve output pressure decreases, sleeve (2) elongates spring (1) to move downward. q Opening (B) between sleeve (2) and spool (3) opens [Opening (A) closes], connecting the large diameter end port to the shuttle valve output pressure [= Small diameter end pressure (PH)]. Thus, servo piston (4) is moved toward the minimum side by the difference in the force resulting from the difference in the pressure receiving areas. q Move of servo piston (4) toward the minimum side is stopped at a position where it contacts against the MIN adjustment screw (6).

PC2000-8

SEN01620-01

Stop of servo piston move in halfway toward the swash plate maximum or minimum position q Move of servo piston (4) is feed back to VC valve by spool (3). q Move of servo piston (4) changes the space of opening of the notch (throttle) between spools (3) and sleeve (2), changing the large diameter end pressure. q Servo piston (4) is stopped as the pressure ratio between the small diameter piston and large diameter piston becomes 2 : 1 (Ratio of pressure receiving areas between small diameter piston and large diameter piston = 1 : 2).

25

SEN01620-01

2.

Servo piston

Outline q Port (PA) pressure or port (PR) pressure, whichever is higher, is applied to port (PH) by the shuttle valve. q Relation of pressure receiving area (A) of chamber (a) and pressure receiving area (B) of chamber (b) is expressed as (A) C [2 × (B)]. q Pressure of port (PH) is constantly applied to chamber (b). PA : Main pump discharge pressure PR : Pilot basic pressure PH : PA or PR pressure whichever is higher Operation of VC valve q The command current from the pump controller is conducted to EPC solenoid (E1). q This command current reduces the control basic pressure applied to EPC valve (2). q EPC valve (2) transmits the command current specified pilot pressure. q The pilot pressure goes to chamber (se1) through port (SE1). q Sleeve (4) of VC valve (1) is maintained at a position where the EPC valve (2) pilot pressure and the spring (5) force are balanced. q The pump controller controls magnitude of the command current sent to EPC valve (2).

26

10 Structure, function and maintenance standard

Operation of servo piston q When sleeve (4) moves upward, port (PH) is disconnected from port (PS) and port (PS) and port (TD) are connected. q Since chamber (a) is connected to drain port (TD), servo piston (3) is moved to the right by (PH) pressure. q When servo piston (3) moves to the right, cam (6) which is coupled with servo piston (3) moves to the right. q Spool of VC valve (1) moves upward. q When spool of VC valve (1) moves upward, port (PS) is disconnected from port (TD). q Port (PS) starts connecting to port (PH) and pressures of chambers (a) and (b) are balanced. q Servo piston (3) stops its move. q Move of servo piston (3) changes in proportion to the moving distance of sleeve (4) of VC valve (1). When EPC valve is not operated q Sleeve (4) of VC valve (1) does not operate if the pilot pressure from EPC valve (2) is not present. q In this case, ports (PH) and (PS) are connected and the connection between ports (PS) and (TD) is cut off. q Since the pressure in chambers (a) and (b) is set to the same level, servo piston (4) is moved to the left. q The pump delivery is kept at the minimum. PC2000-8

10 Structure, function and maintenance standard

3.

SEN01620-01

EPC valve

C : To VC valve P : From pump T : To hydraulic tank

PC2000-8

1. 2. 3. 4. 5. 6. 7.

Body Spool Spring Rod Coil Plunger Connector

27

SEN01620-01

Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the VC valve.

10 Structure, function and maintenance standard

Operation

1. When signal current is 0 (coil is deenergized) q q q

q

28

When there is no signal current flowing from the controller to coil (5), coil (5) is de-energized. Spool (2) is pushed to the right by spring (3). Port (P) closes the pressurized oil from the self pressure reducing valve does not flow to the control valve. The pressurized oil from the VC valve is drained to the tank through port (C) and port (T).

PC2000-8

10 Structure, function and maintenance standard

2. When signal current is very small (coil is energized) q

q q

q q q

q

When a very small signal current flows to coil (5), coil (5) is energized, and a propulsion force is generated on the left side of plunger (6). Rod (4) pushes spool (2) to the left, and the pressurized oil flows from port (P) to port (C). Pressure on port (C) increases and the force to act on surface (a) of spool (2) + the spring load on spring (3) become larger than the propulsion force of plunger (6). Spool (2) is pushed to the right, and port (P) is shut off from port (C). Port (C) and port (T) are connected. Spool (2) moves up and down so that the propulsion force of plunger (6) may be balanced with pressure of port (C) + the spring load of spring (3). The circuit pressure between the EPC valve and the VC valve is controlled in proportion to the size of the signal current.

PC2000-8

SEN01620-01

3. When signal current is maximum (coil is energized) q q

q q

q

As the signal current flows to coil (5), coil (5) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (6) is also at its maximum. Spool (2) is pushed to the left by rod (4). The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit pressure across EPC valve and VC valve to the maximum level. Since port (T) is closed, pressurized oil does not flow to the tank.

29

SEN01620-01

10 Structure, function and maintenance standard

Self pressure reducing valve Function q This valve reduces the discharge pressure of the fan pump and supplies it as the control pressure for the solenoid valve, EPC valve, etc. Operation

2. Fan pump discharge pressure (P3F) is reduced a

When the load pressure (P3) is lower than output pressure (PR) of self pressure reducing valve

q

Valve (1) receives the force of spring (2) and pressure (PR) (which is {0 MPa {0 kg/cm 2} when engine is stopped) in the direction to close the circuit between ports (P3F) and (P3). As the pressurized oil flows in from port (P3F), following balance is reached: [(φd area × P3F pressure) = the force of spring (2) + (φd area × PR pressure)]. Opening of valve (1) is adjusted to maintain pressure (P3F) at a constant pressure above pressure (PR). As (PR) pressure reaches a level higher than the set pressure, poppet (4) opens. The pressurized oil flows from port (PR) to internal orifice (a) of spool (6) and then flows to tank drain port (T) through the opening of poppet (4). The differential pressure is generated through internal orifice (a) of spool (6), actuating spool (6) to close the opening from port (P3F) to (PR). Referencing the given open area, the self pressure reducing valve reduces pressure (P3F) to a specific level (set pressure) in order to supply the difference as pressure (PR).

1. When engine is stopped q

q

q

Since poppet (4) is pressed against the seat by spring (3), the portion of the circuit from port (PR) to port (T) is cut off. Since valve (6) is pressed to the left by spring (5), the portion of the circuit from port (P3F) to port (PR) is open. Since valve (1) is pressed to the left by spring (2), the portion of the circuit from port (P3F) to port (P3) is closed.

q

q

q q

q

q

30

PC2000-8

10 Structure, function and maintenance standard

3. When load pressure (P3F) is high q

q

q

q q

q

q

Change in the fan revolution speed increases load pressure (P3) and, as the result, pump delivery is increased. Since pressure (P3F) increases, [(φd area × P3F pressure) > the force of spring (2) + (φd area × PR pressure)]. As the result, valve (1) is moved to the right up to the stroke end. Since the opening between ports (P3F) and (P3) increases, resistance along the passage is reduced and the loss horsepower of the engine is reduced. As pressure (PR) reaches a level higher than the set pressure, poppet (4) opens. The pressurized oil flows from port (PR) to internal orifice (a) of spool (6) and then flows to tank drain port (T) through the opening of poppet (4). The differential pressure is generated through internal orifice (a) of spool (6), actuating spool (6) to close the opening from port (P3F) to (PR). The self pressure reducing valve reduces pressure (P3F) to a specific level (set pressure) in order to supply the difference as pressure (PR).

PC2000-8

SEN01620-01

4. When abnormally high pressure is generated q

q q q

If pressure (PR) of the self pressure reducing valve turns to an abnormally high pressure, valve (1) compresses spring (2). Port (A) opens and ports (PR) and (TS) are connected. Allows the pressurized oil to (TS) from port (PR) and lowers pressure (PR). Protects PPC valve, solenoid valve and other devices from abnormal pressure.

31

SEN01620-01

10 Structure, function and maintenance standard

PPC valve

1

Work equipment and swing PPC valve

1

P P1 P2 P3 P4 T

32

: : : : : :

From self pressure reducing valve Left PPC valve: Arm OUT/Right PPC valve: Boom LOWER Left PPC valve: Arm IN/Right PPC valve: Boom RAISE Left PPC valve: Swing LEFT/Right PPC valve: Bucket CURL Left PPC valve: Swing RIGHT/Right PPC valve: Bucket DUMP To tank

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01620-01

33

SEN01620-01

34

10 Structure, function and maintenance standard

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8.

SEN01620-01

Spool Piston Disc Nut (for connection of lever) Joint Plate Retainer Body Unit: mm

No.

Check item

Criteria Standard size

9

10

Centering spring (For ports P3 and P4)

Centering spring (For ports P1 and P2)

11 Metering spring

PC2000-8

Remedy Repair limit

Free length × outside diameter

Installed length

Installed load

Free length

Installed load

45.85 × 15.5

34.0

11.8 N {1.2 kg}

—

9.41 N {0.96 kg}

37.95 × 15.5

34.0

3.92 N {0.4 kg}

—

3.14 N {0.32 kg}

27.08 × 8.14

24.9

26.3 N {2.68 kg}

—

21.0 N {2.14 kg}

If damaged or deformed, replace spring

35

SEN01620-01

Operation

1. When in neutral q

Ports (A) and (B) of the control valve and ports (P1) and (P2) of PPC valve are connected to drain chamber (D) at the bottom.

10 Structure, function and maintenance standard

2. During fine control (Neutral o fine control) q

q

q q

q

q

q q q

36

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

PC2000-8

10 Structure, function and maintenance standard

3. During fine control (When control lever is returned) q

q q

q

q

q

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). Port (P1) is connected to drain chamber (D), and the pressurized oil of port (P1) is released. If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). Port (P1) is disconnected from drain chamber (D) and then, almost in that instant, connected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. When the spool of the control valve returns, oil in drain chamber (D) flows in from the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to fill the chamber with the pressurized oil.

PC2000-8

SEN01620-01

4. At full stroke q q

q

q

Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1). Port (P1) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP). The pilot pressurized oil from the self pressure reducing valve is conducted from port (P1) to chamber (A) to push the control valve spool. Return oil from chamber (B) flows from port (P2) to drain chamber (D).

37

SEN01620-01

Travel PPC valve

P P1 P2 P3 P4 T

38

: : : : : :

10 Structure, function and maintenance standard

1

From self pressure reducing valve L.H. reverse L.H. forward R.H. reverse R.H. forward To tank

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01620-01

39

SEN01620-01

40

10 Structure, function and maintenance standard

PC2000-8

10 Structure, function and maintenance standard

1. 2. 3. 4. 5. 6. 7. 8.

SEN01620-01

Plate Body Piston Seal Centering spring Metering spring Valve Damper Unit: mm

No.

Check item

Criteria Standard size

9

Centering spring

10 Metering spring

PC2000-8

Remedy Repair limit

Free length × outside diameter

Installed length

Installed load

Free length

Installed load

47.6 × 15.5

32.5

108 N {11.0 kg}

—

86.3 N {8.8 kg}

26.5 × 8.15

24.9

16.7 N {1.7 kg}

—

13.7 N {1.4 kg}

If damaged or deformed, replace spring

41

SEN01620-01

Operation

10 Structure, function and maintenance standard

q

1. When in neutral q

Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) in spool (1).

q q q

The relationship of the position 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). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, the control valve spool moves to a position where the pressure of chamber (A) [same as pressure at port (P1)] and the force of the return spring of the control valve spool are balanced.

2. During fine control (Neutral o fine control) q

q

q

q

q

42

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

PC2000-8

10 Structure, function and maintenance standard

3. During fine control (When control lever is returned) q

q

q

q

q

q

When lever (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and pressure at port (P1). Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. When the spool of the control valve returns, the oil in drain chamber (D) flows in from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.

PC2000-8

SEN01620-01

4. At full stroke q q

q

q

Lever (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 interconnected to pump pressure chamber (PP). Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole (f) and flows to chamber (A) from port (P1) to push the control valve spool. The oil returning from chamber (B) passes from port (P2) through fine control hole (f') and flows to drain chamber (D).

43

SEN01620-01

10 Structure, function and maintenance standard

Variable back pressure valve

1

TA : From main valve port (T) TB : To oil cooler 1. 2.

PI : From solenoid valve TS : To tank

Block Valve Unit: mm

No.

Check item

Criteria Standard size

3

4

44

Valve return spring

Valve return spring

Remedy Repair limit

Free length × outside diameter

Installed length

187.48 × 38.5

130

1,370 N {140 kg}

—

1,098 N {112 kg}

116.18 × 19.5

90

231 N {23.6 kg}

—

185 N {18.9 kg}

Installed load Free length

Installed load

If damaged or deformed, replace spring

PC2000-8

10 Structure, function and maintenance standard

SEN01620-01

1. When travel operation or swing operation is turned on

Function q In the travel operation or swing operation, back pressure must be generated in the drain circuit in order to prevent cavitation. q In order to reduce power loss, back pressure must be reduced in the drain circuit for any operation other than the travel and swing. Operation q The pressure is not generated in pilot circuit (a) since pressurized oil is not fed from solenoid valve (4). q The pressurized oil from the main valve works on the left end face (AB) of valve (1) to generate back pressure in drain circuit (b) by actuating springs (2) and (3).

PC2000-8

45

SEN01620-01

10 Structure, function and maintenance standard

2. In an operation other than travel or swing

Operation q The pressurized oil being led from solenoid valve (4) to pilot circuit (a) works on the left toric surface (Aa) of valve (1) to push springs (2) and (3). q The back pressure in drain circuit (b) that is generated by pressurized oil from main valve goes low due to the right stroke of valve (1).

46

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01620-01

47

SEN01620-01

Suction selector valve

48

10 Structure, function and maintenance standard

1

PC2000-8

10 Structure, function and maintenance standard

C1 : C2 : C3 : C4 : C5 : C6 : PP1 : PP2 : PP3 : PP4 : PP5 : PP6 : PP1 : PP2 : T : 1. 2. 3. 4. 5.

SEN01620-01

To bucket CURL (Pilot port of control valve) To bucket DUMP (Pilot port of control valve) To arm IN (Pilot port of control valve) To arm OUT (Pilot port of control valve) To boom RAISE (Pilot port of control valve) To boom LOWER (Pilot port of control valve) From R.H. PPC valve (Bucket CURL port) From R.H. PPC valve (Bucket DUMP port) From L.H. PPC valve (Arm IN port) From L.H. PPC valve (Arm OUT port) From R.H. PPC valve (Boom RAISE port) From R.H. PPC valve (Boom LOWER port) From R.H. PPC valve (Tank port) From L.H. PPC valve (Tank port) To hydraulic tank

Spool Body Flange Retainer O-ring Unit: mm

No.

Check item

Criteria Standard size

6

Centering spring

PC2000-8

Remedy Repair limit

Free length × outside diameter

Installed length

Installed load

Free length

Installed load

31.72 × 17

24

14.7 N {1.5 kg}

—

11.8 N {1.2 kg}

If damaged or deformed, replace spring

49

SEN01620-01

Operation

1. When in neutral q

q

Ports (A) and (B) of control valve (6) and ports (C1), (C2) and (PT1) of suction selector valve (1) are connected to the hydraulic tank through port (T) of selector valve (1). Ports (PP1) and (PP2) of selector valve (1) and ports (P1) and (P2) of PPC valve (2) are connected to drain chamber (D).

10 Structure, function and maintenance standard

2. During fine control (Neutral o fine control) q

q

q

q

50

Operating lever (3) conducts the pilot pressurized oil to chamber (E1) through ports (P1) and (PP1). As the pressure in chamber (E1), which is used to press spool (4) of selector valve (1), goes larger than the opposing force of spring (5), spool (4) is actuated and opens the circuit from port (PP1) to port (C1). Spool (7) of control valve (6) moves to a position where the pressure in chamber (A) [equal to the pre ssure in p ort (P1)] is ba lan ce d against the force of spool return spring (8) of control valve (6). Return oil from chamber (B) of control valve (6) is returned to the tank from port (T) of selector valve (1).

PC2000-8

10 Structure, function and maintenance standard

SEN01620-01

3. During fine control (Fine control o neutral) q

q

q

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

PC2000-8

51

SEN01620-01

PPC cut-off valve

10 Structure, function and maintenance standard

1

1. For straight travel and swing priority

52

PC2000-8

10 Structure, function and maintenance standard

AIN : AOUT1: AOUT2: AOUT3: BIN : BOUT1: BOUT2: BOUT3: CIN : COUT1: COUT2: COUT3: DIN : DOUT1: DOUT2: DOUT3: EIN : EOUT1: EOUT2: EOUT3: PI1 : PI2 : T1 : T2 : 1. 2. 3. 4.

SEN01620-01

From boom RAISE port of PPC valve To R2 valve port (PB22) and L2 valve port (PA22) To R1 valve port (PA21) and L1 valve port (PA21) – From bucket CURL port of PPC valve To R2 valve port (PA32) and L2 valve port (PA32) To L1 valve port (PA31) To R1 valve port (PA31) From arm IN port of PPC valve To R2 valve port (PA12) and L2 valve port (PA12) To L1 valve port (PA11) To R1 valve port (PA11) From arm OUT port of PPC valve To R2 valve port (PB12) and L2 valve port (PB12) To L1 valve port (PB11) To R1 valve port (PB11) From bucket DUMP port of PPC valve To R2 valve port (PB32) and L2 valve port (PB32) To L1 valve port (PB31) To R1 valve port (PB31) From solenoid valve From solenoid valve To tank To tank

Block Spool Block Spool Unit: mm

No.

Check item

Criteria Standard size

5

Spring

PC2000-8

Remedy Repair limit

Free length × outside diameter

Installed length

Installed load

Free length

Installed load

66.6 × 26.5

57.3

320 N {32.7 kg}

—

256 N {26.2 kg}

If damaged or deformed, replace spring

53

SEN01620-01

10 Structure, function and maintenance standard

2. For straight travel

54

PC2000-8

10 Structure, function and maintenance standard

AIN : AOUT1: AOUT2: BIN : BOUT1: BOUT2: CIN : COUT1: COUT2: DIN : DOUT1: DOUT2: EIN : EOUT1: EOUT2: PI : T : 1. 2. 3.

SEN01620-01

From R.H. travel reverse port of PPC valve To R1 valve port (PA51) To R2 valve port (PA52) From L.H. travel reverse port of PPC valve To L1 valve port (PA51) To L2 valve port (PA52) From L.H. travel forward port of PPC valve To L1 valve port (PB51) To L2 valve port (PB52) From R.H. travel forward port of PPC valve To R1 valve port (PB51) To R2 valve port (PB52) From boom LOWER port of PPC valve To R2 valve port (PB22) To L1 valve port (PB21) From solenoid valve To tank

Block Spool Block Unit: mm

No.

Check item

Criteria Basic dimensions

4

Spring

PC2000-8

Remedy Repair limit

Free length × outside diameter

Installed length

Installed load

Free length

Installed load

66.6 × 26.5

57.3

320 N {32.7 kg}

—

256 N {26.2 kg}

If damaged or deformed, replace spring

55

SEN01620-01

10 Structure, function and maintenance standard

Swing priority function 1.

When operating work equipment (Arm, bucket and boom RAISE)

Operation q The solenoid valve of the swing priority valve does not output the pilot pressure. Swing priority valve (CV2) and selector valve (PV2) stay at the neutral position. q The pilot pressure from the bucket PPC valve and arm PPC valve is led to R1 valve. q The arm spool and bucket spool of R1 valve is actuated by the above pressure. q The boom throttle valve remains not actuated.

56

PC2000-8

10 Structure, function and maintenance standard

2.

SEN01620-01

Simultaneous operation of swing and work equipment [Swing + Work equipment (Arm, bucket or boom RAISE)]

Operation q Swing priority valve (CV2) and selector valve (PV2) are switched by the pilot pressure from the solenoid valve of the swing priority valve. q The pilot pressure from bucket PPC valve and arm PPC valve is cut off by the swing priority valve. q The arm spool and bucket spool of R1 valve remain not actuated. The pilot pressure is conducted to the swing spool. q In the boom raise operation, the boom throttle valve is actuated. Thus, the pressure keeps on flowing to the swing spool.

PC2000-8

57

SEN01620-01

10 Structure, function and maintenance standard

Straight-travel function 1.

In boom, arm, bucket or swing operation excluding travel

Operation q The solenoid valve of the straight travel valve does not output the pilot pressure. The straight travel valve spool stays at the neutral position. q The pilot pressure from arm PPC valve, boom PPC valve, bucket PPC valve, and L.H. and R.H. travel PPC valves is led to L1 valve, L2 valve, R1 valve and R2 valve. q Respective spools of L1 valve travel, L2 valve bucket, boom, arm, R1 valve travel, R2 valve bucket, boom, arm are actuated.

58

PC2000-8

10 Structure, function and maintenance standard

2.

SEN01620-01

In travel + operation (Boom, arm, bucket or swing)

Operation q Both spools (CV1) and (CV2) of the straight travel valve are switched by the pilot pressure from the solenoid valve of the straight travel valve. q Respective spools remain not actuated since the pilot pressure from arm, boom, bucket, R.H. and L.H. travel PPC valves is cut off. q Arm PPC valve: L2 valve and R2 valve q Boom PPC valve: L2 valve and R2 valve q Bucket PPC valve: L2 valve and R2 valve q R.H. and L.H. travel PPC valves: L1 valve and R1 valve

PC2000-8

q

q

L2 and R2 valves are actuated for the independent L.H. or R.H. operation and L1 and R1 valves are actuated for the operations other than travel. Any change in the work equipment operation (boom RAISE o boom LOWER, for instance) during this period does not change the flow rate to the R.H. and L.H. travel. Thus, the straight traveling function of the machine is maintained.

59

SEN01620-01

PC2000-8 Hydraulic excavator Form No. SEN01620-01

© 2007 KOMATSU All Rights Reserved Printed in Japan 05-07 (01)

60

SEN01621-02

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

10 Structure, function and maintenance standard

1

Work equipment Work equipment .............................................................................................................................................. 2 Dimensions of work equipment....................................................................................................................... 6

PC2000-8

1

SEN01621-02

Work equipment

10 Structure, function and maintenance standard

1

Backhoe specification

2

PC2000-8

10 Structure, function and maintenance standard

SEN01621-02

Unit: mm No.

1

Check item Clearance between boom-revolving frame mounting pin and bushing

Criteria Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

160

–0.043 –0.106

+0.456 +0.343

0.386 – 0.562

1.5

Standard size

2

Clearance between boom-revolving frame mounting pin and bushing

160

–0.043 –0.106

+0.172 +0.085

0.128 – 0.278

2.5

3

Clearance between boom cylinder-revolving frame mounting pin and bushing

180

–0.043 –0.106

+0.174 +0.085

0.128 – 0.280

3.5

4

Clearance between boom-boom cylinder head mounting pin and bushing

180

–0.043 –0.106

+0.160 +0.085

0.128 – 0.266

4.5

5

Clearance between boom-boom cylinder head mounting pin and bushing

180

–0.043 –0.106

+0.166 +0.085

0.128 – 0.272

5.5

6

Clearance between boom-arm cylinder mounting pin and bushing

140

–0.043 –0.106

+0.172 +0.085

0.128 – 0.278

6.5

7

Clearance between boom-arm mounting pin and bushing

200

–0.050 –0.122

+0.581 +0.470

0.520 – 0.703

7.5

8

Clearance between boom-arm mounting pin and bushing

200

–0.050 –0.122

+0.783 +0.660

0.710 – 0.905

8.5

9

Clearance between arm-arm cylinder mounting pin and bushing

140

–0.043 –0.106

+0.172 +0.085

0.128 – 0.278

9.5

Clearance between 10 arm-bucket cylinder mounting pin and bushing

120

–0.036 –0.090

+0.190 +0.085

0.121 – 0.280

10.5

Clearance between 11 link-bucket mounting pin and bushing

140

–0.043 –0.106

+0.408 +0.292

0.335 – 0.514

11.5

Clearance between 12 link-bucket mounting pin and bushing

140

–0.043 –0.106

+0.2 +0.0

0.043 – 0.306

12.5

Clearance between 13 bucket cylinder-link mounting pin and bushing

140

–0.043 –0.106

+0.393 +0.306

0.349 – 0.499

13.5

Clearance between 14 bucket cylinder-link mounting pin and bushing

140

–0.043 –0.106

+0.1 +0.1

0.043 – 0.206

14.5

15

Clearance between arm-link mounting pin and bushing

140

–0.043 –0.106

+0.430 +0.299

0.342 – 0.536

15.5

16

Clearance between arm-link mounting pin and bushing

140

–0.043 –0.106

+0.1 +0.1

0.043 – 0.206

16.5

140

–0.043 –0.106

+0.421 +0.339

0.382 – 0.527

17.5

Clearance between 17 arm-bucket mounting pin and bushing

PC2000-8

Replace

3

SEN01621-02

10 Structure, function and maintenance standard

Loading shovel specification

4

PC2000-8

10 Structure, function and maintenance standard

SEN01621-02

Unit: mm No. 1

Check item Clearance between boom-revolving frame mounting pin and bushing

Criteria Tolerance

Standard size

Shaft

180

— —

Remedy

Hole

Standard clearance

Clearance limit

—

—

—

—

—

—

2

Clearance between boom-arm mounting pin and bushing

160

3

Clearance between arm-bucket mounting pin and bushing

180

—

—

—

—

4

Clearance between front bucket-rear bucket mounting pin and bushing

170

—

—

—

—

PC2000-8

Replace

5

SEN01621-02

Dimensions of work equipment 1.

6

10 Structure, function and maintenance standard

1

Arm

PC2000-8

10 Structure, function and maintenance standard

SEN01621-02

Unit: mm

No.

(140)

2

110 –20

3

0 936 –0.5

4

(200)

5

489 ± 1

6

672.8 ± 1

7

1199 ± 1

8

3,841.7

9

5,103 ± 2

10

719 ± 1

11

1,300 ± 0.5

12

1,210 ± 0.5

13

955.2 ± 0.7

14

3,900

15

(140)

17

19

3.9 m arm

1

16

18

PC2000-8

0 364 –0.5

(140)

Arm as individual part

0 348 –0.5

When press-fitting bushing

0 364 –0.9

Min.

3,250

Max.

5,420 20

PC2000-8

124 ± 1

7

SEN01621-02

2.

8

10 Structure, function and maintenance standard

Bucket

PC2000-8

10 Structure, function and maintenance standard

SEN01621-02

Unit: mm No.

PC2000-8 12 m3 bucket

1

940 ± 0.5

2

170 ± 0.5

3

100°

4

955.2 ± 0.7

5

3,076

6

524

7

1,322 +3 –5

8

410 ± 1

9

330 –0.7 –0.9

10

165

11

71

12

86 ± 0.5

13

20

14

365 ± 0.5

15

370 ± 0.5

16

98

17

88

18

218

19

233

20

R180

21

R130

22

φ160 +0.1 0

23

φ185 +0.115 0

24

φ140 +0.2 0

25

φ326

26

φ220

27

25°

28

134

29

55 +10

30

φ248 +10

31

R1000

32

3,120

33

2,600: Wothout side shroud 2,670: With side shroud

34

212

35

352

36

135

M×P

M36 × 3

PC2000-8

9

SEN01621-02

PC2000-8 Hydraulic excavator Form No. SEN01621-02

© 2007 KOMATSU All Rights Reserved Printed in Japan 07-07 (01)

10

SEN01622-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

10 Structure, function and maintenance standard

1

Cab and its attachments Cab and its attachments ................................................................................................................................. 2 Air conditioner piping............................................................................................................................ 2 Cab....................................................................................................................................................... 3

PC2000-8

1

SEN01622-00

10 Structure, function and maintenance standard

Cab and its attachments

1

Air conditioner piping

1

1. 2. 3. 4. 5. 6. 7. 8.

Duct Condenser Air conditioner compressor Hot water return piping Hot water pickup piping Refrigerant piping Receiver tank Air conditioner unit

A : Fresh air B : Recirculated air C : Hot air/cold air

2

PC2000-8

10 Structure, function and maintenance standard

Cab

SEN01622-00

1

Wiper system

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Washer tank Washer hose Lower wiper motor Lower wiper blade, wiper Upper wiper motor Upper wiper blade, wiper Proximity switch Wiper relay Controller Machine monitor

PC2000-8

3

SEN01622-00

10 Structure, function and maintenance standard

Wiper system

Function q The wipers can be driven in the 3 modes of intermittent, continuous and continuous (only upper wiper) with the machine monitor. q The large wipers are used to wipe wider area of the window. The wiping ranges of the upper and lower wipers are overlapped to eliminate an unwiped part. q The controller receives the sensing signal from the proximity switch and the contact signals from the wiper motors and operates the wiper motors separately through the wiper relays so that the upper and lower wiper will not interfere with each other. q When the wipers are operated, the wiper drive relays are shorted to supply the battery power to the wiper motors. q When the wipers are stopped, the wiper brake relays are shorted to connect the inverse current from the wiper motors to the ground to brake the motors.

4

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01622-00

5

SEN01622-00

PC2000-8 Hydraulic excavator Form No. SEN01622-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 09-06 (01)

6

SEN01623-01

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

10 Structure, function and maintenance standard

1

Electrical system Electrical system ............................................................................................................................................. 2 Engine control ...................................................................................................................................... 2 Electrical control system .................................................................................................................... 13 Monitor system................................................................................................................................... 55 Sensor................................................................................................................................................ 83 ORBCOMM terminal .......................................................................................................................... 95

PC2000-8

1

SEN01623-01

10 Structure, function and maintenance standard

Electrical system

1

Engine control

1

Operation of system Starting engine q If the starting switch is turned to the “START” position, the engine controller checks the state that the engine stop switch is OFF and the lock lever is reset and the hydraulic tank strainer is installed and supplies the start signal to the starting motor and then the starting motor rotates to start the engine. At this time, the engine controller checks the signal voltage from the fuel control dial and controls the engine speed to the set speed.

2

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Engine speed control q The fuel control dial sends the signal voltage according to the set engine speed. q The pump controller receives the information of the fuel control dial position from the engine controller through the network. q The pump controller calculates proper engine speed for the working mode, deceleration state, etc. and outputs commands to the engine controller. q The engine controller decides the fuel injection rate according to the commands from the pump controller.

PC2000-8

3

SEN01623-01

10 Structure, function and maintenance standard

Stopping engine q If the engine controller senses that the starting switch or the engine stop switch is set in the “STOP” position, it stops fuel injection to stop the engine.

4

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Component Fuel control dial

1. 2. 3.

Knob Dial Spring

4. 5. 6.

Ball Potentiometer Connector

Function q A potentiometer is installed under the knob. As the knob is turned, the potentiometer shaft is turned. q As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer (5) changes and a throttle signal is sent to the engine controller. q The hatched area in the graph shown at right is the abnormality detection area. While the throttle voltage is in this area, the engine speed is in low idle.

PC2000-8

5

SEN01623-01

10 Structure, function and maintenance standard

Engine controller, left bank

Input and output signals q Meanings of signal classes in the terminal table shown below are as follows. A: Power supply B: Input C: Ground/Shield/Return D: Output E: Communication CN-CE01 Input/ output 1 NC(*) — 2 NC(*) — 3 Atmosphere sensor B 4 Supply pump #1 (+) D 5 Supply pump #1 (–) C 6 CAN (–) E 7 NC (*) — 8 CAN (+) E 9 Supply pump #2 (–) D 10 Supply pump #2 (–) C *: Never connect to NC or malfunctions or failures will occur. Pin No.

6

Signal name

CN-CE01 Input/ output 11 NC(*) — 12 NC(*) — 13 Engine oil pressure sensor B 14 NC(*) — 15 Coolant temperature sensor B 16 5V electric power supply for sensor A 17 Engine oil level sensor B 18 NC(*) — 19 NC(*) — 20 NC(*) — 21 NC(*) — 22 NC(*) — 23 Boost temperature sensor B 24 NC(*) — 25 Common rail pressure sensor B 26 Bkup sensor (+) B 27 NE sensor (+) B *: Never connect to NC or malfunctions or failures will occur. Pin No.

Signal name

PC2000-8

10 Structure, function and maintenance standard

CN-CE01

CN-CE02

Input/ output 28 NC(*) — 29 NC(*) — 30 Fuel temperature sensor B 31 NC(*) — 32 NC(*) — 33 5 V electric power supply for sensor A 34 NC(*) — 35 NC(*) — 36 NC(*) — 37 5 V electric power supply for sensor A 38 GND C 39 NC(*) — 40 NC(*) — 41 NC(*) — 42 NC(*) C 43 Intake temperature sensor B 44 Boost pressure sensor B 45 Injector #1 (+) D 46 Injector #5 (+) D 47 Sensor GND C 48 Ne sensor (–) C 49 NC(*) — 50 NC(*) — 51 Injector #2 (–) C 52 Injector #3 (–) C 53 Injector #1 (–) C 54 Injector #2 (+) D 55 Injector #3 (+) D 56 Injector #4 (+) D 57 Injector #6 (+) D 58 Injector #4 (–) C 59 Injector #6 (–) C 60 Injector #5 (–) C *: Never connect to NC or malfunctions or failures will occur.

Pin No.

Signal name

CN-CE02 Input/ output 1 NC(*) — 2 NC(*) — 3 NC(*) — 4 NC(*) — 5 NC(*) — 6 NC(*) — 7 Model selection B 8 NC(*) — 9 Fuel control dial (+) B 10 NC(*) — 11 NC(*) — 12 NC(*) — *: Never connect to NC or malfunctions or failures will occur. Pin No.

PC2000-8

SEN01623-01

Signal name

Input/ output 13 NC(*) — 14 NC(*) — 15 NC(*) — 16 NC(*) — 17 NC(*) — 18 NC(*) — 19 NC(*) — 20 NC(*) — 21 NC(*) — 22 Fuel control dial (+5V) A 23 Fuel control dial (–) C 24 NC(*) — 25 NC(*) — 26 NC(*) — 27 NC(*) — 28 NC(*) — 29 NC(*) — 30 NC(*) — 31 NC(*) — 32 NC(*) — 33 NC(*) — 34 GND C 35 NC(*) — 36 NC(*) — 37 NC(*) — 38 NC(*) — 39 Key switch (ACC) B 40 Electrical intake air heater relay drive D 41 NC(*) — 42 Electrical intake air heater relay GND C 43 NC(*) — 44 NC(*) — 45 NC(*) — 46 CAN(+) E 47 CAN(–) E 48 NC(*) — 49 NC(*) — 50 NC(*) — *: Never connect to NC or malfunctions or failures will occur. Pin No.

Signal name

CN-CE03 Pin No. 1 2

Signal name

Input/ output C —

GND NC(*) Electric power supply 3 A (+24V constantly) 4 NC(*) — *: Never connect to NC or malfunctions or failures will occur.

7

SEN01623-01

10 Structure, function and maintenance standard

Engine controller, right bank

Input and output signals q Meanings of signal classes in the terminal table shown below are as follows. A: Power supply B: Input C: Ground/Shield/Return D: Output E: Communication CN-CE01 Input/ output 1 NC(*) — 2 NC(*) — 3 NC(*) — 4 Right bank supply pump #1 (+) D 5 Right bank supply pump #1 (–) C 6 CAN (–) E 7 NC (*) — 8 CAN (+) E 9 Right bank supply pump #2 (+) D 10 Right bank supply pump #2 (–) C *: Never connect to NC or malfunctions or failures will occur. Pin No.

8

Signal name

CN-CE01 Input/ output 11 NC(*) — 12 NC(*) — 13 NC(*) — 14 NC(*) — 15 NC(*) — 16 NC(*) — 17 NC(*) — 18 NC(*) — 19 NC(*) — 20 NC(*) — 21 NC(*) — 22 NC(*) — 23 NC(*) — 24 NC(*) — 25 Common rail pressure sensor B 26 Bkup sensor (+) B 27 NE sensor (+) B *: Never connect to NC or malfunctions or failures will occur. Pin No.

Signal name

PC2000-8

10 Structure, function and maintenance standard

CN-CE01

CN-CE02

Input/ output 28 NC(*) — 29 NC(*) — 30 Fuel temperature sensor B 31 NC(*) — 32 NC(*) — 33 5 V electric power supply for sensor A 34 NC(*) — 35 NC(*) A 36 NC(*) — 37 5 V electric power supply for sensor A 38 NC(*) — 39 NC(*) — 40 NC(*) — 41 NC(*) — 42 NC(*) — 43 NC(*) — 44 NC(*) — 45 Injector #1 (+) D 46 Injector #5 (+) D 47 Sensor GND — 48 Ne sensor (–) C 49 NC(*) — 50 NC(*) — 51 Injector #2 (–) C 52 Injector #3 (–) C 53 Injector #1 (–) C 54 Injector #2 (+) D 55 Injector #3 (+) D 56 Injector #4 (+) D 57 Injector #6 (+) D 58 Injector #4 (–) C 59 Injector #6 (–) C 60 Injector #5 (–) C *: Never connect to NC or malfunctions or failures will occur.

Pin No.

Signal name

CN-CE02 Input/ output 1 NC(*) — 2 NC(*) — 3 NC(*) — 4 NC(*) — 5 NC(*) — 6 NC(*) — 7 NC(*) — 8 Model selection B 9 NC(*) — 10 NC(*) — 11 NC(*) — 12 NC(*) — *: Never connect to NC or malfunctions or failures will occur. Pin No.

PC2000-8

SEN01623-01

Signal name

Input/ output 13 NC(*) — 14 NC(*) — 15 NC(*) — 16 NC(*) — 17 NC(*) — 18 NC(*) — 19 NC(*) — 20 NC(*) — 21 NC(*) — 22 NC(*) — 23 NC(*) — 24 NC(*) — 25 NC(*) — 26 NC(*) — 27 NC(*) — 28 NC(*) — 29 NC(*) — 30 NC(*) — 31 NC(*) — 32 NC(*) — 33 NC(*) — 34 GND C 35 NC(*) — 36 NC(*) — 37 NC(*) — 38 NC(*) — 39 Key switch (ACC) B 40 NC(*) — 41 NC(*) D 42 NC(*) — 43 NC(*) — 44 NC(*) — 45 NC(*) — 46 CAN(+) E 47 CAN(–) E 48 NC(*) — 49 NC(*) — 50 NC(*) — *: Never connect to NC or malfunctions or failures will occur. Pin No.

Signal name

CN-CE03 Pin No. 1 2

Signal name

Input/ output C —

GND NC(*) Electric power supply 3 A (+24V constantly) 4 NC(*) — *: Never connect to NC or malfunctions or failures will occur.

9

SEN01623-01

Fuel temperature sensor q

q

The fuel temperature sensor senses the fuel temperature and sends it to the engine controller. The sensor unit is a thermistor, the resistance of which changes according to the temperature. The engine throttle controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.

10 Structure, function and maintenance standard

NE speed sensor (Crank angle sensor) q q

If the signal hole made on the flywheel passes the sensor, the magnetic line of force changes. If the magnetic line of force changes, the output of the Hall element sensor changes linearly and it is converted into pulse of 0 – 5 V by the wave form shaping circuit in the sensor, and then output.

Atmospheric pressure sensor q

This sensor is used to correct altitude.

Common rail pressure sensor, oil pressure sensor

10

PC2000-8

10 Structure, function and maintenance standard

Bkup speed sensor (G sensor) q

q

q

q

Similarly to the NE speed sensor, this sensor utilizes the pulses of 0 – 5 V generated by the change of the magnetic line of force crossing the sensor unit. The disc gear installed to the central part of the camshaft of the high-pressure pump has teeth (cut parts) around it at intervals of 120°. In addition to the above teeth, one more tooth is installed. Accordingly, 7 pulses are generated every 2 revolutions of the engine. The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed sensor pulse and Bkup speed sensor pulse.

SEN01623-01

Boost temperature sensor q

q

The boost temperature sensor senses the intake air temperature (charge temperature) and sends it to the engine controller. The sensor unit is a thermistor, the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.

Boost pressure sensor q

This sensor is used to sense the boost pressure (charge pressure).

PC2000-8

11

SEN01623-01

10 Structure, function and maintenance standard

Coolant temperature sensor • •

12

The coolant temperature sensor senses the coolant temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.

PC2000-8

10 Structure, function and maintenance standard

Electrical control system

SEN01623-01

1 Engine output control function

Engine and pump compound control function Pump absorption torque control function Auto-deceleration function Auto-low idle function

Electronic CLSS function

Heavy lift function

OFF (Reset) ON

NC flow control PC characteristic flow control Cut-off control Cut-off reset Emergency pump drive OFF (Reset) ON

2-stage boom pushing force selector function

ON (High digging performance mode) OFF (Machine push-up mode)

Swing control function Electrical control system Engine automatic warming-up, overheat prevention function, turbo protect function, split injection function Boom shockless control function

OFF (Reset) ON

Straight travel function

Swing priority function

Compound operation compensation function

Variable back pressure compensation function

Hydraulic fan control function

14

PC2000-8

Fan reverse function

13

SEN01623-01

10 Structure, function and maintenance standard

System diagram

14

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01623-01

15

SEN01623-01

10 Structure, function and maintenance standard

Engine and pump compound control function

16

PC2000-8

10 Structure, function and maintenance standard

Function With this function, the engine output and pump absorption torque are controlled properly and excessive fuel consumption is reduced by using multiple engine output curves and selecting proper matching points.

PC2000-8

SEN01623-01

q

q

The pump controller selects a proper engine output curve and pump absorption torque according to the operation pattern. The engine controller controls the fuel injection to obtain the selected engine output curve and reduces excessive fuel consumption.

17

SEN01623-01

1) q

q

10 Structure, function and maintenance standard

Control method in each mode As the working modes, 2 modes of P and E (with the E mode adjustment function) are set. Select either working mode with the working mode selector switch on the machine monitor.

P mode and E mode (E0, E1) (Including maximum pump absorption horsepower in each mode and the fan pump absorption horsepower at maximum fan speed) Mode All modes

Matching point During travel

728 kW/1800 rpm {976 HP/1800 rpm}

During work (Heavy lift ON)

P

During work (Heavy lift OFF)

699 kW/1800 rpm [721 kW/1800 rpm] {937 HP/1800 rpm} [966 HP/1800 rpm]

E0

During work

691 kW/1700 rpm [706 kW/1700 rpm] {927 HP/1700 rpm} [947 HP/1700 rpm]

E1

During work

610 kW/1700 rpm [632 kW/1700 rpm] {818 HP/1700 rpm} [848 HP/1700 rpm]

E

[ ]: 55°C spec. q

q

q

18

If the work equipment pump load increases and the pressure rises, the engine speed decreases. At this time, pump delivery (Q) is decreased to control engine speed (N) to a speed near the rated output point. If the pressure lowers reversely, pump delivery (Q) is increased to control the engine speed to the rated output point. The engine speed is kept near the rated output point by repeating the above controls. The engine speed and engine torque are so matched that the maximum output will be obtained for boom raising operation, digging operation, etc. which need larger output. For the other operations which do not need the maximum output, the engine output is lowered to decrease the fuel consumption. In the P mode and the E mode (E0), CO is canceled so that delivery (Q) at high pressure will be larger than in the E mode (E1).

2) q

q

q

E mode adjustment function The matching point in control of engine speed (N) and engine torque (T) in the E mode can be adjusted by operating the machine monitor. The matching point can be set to 2 levels of E0 and E1. In E1, the fuel efficiency is higher than in E0 but the production in unit time is lower. In the E mode (E1), the engine speed and engine output are lowered and fuel efficiency is higher in the P mode and E mode (E0). The production in unit time is lower, however.

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Auto-deceleration function

Function q If all the control levers are set in neutral when waiting for a dump truck or a next work, the engine speed is decreased to the medium speed automatically to reduce fuel consumption and noise.

q

q

PC2000-8

While the auto-low idle setting is ON, if all the control levers are set in neutral when waiting for a dump truck or a next work, the engine speed is decreased to the medium automatically. If the levers are kept in neutral for 30 seconds, the engine speed is decreased to the low speed automatically to reduce fuel consumption and noise further. If any lever is operated, the engine speed increases instantaneously to the set speed.

19

SEN01623-01

10 Structure, function and maintenance standard

Operation 1) While auto-deceleration switch is ON (with auto-low idle setting OFF) When all levers are set in neutral q While the engine is running at a speed above the deceleration speed (approx. 1,400 rpm), if all the control levers are set in neutral, the engine speed decreases instantaneously to the 1st deceleration speed which is about 100 rpm lower than the set speed. q If this condition is kept for 4 seconds, the engine speed decreases to the 2nd deceleration speed (approx. 1,400 rpm) and then it is kept at that speed until a lever is operated. When any lever is operated q While the engine speed is kept at the 2nd deceleration speed, if any control lever is operated, the engine speed increases instantaneously to the speed set with the fuel control dial.

20

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

2)

While auto-deceleration switch is ON (with auto-low idle setting ON) When all levers are set in neutral q While the engine is running at a speed above the deceleration speed (approx. 1,400 rpm), if all the control levers are set in neutral, the engine speed decreases instantaneously to the 1st deceleration speed which is about 100 rpm lower than the set speed. q If this condition is kept for 4 seconds, the engine speed decreases to the 2nd deceleration speed (approx. 1,400 rpm). q If this condition is kept for 30 seconds, the engine speed decreases to the low idle speed (approx. 825 rpm) and then it is kept at that speed until a lever is operated. When any lever is operated While the engine speed is kept at the 2nd deceleration speed or low idle speed, if any control lever is operated, the engine speed increases instantaneously to the speed set with the fuel control dial.

q

PC2000-8

21

SEN01623-01

10 Structure, function and maintenance standard

Electronic OLSS function

Function The electronic OLSS system, which replaced the TVC valve, CO valve and NC valve of the former hydraulic OLSS system, converts the pump discharge pressure and J/S differential pressure into electric signals with sensors. The controller performs NC control calculation, PC characteristic control calculation and CO control calculation and controls the variable swash plate control EPC to control the pump swash plate.

22

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01623-01

23

SEN01623-01

1) q

q

q q

q

24

10 Structure, function and maintenance standard

NC control function If the operation stroke is increased, the carryover flow is decreased (See Fig. 1) and the output pressure difference of the jet sensor (Pt – Pd) is decreased (See Fig. 2). The differential pressure (Pt – Pd) is applied to the differential pressure sensor and a voltage is output. The relationship between the input and output signals is shown in Fig. 3. If the output pressure difference (Pt – Pd) is decreased, the output voltage is increased. The output voltage of the differential pressure sensor is input to the controller. The pump swash plate capacity is set according to Fig. 4 and the controller supplies a current to the pump EPC valve according to the characteristics in Fig. 5. Since output pressure (Pi) of the EPC is increased, the pump delivery is increased.

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

2)

5)

q

q

PC characteristic control function The absorption torque of each pump is set with the engine and pump compound function and the pump capacity is calculated according to the characteristics in Fig. 6. If the load on the machine increases and the pump pressure rises, the pump capacity is decreased and the pump absorption torque on the whole machine is controlled constant.

3) q

4) q

q

Emergency pump drive function This function is used when the machine has a trouble (when user mode E07 occurs). If the emergency pump drive switch (1) is turned “ON”, the pump capacity is set constant.

Cut-off control function (Only when E1 is set in E mode) If the load increases and pump discharge pressure (P) rises to near the relief pressure during work, the pump controller decreases the pump delivery to decrease the relief loss. Cut-off reset function The cut-off reset function means the function of stopping the cut-off function and secures the pump delivery near the relief pressure to prevent the speed from lowering. Each switch and cut-off function The cut-off function is reset in the P mode and E mode (when E0 is set). Switch

Function Cut-off function

PC2000-8

Travel lever

Heavy lift

ON

OFF

ON

OFF

Reset

Used

Reset

Used

25

SEN01623-01

10 Structure, function and maintenance standard

Heavy lift function

Outline q This function increases the boom lifting power by approx. 10%. q It can be actuated only when the boom RAISE is being actuated independently. If the arm IN or bucket CURL are operated at the same time, the heavy-lift function is automatically canceled. q Heavy lift function and Cut-off cancel function will act at the same time.

26

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Operation Lever operation Heavy-lift switch

OFF

ON

Boom RAISE

Arm IN or bucket CURL

Operated

—

De-energized

29.4 MPa {300 kg/cm2}

Canceled Actuated

Normal

Neutral

Energized

32.9 MPa {335 kg/cm2}

Canceled

10% up

Operated Operated

Main relief valve set pressure

CO control

Heavy-lift solenoid valve

P and E1 mode E0 mode

If the arm IN or bucket CURL is operated during boom RAISE operations, this function is automatically canceled, and the condition becomes the same as when the switch is turned OFF.

Boom lifting force

Normal

a Heavy-lift solenoid valve For details of the structure and function, see “Solenoid valve”. a Main relief valve For details of the structure and function, see “L.H. 5-spool control valve”.

PC2000-8

27

SEN01623-01

10 Structure, function and maintenance standard

2-stage boom pushing force selector function

Outline q This function switches the pushing force of the boom. It is aimed to provide both increased digging efficiency by reducing the digging resistance of the boom, and increased ease of operation by increasing the thrusting force for excavation, digging square holes, carrying out twist turns, or escaping from soft ground.

28

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Operation q This function acts to change the set pressure of the safety valve at the boom cylinder end of the L1 and L2 control valve boom Lo in 2 ways: to low pressure (12.3 MPa {125 kg/cm2}) and high pressure (27.9 MPa {285 kg/cm2}. Mode

Boom pushing force (low mode)

Boom pushing force (high mode)

a a

Machine pushup switch

Machine pushup solenoid valve

Energized

De-energized

Safety valve set pressure

Effect

12.3 MPa {125 kg/cm2}

By reducing the boom pushing force, it is made easier for the boom to escape automatically in the RAISE direction and to reduce the number of times that the boom is operated. At the same time it also makes the digging operation smoother.

27.9 MPa {285 kg/cm2}

By increasing the thrust force for boom LOWER, the ease of operation is improved for excavation, digging square holes, carrying out twist turns, or escaping from soft ground.

Machine push-up solenoid valve For details of the structure and function, see “Solenoid valve”. Boom safety valve For details of the structure and function, see “L1 and L2 control valve”.

PC2000-8

29

SEN01623-01

10 Structure, function and maintenance standard

Swing control function

1. q

q

a a

30

Swing lock, swing holding brake function The swing lock (manual) can be locked at any desired position, and the swing holding brake (automatic) is interconnected with the swing, so they prevent any hydraulic drift after the swing is stopped. The swing holding brake and ladder are linked together. While the ladder is lowered and not in the retraction position, the swing lock is applied to prevent breakage of the ladder and secure safety when the operator climb up and down the ladder. While the ladder is lowered, the ladder lower warning lamp in the cab lights up. Swing brake solenoid valve For details of the structure and function, see “Solenoid valve”. Swing motor For details of the structure and function, see “Swing motor”.

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Actuation Swing lock switch

Mode

Swing lock monitor

Swing brake solenoid valve

Actuation When swing and work equipment levers are placed at neutral, swing brake is applied after approx. 12 sec; when any swing or work equipment lever is operated, brake is canceled and swing can be operated freely.

Swing holding brake

OFF

OFF

See diagram on right

Swing brake

ON

ON

Swing lock is actuated and swing is held in position. De-energized Even when swing lever is operated, swing lock is not canceled and swing does not run.

Operation of swing holding brake release switch q If any abnormality should occur in the controller, and the swing holding brake is not actuated normally and the swing cannot be operated, the swing holding brake release switch (1) can be operated to cancel the swing lock and allow the swing to be operated. a Even when the swing holding brake release switch is turned ON, the swing lock switch stays ON and the swing brake is not canceled. a When the swing brake is canceled, the swing has only a hydraulic brake operated by the safety valve, so if the swing is stopped on a slope, there may be hydraulic drift. a Even if the swing holding brake release switch is turned ON, the swing brake is not reset unless the ladders is in the retraction position.

Swing brake

PC2000-8

Swing lock applied

Swing lock canceled

ON

— OFF —

—

Swing lock applied

—

Storing position

—

OFF (when controller is normal)

Lower

—

Storing position

Ladder

Lower

Swing holdON ing brake (when controller is release abnormal) switch Swing lock ON — OFF — switch

Swing lock canceled

31

SEN01623-01

10 Structure, function and maintenance standard

Engine automatic warming-up, overheat prevention function, turbo protect function, split injection function

Function q If the coolant temperature is low, this automatically raises the engine speed to warm up the engine after it is started. In addition, if the coolant temperature rises too high during operations, it reduces the load of the pump to prevent overheating. q To protect the turbocharger bearing during cold weather, the engine speed is kept below the fixed speed when the engine is started. In addition, to improve the starting ability, a small amount of fuel is injected two or more times before the main injection.

32

PC2000-8

10 Structure, function and maintenance standard

1. q

2. q q

SEN01623-01

Engine automatic warming-up function After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm up the engine.

Engine overheat prevention function This function protects the engine by lowering the pump load and engine speed to prevent overheating when the engine coolant temperature has risen too high. This system is actuated at 95°C and above. Operating condition

Coolant temperature: Above 105°C

Operation/Remedy

⇒

Operating condition Coolant temperature: Above 102°C

⇒

Operation/Remedy Work mode: Any mode Engine speed: Keep as is. Monitor alarm lamp: Lights up Alarm buzzser: Does not sound Lower pump delivery.

⇒

Operation/Remedy Work mode: Any mode Engine speed: Keep as is. Monitor alarm lamp: Does not light Alarm buzzser: Does not sound Lower pump delivery.

⇒

Operation/Remedy Work mode: Travel Engine speed: Keep as is. Monitor alarm lamp: Does not light Alarm buzzser: Does not sound Lower travel speed.

Operating condition Hydraulic oil temperature: Above 95°C or Coolant temperature: Above 100°C Operating condition Hydraulic oil or coolant temperature: Above 95°C

PC2000-8

Work mode: Any mode Engine speed: Low idle Monitor alarm lamp: Lights up Alarm buzzer: Sounds

⇒

Resetting condition Coolant temperature: Below 105°C Fuel control dial: Return to low idle position once. • Under above condition, controller is set to condition before operation of function. (Manual reset) Resetting condition

⇒

Coolant temperature: Below 102°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)

⇒

Resetting condition Coolant temperature: below 100°C and hydraulic oil temperature: below 95°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)

⇒

Resetting condition Coolant temperature below 95°C and hydraulic oil temperature below 95°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)

33

SEN01623-01

3. q

10 Structure, function and maintenance standard

Turbo protection function Function to protect turbocharger bearing during cold weather by keeping engine speed below fixed speed when engine is started. Actuation condition Engine coolant temperature

Turbo protect time (sec)

More than +10°C

0

+10°C to –10°C

Gradually changes between 0 and 5

Less than –10°C

5

Engine speed: 1000 rpm q

Even if the fuel control dial is operated during the above time, the engine speed will not change. After the set time passes, the operation moves to the automatic warming up function.

4.

Split injection function To improve the ease of starting in cold weather, a small amount of fuel is injected two or more times within the set time after calculating in the table below before starting the main injection. As a result, the lower idle speed during this time becomes slightly higher.

q

Actuation condition

34

Coolant temperature

Split injection time (sec)

More than 20°C

0

20°C to –30°C

0 – 15

Less than –30°C

15

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Boom shockless control function This function improves safety by preventing spillage of the load from the bucket and by reducing the shock when the boom is stopped, thereby reducing operator fatigue.

Actuation

q

Boom shockless switch

Cancel solenoid valve

Boom shockless control

Remarks

ON (Contacts open)

De-energized

ON

Suitable for normal operations

OFF (Contacts closed)

Energized

Canceled

Suitable for compacting or skeleton work

If the boom is raised, the pilot pressure (A) from the PPC valve is generated in line (A). When this happens, the pressure in line (A) passes through check valve (2) and pushes the spool of the control valve in the direction of the arrow. The pilot oil at the left end of the spool passes through line (B) and the PPC valve, and returns to the tank. However, when this happens, check valve (4) is being pushed open by the pressure in line (A), so it also allows the oil to pass in the opposite direction. For this reason, the boom can be raised without any delay in response.

PC2000-8

q

In this condition, if the boom RAISE operation is stopped, the spool of the control valve moves in the opposite direction to the arrow and drains the oil from line (A). However, the action of check valve (2) means that the oil must pass through orifice (1). As a result, the spool returns slowly to the neutral position to prevent any shock.

35

SEN01623-01

10 Structure, function and maintenance standard

Straight travel function Outline q If the travel system and boom, arm, bucket or swing system are operated simultaneously, some of the oil flowing into the right or left travel circuits is delivered to the boom, arm, bucket or swing circuit. In the travel circuit, the oil in which is divided, less oil is supplied to the travel motor than in the travel circuit, the oil in which is not divided. As a result, the pressure in the former circuit lowers and the machine deviates. To prevent this, the straight travel PPC cut-off valve sets the valves L1 and R2 for the work equipment system and valves L2 and R1 for the travel system by setting the spools of those valves in neutral.

Operation When boom, arm, bucket or swing system is operated and travel system is not operated q The straight travel valve solenoid valve does not output oil and the straight travel valve spool is in neutral. The outputs from the arm PPC lever, boom PPC lever, bucket PPC lever and right and left travel PPC levers are input to valves L1, L2, R1 and R2. Accordingly, the travel spool of valve L1, bucket, boom and arm spools of valve L2, travel spool of valve R1, and bucket, boom and arm spools of valve R2 are operated.

36

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Operation When travel system and boom, arm, bucket or swing system are operated q The output from the straight travel valve solenoid valve changes the spools of both straight travel valves CV1 and CV2, and then the outputs from the PPC levers of the arm, boom, bucket and both travel systems are cut off. Accordingly, valves L2 and R2 are used for the operations of the left travel and right travel systems respectively, and valves L1 and R1 are used for the operations of the systems other than the travel system. Even if the work equipment is operated under this condition, the oil flow to the right and left travel systems does not change and the machine travels straight.

PC2000-8

37

SEN01623-01

10 Structure, function and maintenance standard

Swing priority function

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

38

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

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

PC2000-8

39

SEN01623-01

10 Structure, function and maintenance standard

Compound operation compensation function

Outline q When the arm system and boom raise system or bucket system are operated simultaneously, the oil flow to the boom or bucket circuit is secured by the throttle valve in the arm circuit to maintain the compound operation performance.

40

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

10 Structure, function and maintenance standard

SEN01623-01

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

41

SEN01623-01

10 Structure, function and maintenance standard

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

Explanation of operation of variable back pressure valve During swing or travel operation:The solenoid valve is turned OFF and the poppet is pressed by the spring force as ever and back pressure is generated in the main valve return circuit. During other operations: The solenoid valve is turned ON and the poppet moves in the direction of the arrow to cancel the spring force. As a result, the resistance in the control valve return circuit is decreased and the back pressure is decreased accordingly.

42

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Function q During the travel or swing operation, back pressure is generated in the drain circuit to prevent cavitation. q During the operations other than the travel and swing operations, the back pressure in the drain circuit is decreased to reduce the loss. Operation 1. During travel or swing operation q No oil is supplied from solenoid valve (4) and no pressure is generated in pilot circuit (a). q The oil from the control valve acts on left end (Ab) of valve (1) and generates back pressure in drain circuit (b) with springs (2) and (3).

PC2000-8

43

SEN01623-01

2. q

q

10 Structure, function and maintenance standard

During operations other than 1 The oil from solenoid valve (4) flows in pilot circuit (a) and acts on left ring surface (Aa) of valve (1) to push back springs (2) and (3). Since valve (1) is moved to the right, the oil from the control valve generates less back pressure in drain circuit (b).

Unit: mm Criteria Standard size No.

Check item

Repair limit

Free length × Outside Installed length Installed load diameter

Remedy Free length

Installed load

2

Spring (2)

187.48 × 38.5

130

1372. 8 N {140 kg}

—

1098. 3 N {112 kg}

3

Spring (3)

116.18 × 19.5

90

231.4 N {23.6 kg}

—

185.3 N {18.9 kg}

44

If damaged or deformed, replace spring

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Hydraulic fan control function 1) q

q

q

Hydraulic fan speed control function The fan speed on the radiator side is controlled according to the engine speed and coolant temperature. The fan speed on the oil cooler side is controlled according to the engine speed and hydraulic oil temperature. When the coolant temperature and hydraulic oil temperature are low, the fan speed is lowered to decrease the noise and fuel consumption.

PC2000-8

45

SEN01623-01

2) q

46

10 Structure, function and maintenance standard

Engine output control function The pump controller calculates the horsepower consumed by the fans and controls engine output curve (A) according to the fan speed to decrease the fuel consumption.

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Fan reverse function q q

q

q q

The cooling devices can be cleaned easily by rotating the fan in reverse. The heat in the power container can be discharged before servicing by rotating the fan in reverse. Upon receiving the fan reverse signal from the machine monitor, the pump controller drives the reverse EPC valve of the fan motor to change the fan reverse valve. By this operation, the fan rotation direction is reversed. The fans on the radiator side and oil cooler side cannot be reversed separately. The fan speed in reverse direction is controlled by only the engine speed, regardless of the coolant temperature and hydraulic oil temperature.

PC2000-8

47

SEN01623-01

10 Structure, function and maintenance standard

Pump controller Pump controller 1

48

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Input and output signals CN1

CN2

1

NC

Input/ Output Output

VL1/P1R J/S differential pressure sensor Input VL1/P1R pump pressure sensor Input

2 3

NC NC

Input Input

4 5

GND_SIG_D NC

— Input

4 5

232C_R x D Fuel level switch (Middle)

Input Input

6 7

NC RAD_FAN pump pressure sensor

Input Input

6 7

NC Machine select 4

Input Input

8 9

VR1/P1F J/S differential pressure sensor Input VR1/P1F pump pressure sensor Input

8 9

NC NC

Output Output

10 11

GND_SIG_D NC

— Input

10 11

NC NC

Input Output

12 13

NC VL2/P2R J/S differential pressure sensor

Input Input

12 13

CAN shield Machine select 5

14 15

VL2/P2R pump pressure sensor NC

Input Input

14 15

232C_T x D Fuel level switch (H1)

16 17

NC Start switch (C)

Output Input

16 17

NC Machine select 3

18 19

Auto grease manual select switch Input VR2/P2F J/S differential pressure sensor Input

18 19

NC Manual grease operation lamp

Output Output

20 21

VR2/P2F pump pressure sensor GND_SIG_A

20

NC

22 23

PWR_OUT_5V_0 Key switch (ACC)

21

S_NET

22

COMM_CAN_L_0

24

NC

Input Input/ Output Input/ Output

23

COMM_CAN_L_1

24 25

PWR_CTR_EXT NC

Input Input

26 27

NC Machine select 2

Input Input

28 29

NC GND_SIG_P

Input —

30 31

NC GND (S_NET_GND)

Input —

32

COMM_CAN_H_0

33

COMM_CAN_H_1

34

GND (232C_GND)

35 36

Auto grease low level switch Fuel level switch (Low)

Input Input

37 38

Machine select 1 NC

Input Input

39 40

GND_SIG_P NC

— Input

Pin No.

Signal name

1

O/C FAN pump pressure sensor

2 3

PC2000-8

Input/ Output Input

Input — Output Input

Pin No.

Signal name

Input

— Input Output Input Input Input

Input/ Output

Input/ Output Input/ Output —

49

SEN01623-01

10 Structure, function and maintenance standard

CN3

1

PWR_IN_BATT

Input/ Output Input

2 3

PWR_IN_BRY GND_ACT

Input Input

4 5

Battery relay hold RAD FAN EPC solenoid

Output Output

6 7

P1F pump EPC solenoid Auto grease solenoid

Output Output

8 9

Auto grease caution LED NC

Output Input

10 11

NC PWR_IN_BATT

Input Input

12 13

PWR_IN_BRY GND_ACT

Input Input

14

PWR_CTR_KEY

15 16

O/C FAN EPC solenoid P1R pump EPC solenoid

Output Output

17 18

NC FAN reverse caution LED

Output Output

19 20

NC NC

Input Input

C21 22

GND_PWR PWR_CTR_BRY

Input Input

23 24

GND_ACT PWR_CTR_KEY

Input Input

25 26

RAD FAN reverse solenoid P2F pump EPC solenoid

Output Output

27 28

NC NC

Output Output

29 30

NC NC

Input Input

31 32

GND_PWR GND_PWR

Input Input

33 34

GND_PWR PWR_OUT_5V_0

Input Output

35 36

O/C FAN reverse solenoid P2R pump EPC solenoid

Output Output

37 38

NC NC

Output Output

39 40

NC NC

Input Input

Pin No.

50

Signal name

Input

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Pump controller 2

PC2000-8

51

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10 Structure, function and maintenance standard

Input and output signals CN1

CN2

1

Swing right PPC pressure sensor

Input/ Output Input

2 3

Arm dump PPC pressure sensor Auto grease pressure sensor

4 5

Pin No.

Signal name

Pin No.

Signal name

Input/ Output Output

1

NC

Input Input

2 3

Swing redundancy switch NC

Input Input

GND_SIG_D NC

— Input

4 5

232C_R x D NC

Input Input

6 7

Upper wiper proximity switch Swing left PPC pressure sensor

Input Input

6 7

NC Machine select 4

Input Input

8 9

Arm digging PPC pressure sensor Hydraulic oil temperature sensor

Input Input

8 9

Step light relay output NC

Output Output

10 11

GND_SIG_D Step light switch

— Input

10 11

NC NC

Input Output

12 13

NC Bucket dump PPC pressure sensor

Input Input

12 13

CAN shield Machine select 5

14 15

Boom down PPC pressure sensor NC

Input Input

14 15

232C T x D NC

16 17

NC Start switch (C)

Output Input

16 17

NC Machine select 3

18 19

Horn switch Bucket digging PPC pressure sensor

Input Input

18 19

NC NC

Output Output

20 21

Boom up PPC pressure sensor GND_SIG_A

Input —

20

NC

22 23

PWR_OUT_5V_0 Key switch (ACC)

21

S_NET

22

COMM_CAN_L_0

24

Ladder down signal

Input Input/ Output Input/ Output

23

COMM_CAN_L_1

24 25

PWR_CTR_EXT NC

Input Input

26 27

NC Machine select 2

Input Input

28 29

NC GND_SIG_P

Input —

30 31

NC GND (S_NET_GND)

Input —

32

COMM CAN_H_0

33

COMM CAN_H_1

34

GND (232C_GND)

35 36

Service PPC pressure switch NC

Input Input

37 38

Machine select 1 Swing lock switch

Input Input

39 40

GND_SIG_P NC

— Input

52

Output Input Input

— Input Output Input Input Input

Input/ Output

Input/ Output Input/ Output —

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

CN3

1

PWR_IN_BATT

Input/ Output Input

2 3

PWR_IN_BRY GND_ACT

Input Input

4 5

NC Travel straight valve solenoid

Output Output

6 7

Upper wiper lo output Swing parking brake valve solenoid

Output Output

8 9

Flash light relay output NC

Output Input

10 11

Upper wiper limit switch PWR_IN_BATT

Input Input

12 13

PWR_IN_BRY GND_ACT

Input Input

14

PWR_CTR_KEY

15 16

Two stage relief valve solenoid Upper wiper lo brake output

Output Output

17 18

Window washer output Travel alarm output

Output Output

19 20

NC Lower wiper limit switch

Input Input

21 22

GND_PWR PWR_IN_BRY

Input Input

23 24

GND_ACT PWR_CTR_KEY

Input Input

25 26

Bucket Hi cancel valve solenoid Lower wiper lo output

Output Output

27 28

Arm restriction L valve solenoid Variable back pressure valve solenoid

Output Output

29 30

Travel left PPC pressure switch NC

Input Input

31 32

GND_PWR GND_PWR

Input Input

33 34

GND_PWR PWR_OUT_5V_0

Input Output

35 36

Boom restriction valve solenoid Lower wiper lo brake output

Output Output

37 38

Arm restriction R valve solenoid Swing priority valve solenoid

Output Output

39 40

Travel right PPC pressure switch NC

Input Input

Pin No.

Signal name

PC2000-8

Input

53

SEN01623-01

10 Structure, function and maintenance standard

Pump emergency drive resistor

1. 2.

Resistor Connector

Specification Resistance: 30 z

54

Function q When the pump emergency drive switch is turned ON, a proper current is supplied to the pump EPC through this resistor.

PC2000-8

10 Structure, function and maintenance standard

Monitor system

q

q

SEN01623-01

1

The monitor system notifies the operator of machine status. It monitors the condition of the machine with the sensors mounted on various parts of the machine, processes and immediately displays the obtained information on the panel. Contents displayed on the panel are largely divided into the following. 1. Alarm when an abnormality occurs on the machine 2. Machine condition (Temperature of coolant and hydraulic oil, fuel level, etc.) Also, the machine monitor is provided with various mode selector switches that function as the operation unit of the machine control system.

PC2000-8

55

SEN01623-01

Machine monitor

10 Structure, function and maintenance standard

1

Outline q The machine monitor has the functions to display various items and the functions to select modes and electric parts. q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information. q The monitor display employs an LCD (Liquid Crystal Display). The switches are flat sheet switches.

56

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Input and output signals CN-CM01

CN-CM04

Input/ Pin No. Signal name output 1 Battery power (+24V constantly) Input 2 Battery power (+24V constantly) Input 3 Battery power GND — 4 Battery power GND — Input/ 5 Wake-up Output 6 Relay output Output 7 Chassis signal GND — 8 Hydraulic oil temperature Input 9 Fuel level Input 10 Coolant temperature Input 11 Charge amount Input 12 Chassis analog signal GND — 13 Light switch Input 14 Key switch (ACC) Input 15 Key switch (C) Input 16 Preheating Input 17 Power out Output 18 GND power — *: Never connect to NC or malfunctions or failures will occur.

Input/ output 1 GND — 2 DOS Output 3 GND — 4 Communication 232C Output 5 Communication 232C Input 6 NC(*) — 7 NC(*) — 8 NC(*) — 9 NC(*) — 10 NC(*) — 11 NC(*) — 12 PWR OUT Output *: Never connect to NC or malfunctions or failures will occur.

CN-CM02 Input/ output 1 Engine oil pressure sensor Input 2 Engine oil level sensor Input 3 Coolant level sensor Input 4 Air cleaner clogging sensor Input 5 Swing lock Input 6 NC(*) Input 7 Chassis signal GND — 8 CAN terminating resistance — Input/ 9 CAN_H Output Input/ 10 CAN_L Output Input/ 11 NC(*) Output Input/ 12 NC(*) Output *: Never connect to NC or malfunctions or failures will occur. Pin No.

PC2000-8

Signal name

Pin No.

Signal name

CN-CM05 Pin No.

Signal name

Input/ output

1

Electric power supply for camera

2

Camera NTSC signal input 1

Input

3

Camera NTSC signal input 2

Input

4

Camera NTSC signal input 3

Input

5

Electric power supply GND for camera

—

6

Camera signal GND1

—

7

Camera signal GND2

—

8

Camera signal GND3

—

Output

57

SEN01623-01

10 Structure, function and maintenance standard

Monitor control, display portion

1

AA (1/2): Ordinary work screen (1/2) AA (2/2): Ordinary work screen (2/2)

q

q

q

BB: Check before starting screen CC: Maintenance interval caution screen

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Engine coolant temperature monitor Engine coolant temperature gauge Hydraulic oil temperature monitor Hydraulic oil temperature gauge Fuel level monitor Fuel gauge Wiper monitor Swing lock monitor Engine pre-heating monitor Auto-greasing monitor Engine stop monitor Time/service meter Auto-deceleration monitor Working mode monitor Heavy lift monitor

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

Truck counter 1 Truck counter 2 ECO indicator PTO oil temperature monitor PTO oil temperature gauge Engine oil temperature monitor Engine oil temperature gauge Engine oil pressure monitor Engine oil pressure gauge Radiator coolant level monitor Charge level monitor Engine oil pressure monitor Engine oil level monitor Air cleaner clogging monitor Maintenance interval monitor

q

58

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Precautions on the machine monitor display q The liquid crystal display panel may have black spots (which do not light up) or bright spots (which stay on). Products having 10 or less black or bright spots conform the product specification; such the condition is quite normal. q Battery voltage may suddenly drop at enginestart due to ambient temperature or the condition of the battery. The machine monitor display may temporarily disappear if it happens; it is quite normal. q Continuous operation of the machine monitor may display blue bright spots on the screen having a black background; it is quite normal. The screen normally displayed on the monitor has a blue or white background. For this reason, blue spots will not cause any problem (since the liquid crystal lights up red, blue, and green spots when displaying white).

PC2000-8

59

SEN01623-01

10 Structure, function and maintenance standard

Monitor items and display Symbol

Display item

Swing lock

Display method Swing lock switch

Swing holding brake release switch

Display of symbol

OFF

OFF

OFF

ON

OFF

ON

OFF

ON

Flashes

ON

ON

Flashes

Automatic preheating Preheating Manual preheating

Preheater operates at low temperature and symbol keeps lighting up for up to about 30 seconds and then goes off after engine starts. Time after setting

Display of symbol

0 – 30 sec

ON

30 – 40 sec

Flashes

After 40 sec

OFF

Engine coolant temperature Hydraulic oil temperature Fuel level

See gauge display on next page.

PTO oil temperature Engine oil Pressure

60

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot be obtained due to disconnection of CAN. Gauge display: 1/2 Gauge

Engine coolant temperature (°C)

Hydraulic oil temperature (°C)

Fuel level (l)

PC2000-8

Range

Temperature or volume

Indicator

Buzzer sound

A1

105

Red

Q

A2

102

Red

A3

100

Off

A4

85

Off

A5

60

Off

A6

30

White

B1

103

Red

B2

100

Red

B3

97

Off

B4

85

Off

B5

40

Off

B6

20

White

C1

2,800

Off

C2

2,100

Off

C3

1,250

Off

C4

700

Off

C5

500

Off

C6

250

Red

61

SEN01623-01

10 Structure, function and maintenance standard

Gauge display: 2/2 Gauge

PTO oil temperature (°C)

Engine oil temperature (°C)

Engine oil pressure (kg/cm2)

62

Range

Temperature or volume

Indicator

Buzzer sound

D1

125

Red

Q

D2

122

Red

D3

120

Off

D4

100

Off

D5

50

Off

D6

0

White

E1

125

Red

E2

122

Red

E3

120

Off

E4

100

Off

E5

50

Off

E6

0

White

F1

7

Off

F2

6

Off

F3

4

Off

F4

2

Off

F5

0.6

Off

F6

0.2

Red

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Checks before starting (all symbols light up), when maintenance interval is exceeded. If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature gauge and the hydraulic oil temperature monitor disappear and the following symbols are displayed. Display item

Check before starting item

While engine is stopped

While engine is running

Engine oil pressure

q

—

Lights up and buzzer sounds when abnormal.

Battery charge

q

—

Lights up when abnormal.

Radiator coolant level

q

Lights up when abnormal.

Lights up and buzzer sounds when abnormal.

Engine oil level

q

Lights up when abnormal.

—

Air cleaner clogging

q

—

Lights up when abnormal.

Symbol

Notice lamp (yellow)/Warning lamp (red). Lights up for only 30 seconds after starting switch is turned ON.

Maintenance

Symbols appear in the order in which they occur from the upper left. When symbols are displayed, if the hydraulic oil temperature is high or low, only its symbol is displayed. Condition of hydraulic oil

Color of symbol

Low temperature (below B6 or equivalent)

Black on white background

Normal (B6 – B2)

No display

High temperature (above B2)

White on red background

PC2000-8

63

SEN01623-01

10 Structure, function and maintenance standard

Items other than work check items Caution

Check component

Symbol

Method of notifying operator

Condition for occurrence Item

Sub item

Connection of sensor

Condition for reset

Monitor analog input

Normal Fuel level gauge display 1 While engine judgment is stopped Abnormal Fuel level gauge display 0 judgment Fuel level Monitor reduction

Change of Normal Same as while engine is symbol color While engine judgment stopped (Blue o Red) is operated Abnormal judgment

Above fuel level gauge display 1

Moving average of values input at intervals of 500 msec is obtained.

Filter time Remarks Connection of sensor

Engine controller

Normal Temperature equivalent to While engine judgment 102°C or below is stopped Abnormal Temperature equivalent to judgment 102°C or above

Engine coolant overheat

Engine controller

Change of symbol color (Blue o Red) When above While engine 105°C, buzzer is operated sounds intermittently. Filter time

Same as while engine is Normal judgment running Abnormal judgment

As per logic in engine controller

As per logic in pump controller

Remarks

Alarm is masked in 100 sec after engine is started.

Connection of sensor

Engine controller

Normal Temperature equivalent to While engine judgment 102°C or below is stopped Abnormal Temperature equivalent to judgment 102°C or above

Hydraulic oil overheat

Autogrease system abnormality

64

Pump controller

Change of symbol color (Blue o Red) When above While engine 105°C, buzzer is operated sounds intermittently. Filter time

Normal Same as while engine is judgment running Abnormal judgment As per logic in pump controller

Remarks

Alarm is masked in 100 sec after engine is started.

Connection of sensor

Pump controller

Normal As per logic in pump conWhile engine judgment troller is stopped Abnormal As per logic in pump conjudgment troller Display of symbol

As per logic in engine controller

Normal As per logic in pump conWhile engine judgment troller is operated Abnormal As per logic in pump conjudgment troller Filter time

As per logic in pump controller

Remarks

Obtained by RTCDB2

As per logic in pump controller

PC2000-8

10 Structure, function and maintenance standard

Caution

Check component

Symbol

Method of notifying operator

SEN01623-01

Condition for occurrence Item

Connection of sensor

Hydraulic oil level reduction

Display of symbol

Condition for reset

Sub item VHMS ON/OFF input

Normal While engine judgment is stopped Abnormal judgment

Other than conditions shown at left

Normal When sensor contact is While engine judgment closed is operated Abnormal When sensor contact is judgment open Filter time

3 sec

Remarks Connection of sensor

VHMS ON/OFF input

Normal When sensor contact is While engine judgment closed is stopped Abnormal When sensor contact is judgment open Hydraulic oil filter clogging

Display of symbol

Check before starting

Normal While engine judgment is operated Abnormal judgment

Other than conditions shown at left

Filter time

10 sec

Remarks

Detected only when hydraulic oil temperature is above 25°C Obtained by RPC

Screen page 1/2 Gauge

Monitor

Engine coolant temperature

q

q

Hydraulic oil temperature

q

q

Fuel level

q

q

2/2 Caution

Gauge

Monitor

Caution q

a

q q

PTO oil temperature

q

q

q

Engine oil temperature

q

q

q

q

q

a

Engine oil pressure

q

q

Charge level

q

q

q

Radiator coolant level

q

q

q

Engine oil level

q

q

q

Air cleaner clogging

q

q

q

Auto-grease system abnormality

q

q

Hydraulic oil level

q

q

Hydraulic oil filter clogging

q

q

Maintenance

q

q

a: If another caution is displayed, these items are displayed only when abnormal.

PC2000-8

65

SEN01623-01

Display category

10 Structure, function and maintenance standard

Symbol

Display item

Display range

Windshield wiper

Setting condition is displayed.

Working mode

Auto-deceleration

Heavy lift

P, E

Setting mode is displayed.

Operation

ON

Reset

OFF

Monitor Auto-low idle

Truck counter

Stop

Display of autogrease low level

Alarm

Auto-greasing

Operation

ECO indicator

ECO indicator

Service meter

Service meter indicator

Clock

66

Operation

Engine stop indicator

Truck counter 1 Truck counter 2

Clock

Display method

Reset

Operating condition is displayed. (Auto-deceleration or auto-low idle is selected on user mode menu)

Setting condition is displayed.

Operating condition is displayed. (Auto-deceleration or auto-low idle is selected on user mode menu)

Operation

Displayed when engine stop is judged

Normal

Displayed when grease level is low

Stop

Displayed during auto-greasing

0 – 99

Green: Work load is light – medium. Orange: Work load is heavy.

While service meter is operating

12-hour display 24-hour display

Number of counts

Average of load in 1 minute is displayed in 10 levels. (Not displayed if ECO display is turned “OFF” in service menu.) Operating time is displayed. (If F4 is pressed, clock is displayed instead.) Clock is displayed. (If F4 is pressed, service meter is displayed instead.)

PC2000-8

10 Structure, function and maintenance standard

PC2000-8

SEN01623-01

67

SEN01623-01

Switches

1. 2. 3. 4. 5. 6. 7. 8.

Buzzer cancel switch Auto-deceleration switch/auto low idle switch Guidance icon Function switch Working mode selector switch Heavy lift switch Window washer switch Wiper switch

10 Structure, function and maintenance standard

1

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. Auto-deceleration switch/auto low idle switch This switch toggles the auto-deceleration or auto low idle function on and off. When the working mode is switched, it is automatically set to ON. When it is set to ON, the auto-deceleration monitor appears.

68

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Guidance icon and function switch The function switches differ depending on the screen display. Each guidance icon shows the function of the switch below it. Switches with no guidance icon are disabled. The functions shown by the guidance icons are as shown in the table below. Symbol

Switch

Function

F6

Enter

Enters selected/set item.

F5

Return

Returns to previous screen.

F4

Select service meter/clock

Selects service meter and clock alternately.

F5

Select maintenance screen

Selects maintenance screen.

F6

Select user mode screen

Selects user mode screen.

F3

Select item

Selects item on left side (Selects right end item after left end item).

F4

Select item

Selects item on right side (Selects left end item after right end item).

F3

Select item

Selects item on lower side (Selects top item after bottom item)/Resets holding of monitoring.

F4

Select item

Selects item on upper side (Selects bottom item after top item)/Holds monitoring.

F1

Select item

Selects page on lower side (Selects top page after bottom page).

F2

Select item

Selects page on upper side (Selects bottom page after top page).

F1

Display No. 1 camera screen

Selects No. 1 camera screen.

F2

Display No. 2 camera screen

Selects No. 2 camera screen.

F3

Display No. 3 camera screen

Selects No. 3 camera screen.

F4

Display No. 1 and No. 2 camera screens

Displays No. 1 and No. 2 camera screens simultaneously.

F1

Ordinary work screen select

Selects (1/2) or (2/2) screen.

F2

Return to default setting

Returns selected item to default setting. (Used for adjustment of screen.)

F1

Start

Starts operation. (Used to start measurement of split fuel consumption on fuel consumption display screen.)

F1

Stop

Stops operation. (Used to stop measurement of split fuel consumption on fuel consumption display screen.)

F1/F2

Clear

Clears selected/displayed item

Set

Executes setting.

F1

PC2000-8

Item

69

SEN01623-01

10 Structure, function and maintenance standard

Working mode selector switch Pressing working mode selector switch switches among working modes. Check the working mode on the working mode monitor.

Camera screen display function q

q

q

1

For an optional-camera-equipped machine, pressing the F3 on the normal screen switches to the camera image. For a machine with no camera equipped, the guidance icon for switching to the camera screen does not appear; even if you press the switch, the screen does not switch to the camera image. Up to three cameras are mountable.

Window washer switch While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts. Wiper switch Each time you press the wiper switch, the wiper settings switch as follows. OFF o INT o ON (upper, lower) o ON (UPPER) o OFF o …. The wiper operation setting is confirmable on the wiper monitor. The relationship between the wiper setting and the monitor display is shown in the table below. Setting

Display

Wiper actuation status

OFF

None

Stowing stopped or now stowing

F1 : F2 : F3 : F4 :

Displays the image of No. 1 camera full-screen. Displays the image of No. 2 camera full-screen. Displays the image of No. 3 camera full-screen. Displays the images of No. 1 and No. 2 cameras at the same time. F5 : Returns to the normal screen. q

q q

INT

Intermittent actuation

ON (LOWER)

Upper, lower wiper continuous actuation

ON (UPPER)

Upper wiper continuous actuation

70

q

q

Even when the camera screen is displayed, the working mode selector switch, heavy lift switch, auto-deceleration switch, buzzer cancel switch, wiper switch, and window washer switch are enabled. Changing the working mode returns to the normal screen. If an abnormality corresponding to an alarm item with the camera screen displayed, the alarm monitor appears on the upper left of the screen. If it appears, return to the normal screen with F5 to check the alarm display. If an abnormality corresponding to an error item with the camera screen displayed, the error monitor appears on the upper left of the screen. If it appears, you must move the machine to safe posture immediately and make inspections. If you do not operate the lever at least 10 sec. after the error monitor starts to blink, the screen switches to the normal screen.

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Service meter/time selector function q

PC2000-8

1

Pressing F4 on the normal screen when the service meter is displayed in the top center of the screen switches the display to the time, and doing so when the time is displayed switches the display to the service meter.

71

SEN01623-01

Maintenance function q

10 Structure, function and maintenance standard

1

q

Pressing F5 on the normal screen switches to the maintenance screen. q

If the remaining time on the maintenance table screen is less than 30 hours, the relevant items are highlighted in yellow, and if 0 hours, they are done in red. On the maintenance time reset screen, reset the remaining time for the selected item to return to the default.

F5 : Cancels the reset to return to the maintenance table screen. F6 : Resets the remaining time to return to the normal screen. No operation at least 30 sec. : Returns to the normal screen. q

F1 : Displays the next page. Displays the top page when the last page is displayed. F2 : Displays the previous page. Displays the last page when the top page is displayed. F3 : Selects (highlights) an item one down. F4 : Selects (highlights) an item one up. F5 : Returns to the normal screen. F6 : Switches to the maintenance time reset screen. No operation at least 30 sec. : Returns to the normal screen.

72

No. 01 02 03 41 04 05 06 07 08 09 10 30 31 —

The table below shows the maintenance items and replacement intervals. The time remaining to maintenance is reduced as the machine is operated. Item Engine oil Engine oil filter Fuel main filter Fuel prefilter Hydraulic filter Hydraulic tank breather Corrosion resistor PTO case oil Final case oil Machinery case oil Hydraulic oil Hydraulic oil pilot filter Hydraulic oil drain filter Oil cooler accumulator

Replacement interval (Hours) 500 500 1000 500 1000 1000 1000 1000 2000 1000 5000 500 500 4000

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

The content of the caution display differs according to the remaining time. The relationship is as shown in the table below.

q

Display None Notice display (black symbol displayed on yellow background) Warning display (white symbol displayed on red background)

Condition Remaining time for maintenance for all items is more than 30 hours. There is one or more items with less than 30-hour remaining time for maintenance. There is one or more items with less than 0-hour remaining time for maintenance.

q

You can lock the maintenance time by a password to prevent it from carelessly being reset.

q

The default password is “000000”. For information on changing the maintenance pa ss wo rd , se e “M ai nte nan c e pas sw or d change function” in the Testing and adjusting section.

a

PC2000-8

73

SEN01623-01

User mode q q

F3 : F4 : F5 : F6 :

10 Structure, function and maintenance standard

1

Pressing F6 on the normal screen enters the user mode, switching to the user menu screen. In user mode, you can specify items relating to the machine monitor and machine shown below. Screen adjustment ECO display selection Time adjustment Language setting Economy mode adjustment Auto-low idle setting Truck counter correction/clearing Hydraulic fan reverse setting

Selects (highlights) an item one down. Selects (highlights) an item one up. Returns to the normal screen. Switches to the setting screen for the selected item. No operation at least 30 sec. : Returns to the normal screen. (In user mode, no switch operation at least 30 sec. returns to the previous screen.)

Screen adjustment q

q

q q

F2 : Returns all adjusted values to the defaults. F3 : Decreases the value indicated by the indicator one graduation left. F4 : Increases the value indicated by the indicator one graduation right. F5 : Cancels changes you made before confirming them with F6 to return to the menu screen. F6 : Confirms the changes and moves to the next item. q

q

74

Selecting the “Screen adjustment” from the user menu and pressing F6 switches to the screen adjustment screen. From this menu, you can adjust the brightness, contrast, and luminance of the machine monitor screen. When the light switch is in Night mode ON, the night mode screen is adjustable. When the light switch is in Daytime mode ON or OFF, the daytime mode screen is adjustable.

For a camera-equipped machine, the brightness, contrast, and illuminance of the camera screen are also adjustable. For a camera-equipped machine, selecting Sc reen adjustme nt from the us er me nu switches to the screen for selecting a screen you want to adjust.

PC2000-8

10 Structure, function and maintenance standard

F3 : Selects (highlights) an item one down. F4 : Selects (highlights) an item one up. F5 : Cancels changes you made before confirming them with F6 to return to the menu screen. F6 : Moves to the setup items of the selected (highlighted) item. q q

SEN01623-01

Clock adjustment q

q

Selecting the “Clock adjustment” from the user menu and pressing F6 switches to the clock adjustment screen. On this screen, you can change the setting of the time displayed on the normal screen.

The adjustment methods for the camera screen and normal screen are the same. The background when adjusting the camera screen is the No. 1 camera image.

1)

Time setting Set the clock time. If the time setting item is not highlighted, press F6 to highlight it. The time display part is highlighted. F3 : Advances the clock one hour. F4 : Sets the clock back one hour. F5 : Cancels changes you made before confirming them with F6 to return to the user menu. F6 : Confirms the changes and moves to minute setting.

F3 : Selects (highlights) an item one down. F4 : Selects (highlights) an item one up. F5 : Cancels changes you made before confirming them with F6 to return to the menu screen. F6 : Moves to the setup items of the selected (highlighted) item.

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

PC2000-8

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

75

SEN01623-01

3)

Summer time Selecting ON for this sets the time forward one hour. Setting OFF returns to the ordinary time. F3 : Moves to the item one right. F4 : Moves to the item one left. F5 : Cancels changes you made before confirming them with F6 to return to the user menu screen. F6 : Confirms the changes and moves to the time setting. a

10 Structure, function and maintenance standard

Economy mode adjustment q

q q

Selecting the “Economy mode adjustment” from the user menu and pressing F6 switches to the Economy mode setting screen. From this menu, you can adjust engine output to improve fuel consumption in E mode. The fuel consumption level is specified to one of two levels from E0 to E1. The larger the value, the better the fuel consumption, but the smaller the work rate.

Summer time (daylight saving time) is a system to lead a life according to the one-hour advanced time in order to make efficient use of daylight time.

Language setting q

q

F3 : F4 : F5 : F6 :

76

Selecting the “Language” from the user menu screen and pressing F6 switches to the language setting screen. From this menu, you can change the language to be displayed on the monitor. Available languages are as follows. English, Japanese, Chinese, French, Spanish, Portuguese, German, Russian, and Indonesian

F3 : F4 : F5 : F6 :

Selects (highlights) an item one down. Selects (highlights) an item one up. Cancels the changes to return to the user menu. Confirms the changes to return to the user menu.

Selects (highlights) an item one down. Selects (highlights) an item one up. Cancels the changes to return to the user menu. Confirms the changes to return to the user menu.

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

ECO display selection

q

q

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

Auto-low idle setting

q

q

Select “Auto-low idle setting” on the user menu screen and press F6, and the screen changes to the Auto-low idle setting screen. In this menu, you can select the auto-deceleration speed or low idle speed to be set when the auto-deceleration switch is pressed. ON : Low idle speed OFF: Auto-deceleration speed

PC2000-8

77

SEN01623-01

Truck counter correction/clearing

78

10 Structure, function and maintenance standard

Select “Correct/Clear truck counter” on the user menu screen and press F6, and the screen changes to the “Correct/Clear truck counter screen”. q In this menu, you can correct/clear all the truck counter values at a time or one by one. q The contents of the menu are as follows from the top. A. Correct/Clear truck counter 1 B. Correct/Clear truck counter 2 C. Clear truck counters 1 and 2 On screen A or B, the counter value is increased or decreased by 1 in the range between 0 and 99 each time the F3 or F4 switch is pressed. The currently adjusted value is displayed in the box on the right side and entered by pressing F6. If F5 is pressed, the screen is finished without entering the currently adjusted value. If F1 is pressed, the counter value is cleared. On screen C, if F6 is pressed, the values of both truck counters 1 and 2 are cleared to 0. If F5 is pressed, the screen is finished without clearing the counter values. q

PC2000-8

10 Structure, function and maintenance standard

Hydraulic fan reverse setting q

q

q

q

Select “Reverse hydraulic fans” on the user menu screen and press F6, and the screen changes to the screen to reverse the hydraulic fans. The hydraulic fans (2 units) can be reversed by operating according to the guidance shown on the screen. The user menu screen changes to screen A shown below.

SEN01623-01

q q

While this screen is displayed, the fans are rotating in the normal direction. If F6 is pressed, the fans are reversed and the screen changes to screen B.

q

q

q

While the fans are rotating in reverse, the screen shown below is displayed. To return the hydraulic fans to the normal direction, press F5 and change the screen to screen D.

To carry out the operation to return the hydraulic fans to the normal direction, press F6, and the screen changes to screen E. If F5 is pressed or no switch is operated for 5 seconds, the screen returns to screen C.

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

q

PC2000-8

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

79

SEN01623-01

q

q

If the engine coolant temperature is above 80°C and the hydraulic oil temperature is below 20°C or above 85°C, the screen shown below is displayed. In this case, the hydraulic fans cannot be reversed. If F5 is pressed, the screen changes to the user screen.

10 Structure, function and maintenance standard

Idle stop guidance function This function displays guidance to control unnecessary fuel consumption. It is displayed only when all the following conditions are met. q “Energy saving guidance display” of the service menu is specified to ON. q No operation is made at least 5 min. and the engine is running at idle. q No error or caution (excluding low hydraulic oil temperature) is occurring.

This screen switches to the normal screen if one of the following conditions occurs. q When the lever is operated q When F5 is pressed q When an error or caution occurs When you switch to the normal screen by pressing F5, this screen does not appear even if the engine continues to run at idle. If the engine continues to run at least 5 min. after operating the lever, this screen appears again.

80

PC2000-8

10 Structure, function and maintenance standard

Service meter check function q

1

If you continuously press auto-deceleration switch (1) and buzzer cancel switch (2) at the same time when setting the starting switch to the OFF position, the service meter will appear on the screen in 3 to 5 sec.

SEN01623-01

Display LCD check function q

q

q

a

1

Continuously pressing the buzzer cancel switch (1) and F2 at the same time on the normal screen causes the entire LCD to light in white. Release F2 and buzzer cancel switch in order. The liquid crystal display panel may have black spots (which do not light up) or bright spots (which stay on). Products having 10 or less black or bright spots conform the product specification; such the condition is quite normal.

When these switches are released, the LCD goes out. Continuous operation of the machine monitor may display blue bright spots on this screen; it is quite normal. q

PC2000-8

Pressing any function switch returns to the previous screen.

81

SEN01623-01

User code/failure code display function 1 q

q q

q

82

If there is any problem in machine operation, the user code and failure code are displayed on the monitor to advise the operator of the steps to take. These codes appear on the normal screen. On the normal screen, user code (1) and failure code (2) are displayed on the portion for the hydraulic oil temperature gauge.

10 Structure, function and maintenance standard

q

If the telephone number has been set in the service menu, the screen shows the telephone symbol and telephone number simultaneously with the user code/failure code. (For information on how to input and set the telephone number, see “Special functions of machine monitor” in the Testing and adjusting section.)

If multiple user codes or failure codes are issued, they are displayed alternately every 2 sec. The drawing below shows the case two types of user codes and failure codes are displayed.

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Sensor

1

The signals from the sensors are input to the engine controller, pump controller, machine monitor, and VHMS controller. The contact type sensors are always connected at one end to the chassis GND.

q q

Name of sensor

Type of sensor

Fuel level Coolant level

When normal

When abnormal

Input controller

Resistance

—

—

Monitor

Contact

ON (closed)

OFF (open)

Monitor

Air cleaner clogging

Contact

OFF (open)

ON (closed)

Monitor

Engine oil level

Contact

ON (closed)

OFF (open)

Monitor

Fuel level (low, mid, high)

Contact

—

—

Pump controller 1

Main pump pressure Fan pump pressure

Analog

—

—

Pump controller 1 Pump controller 1

Jet sensor differential pressure

Analog

—

—

Resistance

—

—

Pump controller 2

Travel PPC pressure switch

Contact

—

—

Pump controller 2

Work equipment PPC pressure sensor

Analog

—

—

Pump controller 2

Hydraulic oil temperature

Auto-greasing pressure

Analog

—

—

Pump controller 2

Hydraulic filter clogging

Contact

ON (open)

OFF (closed)

VHMS controller

Hydraulic oil level

Contact

ON (closed)

OFF (open)

VHMS controller

Resistance

—

—

VHMS controller

PTO oil temperature

Resistance

—

—

VHMS controller

Ambient temperature

Resistance

—

—

VHMS controller

Blowby temperature

Resistance

—

—

VHMS controller

Exhaust temperature

Analog

—

—

VHMS controller

Exhaust temperature sensor AMP

Analog

—

—

VHMS controller

VHMS hydraulic oil temperature

Coolant level sensor

1.

Reservoir tank

PC2000-8

2.

sensor

3.

Connector

83

SEN01623-01

10 Structure, function and maintenance standard

Detail of sensor

1. 2. 3. 4. 5.

Float Sensor Tube Wire Connector

Fuel level sensor

1. 2. 3. 4.

84

Float Switch Connector Variable resistor

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Air cleaner clogging sensor

Engine oil level sensor

1. 2. 3. 4. 5.

Float Sensor Tube Wire Connector

Fuel level (low, mid, high) sensor

1. 2. 3. 4. 5.

Float Sensor Tube Wire Connector

PC2000-8

85

SEN01623-01

10 Structure, function and maintenance standard

Main pump oil pressure sensor

1. 2.

Sensor Connector

Operation q The oil pressure applied from the pressure intake part presses the diaphragm of the oil pressure sensor, the diaphragm is deformed. q The gauge layer facing the diaphragm 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).

86

q

Relationship between pressure (P) and output voltage (E) is as follows.

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Hydraulic oil temperature sensor, PTO oil temperature sensor

1. 2.

Thermistor Tube

3. 4.

Wire Body

5. 6.

Tube Connector

Grease pump discharge pressure sensor

1. 2.

Sensor Connector

Hydraulic filter clogging sensor

1. 2. 3. 4.

Block Sensor Wire Connector

PC2000-8

87

SEN01623-01

10 Structure, function and maintenance standard

Boom, arm, bucket, swing PPC oil pressure sensor

1. 2.

Sensor Connector

Function q The PPC oil pressure sensor is installed to 6 places of the junction block. q This sensor senses the operating condition of each actuator by the PPC pressure and sends it to the pump controller.

q

Relationship between pressure (P) and output voltage (E) is as follows.

Operation q The oil pressure applied from the pressure intake part presses the diaphragm of the oil pressure sensor, the diaphragm is deformed. q The gauge layer facing the diaphragm 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).

88

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Hydraulic oil level sensor

1. 2. 3. 4. 5.

Float Sensor Tube Wire Connector

VHMS hydraulic oil temperature sensor, Ambient temperature sensor

1. 2.

Thermistor Tube

PC2000-8

3. 4.

Wire Body

5. 6.

Tube Connector

89

SEN01623-01

10 Structure, function and maintenance standard

Engine blow-by pressure sensor

1. 2. 3.

Sensor Connector Ambient pressure intake tube

A: B: C:

GND (Black) Power source (Red) Output (White)

90

Specifications and function q Pressure range: 0 – 20 kPa {0 – 2,040 mmH2O} q Pressure limit: –20 – 100 kPa {–2,040 – 10,200 mmH2O} q Power supply voltage: 5 ± 0.25 V q Output characteristics: See graph. q The blow-by pressure sensor is a relative pressure sensor of low pressure type, which measures the difference between the pressure in the crankcase and ambient pressure. q The pressure in the crankcase is applied to the end side of the sensor and the ambient pressure is applied to the wiring harness side.

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Exhaust temperature sensor

Exhaust temperature sensor amplifier

Travel PPC pressure switch

PC2000-8

91

SEN01623-01

10 Structure, function and maintenance standard

VHMS controller

92

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

Location of pins CN1

CN2

Pin No.

Signal name

Input/Output

Pin No.

Signal name

Input/Output

1

NC

—

A1

NC

2

PWR_OUT_24V

Output

A2

AIS_PTO. OIL TMP. SENS

3

PWR_OUT_12V

Output

A3

NC

4

NC

—

A4

AIS_ALTR_VOLT_VHMS

Input

5

PWR_OUT_5V

Output

A5

AIS_EX. GAS. TMP. SENS. LBR

Input

6

PWR_IN_BATT

Input

A6

AIS_EX. GAS. TMP. SENS. RBR

Input

7

PWR_IN_BATT

Input

A7

AIS_EX. GAS. TMP. SENS. RBF

Input

8

PWR_IN_BRY

Input

A8

NC

Input

A9

DIS_SEL0 (GND)

Input

—

A10

AIS_AIR. TMP. SENS

Input Input

9

PWR_IN_BRY

10

NC

11

GND_PWR

—

A11

AIS_HYD_OIL_LOW_TMP. SENS

12

GND_PWR

—

A12

GND_SIG

13

NC

14

DOS_DUMP_COUNT_BUZZER

15 16 17

PWR_CTR_KEY

18

NC

19 20

— Input —

—

—

—

A13

GND_SIG

—

Output

A14

NC

—

NC

—

A15

AIS_FUEL_REMAIN. SENS

Input

NC

—

A16

AIS_EX. GAS. TMP. SENS. LBF

Input

Input

A17

*DIS_WUL

Input

—

A18

AIS_BLOWBY. PRES. SENS

Input

GND_PWR

—

B1

AIS_HYD_FILTER_CLOG. SENS

Input

GND_PWR

—

B2

AIS_HYD_OIL_LEVEL. SENS

Input

B3

NC

—

B4

NC

—

B5

NC

B6

DIS_WUH (GND)

B7

NC

—

B8

NC

—

— Input

B9

GND_SIG

—

B10

NC

—

B11

NC

B12

DIS_SEL1 (GND)

— Input

NC: Not connected

PC2000-8

93

SEN01623-01

10 Structure, function and maintenance standard

CN3

CN4

Pin No.

Signal name

A1

NC

A2

DIS_CAB. OUT. DL. SW

A3

NC

A4

NC

A5

DIS_ORB

A6 A7 A8

NC

A9

DIS_SEL2 (OPEN)

A10 A11 A12 A13

Input/Output

Pin No.

—

A1

NC

Signal name

—

Input

A2

NC

—

—

A3

NC

—

—

A4

COMM_CAN_H_1 (KOMNET)

Input

A5

NC

NC

—

A6

COMM_CAN_H_0 (MMS)

NC

—

A7

NC

Input/Output

Input/Output — Input/Output —

—

A8

NC

—

Input

A9

GND_COMM

—

Truck_COUNT_SW1

Input

A10

COMM_232C_RXD_0 (PC Tool)

Input

Truck_COUNT_SW2

Input

A11

COMM_232C_TXD_0 (PC Tool)

Output

NC

—

A12

COMM_CAN_L_1 (KOMNET)

GND_SIG

—

A13

NC

A14

NC

—

A14

COMM_CAN_L_0 (MMS)

A15

NC

—

B1

NC

—

A16

NC

—

B2

NC

—

A17

GND_SIG

—

B3

GND_COMM (Orbcomm)

—

A18

NC

—

B4

COMM_232C_TXD_1 (Orbcomm)

B1

NC

—

B5

NC

—

B2

NC

—

B6

NC

—

B3

NC

—

B7

NC

—

B4

NC

—

B8

NC

—

B5

NC

—

B9

GND_COMM (Orbcomm)

—

B6

NC

—

B10

COMM_232C_RXD_1 (Orbcomm)

B7

NC

—

B8

NC

—

B9

GND_SIG

—

B10

NC

—

B11

NC

—

B12

DIS_SEL3 (OPEN)

94

Input/Output — Input/Output

Output

Input

NC: Not connected

Input

PC2000-8

10 Structure, function and maintenance standard

SEN01623-01

ORBCOMM terminal

1. 2.

1

Communication antenna connection DRC connector (40-pole) connection

Outline q The ORBCOMM terminal obtains various kinds of machine information recorded in the VHMS controller and transmits them via the wireless communication antenna. It has a CPU (Central Processing Unit) and wireless communication function. q This terminal has an LED lamp and a 7-segment display lamp used for inspection and troubleshooting. Input/Output signals q

DRC connector Pin No.

Signal name

Input/Output

Pin No.

Signal name

Input/Output

1 2

NC

Input

15

NC

Output

NC

Output

16

NC

3

Input

NC

Input

17

NC

Input

4

Communication signal 232C_TxD

Input

18

NC

Output

5

Communication signal 232C_RxD

Output

19

VHMS controller signal

Output

6

NC

—

20

NC

Output

7

NC

Input/Output

21

NC

Input

8

NC

Input/Output

22

NC

Input

9

NC

—

23

NC

Input

10

NC

Input/Output

24

NC

Input

11

GND_232C

—

25

NC

Input

12

NC

Input

26

NC

Input

13

NC

Input

27

NC

Input

14

NC

Output

28

NC

Input

29

GND

—

30

NC

Output

31

NC

Input

32

NC

Input

33

NC

Input

34

NC

Input

35

NC

Output

36

ACC input (analog)

Input

37

Power supply GND

—

38

Power supply GND

—

39

Unswitched power supply (12/24 V)

Input

40

Unswitched power supply (12/24 V)

Input

PC2000-8

95

SEN01623-01

PC2000-8 Hydraulic excavator Form No. SEN01623-01

© 2007 KOMATSU All Rights Reserved Printed in Japan 05-07 (01)

96

SEN02006-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

20 Standard value table

1

Standard service value table Standard service value table ........................................................................................................................... 2 Standard service value table for testing, adjusting, and troubleshooting ............................................. 2 Standard service value table for chassis .............................................................................................. 3

PC2000-8

1

SEN02006-00

20 Standard value table

Standard service value table

1

Air intake and exhaust system

Performance

Category

Standard service value table for testing, adjusting, and troubleshooting1

Body Lubrication system

a

2

PC2000-8

Engine

SAA12V140E-3

Unit

Standard value for new machine

Service limit value

Max. speed at no load

rpm

1,980 ± 50

1,980 ± 50

Min. speed at no load

rpm

825 ± 50

825 ± 50

Rated speed

rpm

1,800

1,800

At 0°C (without starting aid)

rpm

Min. 110

—

At –20°C (with starting aid)

rpm

Min. 100

—

kPa {mmHg}

Min. 125.70 {Min. 950}

—

°C

Max. 700

750

At sudden acceleration (Low to High)

Bosch index

Max. 4.5

5.5

At rated output

Bosch index

Max. 1.0

2.0

At high idle

Bosch index

Max. 1.0

2.0

Intake valve

mm

0.35 ± 0.02

0.35 ± 0.02

Exhaust valve

mm

0.57 ± 0.02

0.57 ± 0.02

Item

Speed

Necessary speed for starting

Measurement conditions

Air boost pressure

At rated output

Exhaust temperature

Whole speed range (20°C)

Exhaust gas color

Valve clearance

—

Applicable model

Compression pressure

Engine oil temperature: 40 – 60°C Engine speed: 200 – 250 rpm

MPa {kg/cm2}

Min. 4.1 {Min. 42}

2.8 {29}

Blow-by pressure

At rated output Engine coolant temperature: Min. 70°C

kPa {mmH2O}

Max. 2.94 {Max. 300}

5.88 {600}

MPa {kg/cm2}

0.29 – 0.44 {3.0 – 4.5}

0.2 {2.0}

Oil pressure

SAE0W30E0S At rated output Engine oil temperature: Min. 80°C SAE5W40E0S SAE10W30DH At low idle SAE15W40DH Engine oil temperature: Min. 80°C SAE30DH

MPa {kg/cm2}

Min. 0.08 {Min. 0.8}

0.06 {0.6}

Oil temperature

Whole speed range (Oil in oil pan)

°C

90 – 110

120

Alternator belt tension

Deflection under finger pressure of 59 N {6 kg}

mm

20

20

The above values are calculated when the engine is installed in the chassis.

PC2000-8

20 Standard value table

SEN02006-00

Standard service value table for chassis

1

Travel of control levers

Spool stroke of control valves

Engine speed

Category

Applicable model

Item

PC2000-8

Measurement conditions

All pumps at relief

• Engine coolant temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C • Engine at high idle • Working mode: P • Boom up relief

Heavy lift ON + All pumps at relief

• Engine coolant temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C • Engine at high idle • Working mode: P & heavy lift • Boom up relief

Auto-deceleration actuated

• Engine at high idle • Auto-deceleration switch ON • All control levers at neutral

Boom Lo control valve Boom Hi control valve

Unit

Standard value for new machine

Service limit value

1,780 ± 100

1,780 ± 100

1,780 ± 100

1,780 ± 100

1,400 ± 100

1,400 ± 100

16 ± 0.5

16 ± 0.5

85 ± 10

85 ± 10

rpm

• Engine stopped • Stroke (a) or (b) side

Arm Lo control valve Arm Hi control valve Bucket Lo control valve Bucket Hi control valve Swing control valve Travel control valve Boom control lever

N o Raise, Lower

Arm control lever

N o In, Out

85 ± 10

85 ± 10

N o Curl, Dump

85 ± 10

85 ± 10

N o R.H., L.H.

85 ± 10

85 ± 10

Travel control lever

N o F, R (L.H., R.H.)

115 ± 12

115 ± 12

Play of control levers

Work equipment, swing, travel

Max. 10

Max. 15

Bucket control lever Swing control lever

PC2000-8

• Center of lever knob • Read max. value to end of travel (Exclude play at neutral.) • Engine stopped

mm

3

SEN02006-00

20 Standard value table

Category

Applicable model

Item

PC2000-8 Standard value for new machine

Service limit value

15.7 ± 4.9 {1.6 ± 0.5}

15.7 ± 4.9 {1.6 ± 0.5}

15.7 ± 4.9 {1.6 ± 0.5}

15.7 ± 4.9 {1.6 ± 0.5}

12.7 ± 3.9 {1.3 ± 0.4}

12.7 ± 3.9 {1.3 ± 0.4}

12.7 ± 3.9 {1.3 ± 0.4}

12.7 ± 3.9 {1.3 ± 0.4}

Lever

21.6 ± 5.4 {2.2 ± 0.6}

21.6 ± 5.4 {2.2 ± 0.6}

Pedal

98.1 ± 25.4 {10 ± 2.5}

98.1 ± 25.4 {10 ± 2.5}

Normal

29.4 ± 1.0 {300 ± 10}

29.4

Measurement conditions

Unit

Arm control lever Bucket control lever

• • • •

Hydraulic oil temperature: 45 – 55°C Engine at high idle Center of lever knob Measure max. value to end of travel N {kg}

Swing control lever

Travel control lever, pedal

RAISE

Operating effort of control levers

Boom control lever

Hydraulic pressure

Arm relief pressure

• Hydraulic oil temperature: 45 – 55°C • Engine at high idle • Working mode: P • Pump outlet pressure when measured circuit is relieved • Relieve either travel circuit.

LOWER

Boom relief pressure

Pump EPC solenoid valve output pressure

Normal

14.7 ± 2.0 {150 ± 20}

14.7 ± 2.0 {150 ± 20}

At machine push-up

28.4 ± 2.0 {290 ± 20}

28.4 ± 2.0 {290 ± 2.0}

29.4 ± 1.0 {300 ± 10}

29.4

MPa {kg/cm2}

29.4 ± 1.0 {300 ± 10} 29.4 ± 1.0 {300 ± 10}

Relieve L. H. travel: L1/L2 (P1R/ P2R) Relieve R. H. travel: R1/R2 (P1F/ P2F) • Hydraulic oil temperature: 45 – 55°C • Engine at high idle All control levers at neu• Hydraulic oil temperature: 45 – 55°C tral • Engine at high idle Travel under no • Working mode: P load (Lever full) (P1/P2)

4

+1.0 –2.0 +10 } –20

32.1 ± 1.0 {150 ± 20}

Swing relief pressure

Control pressure

32.1

At heavy lift

Bucket relief pressure

Travel relief pressure

{300

+1.0 –2.0 +10 } –20

{327

{300 29.4 {300 29.4 {300

+1.0 –2.0 +10 } –20 +1.0 –2.0 +10 } –20 +1.0 –2.0 +10 } –20 +1.0 –2.0 +10 } –20

32.9/33.8 ± 1.0 {335/345 ± 10}

32.9/33.8

3.24

+0.49 –0 +5 {33 0 }

3.24

Max. 0.59 {Max. 6}

Max. 0.59 {Max. 6}

1.11/2.04 ± 0.39 {11.3/20.8 ± 4.0}

1.11/2.04 ± 0.39 {11.3/20.8 ± 4.0}

{335/345

+0.49 –0.20 +5 {33 –2 }

PC2000-8

20 Standard value table

SEN02006-00

Electronic control

Hydraulic pressure

Category

Applicable model

Item

Measurement conditions

Jet sensor differential pressure

All control levers at neu• Hydraulic oil temperature: 45 – 55°C tral • Engine at high idle Travel under no • Working mode: P load (Lever full)

PPC valve output pressure

• Hydraulic oil temperature: 45 – 55°C • Engine at high idle • Control lever at stroke end

Oil pressure drop

• Hydraulic oil temperature: 45 – 55°C • Difference between relief pressure at high idle and that at low idle

Output voltage of differential pressure sensor

Unit

MPa {kg/cm2}

All control levers at neutral

• Hydraulic oil temperature: 45 – 55°C • Engine: High idle Travel under no • Working mode: P load (Lever full)

Overrun when stopping swing

PC2000-8

• Hydraulic oil temperature: 45 – 55°C • Engine: High idle Travel under no • Working mode: P load (Lever full)

• • • • •

Hydraulic oil temperature: 45 – 55°C Bucket: No load Engine at high idle Working mode: P Stop after swinging one turn and measure distance that swing circle moves

Standard value for new machine

Service limit value

Min. 1.28 {Min. 13.1}

Min. 1.28 {Min. 13.1}

Max. 0.17 {Max. 1.7}

Max. 0.17 {Max. 1.7}

+0.8 –0.2 +8 {30 –2 }

+0.8 –0.2 +8 {30 –2 }

2.9

2.9

Max. 2.0 {Max. 20}

Max. 2.9 {Max. 30}

Min. 2.77

Min. 2.77

Max. 1.40

Max. 1.40

220 ± 60

220 ± 60

450/675 ± 60

450/675 ± 60

Max. 62 (Max. 1,593)

Max. 80 (Max. 2,056)

V

All control levers at neutral

Pump EPC current

Swing

PC2000-8

mA

deg. (mm)

5

SEN02006-00

20 Standard value table

Category

Applicable model

Item

PC2000-8

Measurement conditions

Standard value for new machine

Service limit value

5.7 ± 0.6

Max. 6.8

9.0 ± 0.9

Max. 10.8

sec.

57.5 – 67.5

Max. 70

mm

0

0

l/min

Max. 5

Max. 10

Unit

90° Time taken to start swing

Swing

Time taken to swing

Hydraulic drift of swing

Leakage from swing motor

6

• Hydraulic oil temperature: 45 – 55°C • Bucket: No load • Engine at high idle • Working mode: P • Time taken to swing 90° and 180° from starting position

• • • • •

sec.

180°

Hydraulic oil temperature: 45 – 55°C Bucket: No load Engine at high idle Working mode: P Swing one turn, then measure time taken to swing next 5 turns

• Hydraulic oil temperature: 45 – 55°C • Engine stopped • Set machine on 15° slope, and set upper structure at 90° to the side. • Make match marks on inner race and outer race of circle. • Measure distance that match marks move apart after 5 minutes. • • • •

Hydraulic oil temperature: 45 – 55°C Engine at high idle Swing lock switch: ON Leakage in 1 minute during swing relief

PC2000-8

20 Standard value table

SEN02006-00

Category

Applicable model

Item

Travel speed (Idle travel)

Travel

Travel speed (Actual travel)

Travel deviation

PC2000-8

Measurement conditions

• • • •

Hydraulic oil temperature: 45 – 55°C Engine at high idle Working mode: P Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns with no load.

• • • • •

Hydraulic oil temperature: 45 – 55°C Engine at high idle Working mode: P On level ground Run up for at least 10 m, and measure time taken to travel next 20 m on flat ground.

• • • • • •

Hydraulic oil temperature: 45 – 55°C Engine at high idle Working mode: P Travel speed: Lo On hard and level ground Measure travel deviation (x) in travel of 20 m after running up 10 m.

PC2000-8

Unit

Standard value for new machine

Service limit value

sec.

90.5 – 110.5

90.5 – 110.5

sec.

24.2 – 29.6

24.2 – 29.6

mm

Max. 200

Max. 220

7

SEN02006-00

20 Standard value table

Category

Applicable model

Item

Travel

Hydraulic drift of travel

Leakage of travel motor

Measurement conditions

• Hydraulic oil temperature: 45 – 55°C • Engine stopped • Stop machine on 12° slope with sprocket at uphill end of machine. • Measure the distance the machine moves in 5 minutes. • • • •

Hydraulic oil temperature: 45 – 55°C Engine at high idle Travel: Lock sprocket. Measure leakage in 1 minute during travel relief.

PC2000-8

Unit

Standard value for new machine

Service limit value

mm

0

0

l/min

Max. 25

Max. 30

Max. 1,200 (Max. 650)

Max. 1,800 (Max. 1,000)

Max. 60 (Max. 35)

Max. 90 (Max. 50)

Max. 165 (Max. 70)

Max. 250 (Max. 105)

Max. 50 (Max. 15)

Max. 75 (Max. 25)

Hydraulic drift of work equipment

Work equipment

Total work equipment (hydraulic drift at tip of bucket teeth)

• Measure extraction or retraction distance of each cylinder and lowering distance of Boom cylinder bucket tooth tip from above posture. (amount of retracRated load on work equipment tion of cylinder) Backhoe specification: 21,600 kg • Measure on level and flat ground. • Set lever in neutral. • Stop engine. • Hydraulic oil temperature: 45 – 55°C • Measure just after setting. Arm cylinder (amount of exten- • Measure lowering distance every 5 minutes. Judge by lowering distance in 15 sion of cylinder) minutes. • Values in ( ) are standard values when no load is applied to work equipment.

Bucket cylinder (amount of retraction of cylinder)

8

mm

PC2000-8

20 Standard value table

SEN02006-00

PC2000-8

Backhoe specification

7.5 ± 0.8

Max. 9.0

LOWER

5.3 ± 0.5

Max. 6.4

IN

7.5 ± 0.8

Max. 9.0

5.2 ± 0.5

Max. 6.2

5.0 ± 0.5

Max. 6.0

3.9 ± 0.4

Max. 4.7

*RAISE

Unit

sec.

• Run engine at full throttle. • Set in mode P • Hydraulic oil temperature: 45 – 55°C

Bucket Retract cylinder to stroke end. Extract cylinder to stroke end.

Backhoe specification

*OUT

Work equipment speed

Work equipment

• Run engine at full throttle. • Set in mode P • Hydraulic oil temperature: 45 – 55°C

Arm Retract cylinder to stroke end. Extract cylinder to stroke end.

Service limit value

Measurement conditions

Boom Lower bucket tooth to ground. Extract cylinder to stroke end.

Standard value for new machine

*CURL

Item

PC2000-8

DUMP

Category

Applicable model

• Run engine at full throttle. • Set in mode P • Hydraulic oil temperature: 45 – 55°C

9

SEN02006-00

20 Standard value table

Category

Applicable model

Item

Measurement conditions

PC2000-8

Unit

Boom

Standard value for new machine

Service limit value

Max. 6

Max. 6

Max. 5

Max. 5

Max. 4

Max. 4

Max. 5

Max. 20

Max. 10

Max. 100

Time lag

Work equipment

• Time required to raise chassis after bucket reaches ground • Run engine at slow speed. • Hydraulic oil temperature: 45 – 55°

sec.

Arm • Time from stop of arm to start. • Run engine at slow speed. • Hydraulic oil temperature: 45 – 55°C

Bucket

Fan (Radiator)

Oil leakage

• Time from stop of bucket to start. • Run engine at slow speed. • Hydraulic oil temperature: 45 – 55°C

10

Cylinders Center swivel joint

• Hydraulic oil temperature: 45 – 55°C • Hydraulic oil pressure: 29.4 ± 1.0 MPa {300 ±10 kg/cm2}

cc/min

Fan speed

• Hydraulic oil temperature: 45 – 55°C • Engine: High idle • Fan 100% speed mode

rpm

Output pressure of fan pump EPC solenoid valve

• Hydraulic oil temperature: 45 – 55°C • Engine: High idle • Fan 100% speed mode

MPa {kg/cm2}

STD: 1.69 ± 0.39 {17.2 ± 4.0} +55°C spec.: 1.32 ± 0.39 {13.5 ± 4.0}

STD: 1.69 ± 0.39 {17.2 ± 4.0} +55°C spec.: 1.32 ± 0.39 {13.5 ± 4.0}

Fan pump EPC current

• Hydraulic oil temperature: 45 – 55°C • Engine: High idle • Fan 100% speed mode

mA

STD: 625 ± 50 +55°C spec.: 555 ± 50

STD: 625 ± 50 +55°C spec.: 555 ± 50

STD: 840 ± 50 STD: 840 ± 50 +55°C spec.: 1,100 ± 50 +55°C spec.: 1,100 ± 50

PC2000-8

20 Standard value table

SEN02006-00

Pump performance

Fan (Oil cooler)

Category

Applicable model

Item

Measurement conditions

PC2000-8

Unit

Standard value for new machine

Service limit value

Fan speed

• Hydraulic oil temperature: 45 – 55°C • Engine: High idle • Fan 100% speed mode

rpm

Output pressure of fan pump EPC solenoid valve

• Hydraulic oil temperature: 45 – 55°C • Engine: High idle • Fan 100% speed mode

MPa {kg/cm2}

STD: 1.81 ± 0.39 {18.5 ± 4.0} +55°C spec.: 1.32 ± 0.39 {13.5 ± 4.0}

STD: 1.81 ± 0.39 {18.5 ± 4.0} +55°C spec.: 1.32 ± 0.39 {13.5 ± 4.0}

Fan pump EPC current

• Hydraulic oil temperature: 45 – 55°C • Engine: High idle • Fan 100% speed mode

mA

STD: 650 ± 50 +55°C spec.: 555 ± 50

STD: 650 ± 50 +55°C spec.: 555 ± 50

Delivery amount of hydraulic pump

• See next page

PC2000-8

l/min

STD: 760 ± 50 STD: 760 ± 50 +55°C spec.: 1,100 ± 50 +55°C spec.: 1,100 ± 50

See next page

11

20 Standard value table

Delivery amount of one hydraulic pump (P1 Pump, per one pump) PC2000 No. 1 PUMP IQ standards at 100 kg/cm2

Performance of hydraulic pump

Category

SEN02006-00

• Pump speed: At 1,729 rpm • Pump discharge pressure: 9.8 MPa {100 kg/cm2}

12

Check point

Test pump Test pump EPC current (mA)

Standard value for delivery amount Q (l/min)

Judgement standard lower limit Q (l/min)

As desired

I

See graph

See graph

PC2000-8

SEN02006-00

Delivery amount of one hydraulic pump (P2 Pump, per one pump) PC2000 No. 2 PUMP IQ standards at 100 kg/cm2

Performance of hydraulic pump

Category

20 Standard value table

• Pump speed: At 1,423 rpm • Pump discharge pressure: 9.8 MPa {100 kg/cm2}

Check point

Test pump Test pump EPC current (mA)

Standard value for delivery amount Q (l/min)

Judgement standard lower limit Q (l/min)

As desired

I

See graph

See graph

PC2000-8

13

SEN02006-00

PC2000-8 Hydraulic excavator Form No. SEN02006-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

14

SEN02007-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

30 Testing and adjusting

1

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

PC2000-8

1

SEN02007-00

30 Testing and adjusting

Testing fuel system for leakage .......................................................................................................... 28 Testing and adjusting air conditioner compressor belt tension........................................................... 30

2

PC2000-8

30 Testing and adjusting

SEN02007-00

1

Tools for testing, adjusting, and troubleshooting

1

Measuring intake air pressure (boost pressure)

Q’ty

Testing and adjusting item

symbol

Testing and adjusting, Part 1

Remarks

799-201-2202 Boost gauge kit

1

–101 to 200 kPa {–760 to 1,500 mmHg}

1 799-101-1502 Digital thermometer

1

2

1

A

Measuring exhaust temperature

B

Measuring exhaust gas color

J

Adjusting valve clearance

Part No.

799-201-1150

Part name

Adapter connector

1 799-201-9001 Handy smoke checker

1

2 C

Measuring blow-by pressure

Measuring engine oil pressure

D

2

Smoke meter

1

Purchased

Clearance gauge

1

(Intake: 0.35 mm, Exhaust: 0.57 mm)

1

0 to 6.9 MPa {0 to 70 kg/cm2}

795-471-1310 Adapter

1

For 140E-3, 5 engine

6261-71-6150 Gasket

1

For 140E-3, 5 engine

1

0 – 10 kPa {0 – 1,000 mmH2O}

799-101-5002 Hydraulic tester

1

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

1

Pressure gauge: 58.8 MPa {600 kg/cm2}

1

Pressure gauge: 1 MPa {10 kg/cm2}

799-101-5002 Hydraulic tester

1

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

1

Pressure gauge: 58.8 MPa {600 kg/cm2}

1

8 x 1.25 mm (male) o R1/8 (female)

E 1 799-201-1504 Blow-by checker

1

F

2 799-401-2320 Gauge 1

Testing fuel pressure

G 2 795-471-1450 Adapter 799-101-5220 Nipple

1

07002-11023

O-ring

1

4 799-401-2320 Gauge

1

Pressure gauge: 1 MPa {10 kg/cm2}

1 6151-51-8490 Spacer

1

Ø 14

2 6141-71-1710 Joint

1

Ø 10

3

Purchased

Hose

1

Inside diameter: approx. 11 mm

H 4

Purchased

Hose

1

Inside diameter: approx. 17 mm

5

Purchased

Measuring cylinder

1

6

Purchased

Stopwatch

1

7

07376-70315

Plug

1

Size: 03 With magnet

3

Testing fuel return rate of injector and leakage of pressure limiter

Measuring clearance of swing circle bearing

K

Purchased

Dial gauge (with magnet)

1

Gas filling in HIC circuit accumulator

M

792-610-1700

Charge valve assembly

1

PC2000-8

Bosch index: 0 to 9 (With standard color)

Purchased

1 795-502-1590 Compression gauge Measuring compression pressure

–99.9 to 1,299ºC

Size: 10 × 1.25 mm

3

Testing and adjusting control circuit oil pressure

1 P 2

Testing and adjusting control signal of piston pump

1 Q 2

Measuring fan speed

Measuring fan pump EPC solenoid output pressure

R 1 S 2

1 Measuring PPC valve output pressure, solenoid valve outlet pressure

T

2

3

1 Measuring outlet pressure of solenoid valve, swing PPC shuttle valve, and swing priority selector valve

2 U 3

4

VHMS controller initial setting and replacement time setting Measuring coolant temperature and oil temperature

4

1 W 2

X

Q’ty

Testing and adjusting item

30 Testing and adjusting

symbol

SEN02007-00

Remarks

799-101-5002 Hydraulic tester

1

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

1

Pressure gauge: 58.8 MPa {600 kg/cm2}

799-101-5220 Nipple

1

Size: 10 × 1.25 mm

07002-11023

1

Part No.

Part name

O-ring

799-101-5002 Hydraulic tester

1

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

1

Pressure gauge: 58.8 MPa {600 kg/cm2}

799-101-5220 Nipple

2

Size: 10 × 1.25 mm

07002-11023

2

O-ring

799-203-8001 Multiple tachometer

1

L: 60 – 2000 rpm, H:60 – 19,999 rpm

799-101-5002 Hydraulic tester

1

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

1

Pressure gauge: 58.8 MPa {600 kg/cm2}

799-101-5220 Nipple

1

Size: 10 x 1.5 mm

07002-11023

1

O-ring

799-101-5002 Hydraulic tester

1

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

1

Pressure gauge: 58.8 MPa {600 kg/cm2}

799-401-3200 Adapter

1

Size: 03

02896-11009

1

O-ring

799-401-3300 Adapter assembly

1

02896-11012

1

O-ring

799-101-5002 Hydraulic tester

1

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

1

Pressure gauge: 58.8 MPa {600 kg/cm2}

799-401-3200 Adapter

1

Size: 03

02896-11009

1

O-ring

799-401-3300 Adapter

1

02896-11012

O-ring

1

799-101-5220 Nipple

2

07002-11023

O-ring

2

799-608-3211

Diskette

1

799-608-3220 Wiring harness Purchased

Note type PC

799-101-1502 Digital thermometer

Size: 04

Size: 10 × 1.25 mm

1 1

Windows 98/2000/Me/XP, with RS232C terminal

1

–99.9 to 1,299 ºC

PC2000-8

SEN02007-00

Part No.

Part name

Q’ty

Testing and adjusting item

symbol

30 Testing and adjusting

Measuring operating effort and pressing force

Y

Measuring stroke and hydraulic drift

Z

Purchased

Scale

1

Measuring work equipment speed

AA

Purchased

Stopwatch

1

Measuring voltage and resistance

AB

Purchased

Tester

1

Troubleshooting of sensors and wiring harness

PC2000-8

—

Remarks

79A-264-0021 Push-pull scale

1

0 to 294 N {0 to 30 kg}

79A-264-0091 Push-pull scale

1

0 to 490 N {0 to 50 kg}

799-601-7400 T-adapter assembly

1

SWP, X, M connector

799-601-7500 T-adapter assembly

1

AMP070 connector

799-601-9000 T-adapter assembly

1

DT, HD30 connector

799-601-9300 T-adapter assembly

1

DRC26 – 24, 40 pin

799-601-7360 Adapter

1

Relay (5 pins)

799-601-9420 T-adapter

1

Pressure sensor

799-601-3450 Adapter

1

VHMS download harness

799-601-4100 T-adapter assembly

1

Engine-related connectors

795-799-5530 Adapter

1

Engine coolant, oil, fuel temperature

795-799-5540 Adapter

1

Boost temperature sensor

799-601-4130 T-adapter

1

Ne sensor

799-601-4150 T-adapter

1

Oil pressure sensor

799-601-4211

T-adapter

1

Controller (50 poles)

799-601-4220 T-adapter

1

Controller (60 poles)

799-601-4240 Socket

1

Ambient pressure sensor

799-601-4250 Socket

1

Boost pressure sensor

799-601-4260 T-adapter

1

Controller (40 poles)

799-601-9020 T-adapter

1

Injector

799-601-9420 T-adapter

1

Common rail pressure sensor

799-601-9430 Adapter

1

Supply pump PCV

799-601-9030 T-adapter

1

G sensor

5

SEN02007-00

Measuring engine speed

30 Testing and adjusting

1

a

Measure the engine speed under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: 45 – 55°C

1.

Preparation work Turn the starting switch ON and set the machine monitor to “Monitoring”. a For the operating method, see “Special functions of machine monitor”. a Monitoring code: 01002 Engine speed 01006 Engine speed a Code 01002 is information of the engine controller and code 01006 is information of the pump controller. The engine speed can be measured with either of those codes. a The engine speed is displayed in rpm.

2.

Measuring low idle speed 1) Start the engine and set the fuel control dial in the low idle position (MIN). 2) Set the work equipment control, swing control, and travel levers in neutral and measure the engine speed.

3.

Measuring high idle speed 1) Start the engine and set the fuel control dial in the high idle position (MAX). 2) Set the working mode switch to the P-mode position. 3) Turn the auto-decelerator switch OFF.

6

4.

Measuring all-pump relief speed 1) Start the engine and set the fuel control dial in the high idle position (MAX). 2) Set the working mode switch in the P-mode position. 3) Turn the heavy lift switch OFF. 4) Relieve the boom circuit by raising the boom and measure the engine speed.

5.

Measuring heavy-lift ON + all-pump relief speed 1) Start the engine and set the fuel control dial in the high idle position (MAX). 2) Set the working mode switch in the Pmode position. 3) Turn the heavy lift switch ON. 4) Relieve the boom circuit by raising the boom and measure the engine speed.

6.

Measuring auto-deceleration ON speed 1) Start the engine and set the fuel control dial in the high idle position (MAX). 2) Turn the auto-deceleration switch ON. 3) Set the work equipment control, swing control, and travel control levers in neutral. When the auto-decelerator operates, measure the engine speed. a The engine speed lowers to a certain level about 5 seconds after all the levers are set in neutral. This level is the auto-deceleration speed.

PC2000-8

30 Testing and adjusting

SEN02007-00

Testing air boost pressure a

1

Testing tools for air boost pressure

Symbol A k

Part No.

4.

Install nipple [1] of boost gauge kit A and connect it to gauge [2].

5.

Run the engine at the rated output and test the air boost pressure. (P mode and relieve boomraise)

6.

After finishing testing, remove the testing tools and return the removed parts.

Part name

799-201-2202

Boost gauge kit

790-401-2220

Hose

Be careful not to touch any hot part when removing or installing the testing tools.

1.

Equipped boost pressure sensor for engine control system. The boost pressure signal can be checked by monitoring function equipped machine monitor. q Monitoring code: 36500 L/B boost pressure. a Operation procedure is referred to the “Special function of machine monitor”.

2.

If the testing tools are used, check procedure is as follows.

3.

Remove air boost pressure pickup plug ((L1) on left bank or (R1) on right bank) from the bottom of the air intake connector. a Example of the left bank

PC2000-8

7

SEN02007-00

30 Testing and adjusting

Testing exhaust temperature a

k

a

Part No. 799-101-1502

Digital thermometer

2

799-201-1150

Adapter connector

5.

Points for periodical testing in preventive maintenance service (Pm clinic). 1) Start the engine and set the work mode switch to the P mode. 2) Turn ON the heavy-lift switch. 3) Test exhaust temperature when the engine is at high idle and the boom raise is relieved.

6.

After finishing testing, remove the testing tools and return the removed parts.

Remove and install the testing tools after the exhaust manifold temperature has lowered. Subject section for measuring includes front left, rear left, front right and rear right (4 points in total). Equipped exhaust temperature sensor for VHMS controller system The exhaust temperature signal can be checked by monitoring function equipped machine monitor. q Monitoring code 42600 L/B 1 – 3 exhaust temperature 42601 L/B 4 – 6 exhaust temperature 42608 R/B 1 – 3 exhaust temperature 42609 R/B 4 – 6 exhaust temperature a Operation procedure is referred to the “Special functions of machine monitor”.

2.

If the testing tools are used, check procedure is as follows.

8

Points for testing of the maximum temperature in troubleshooting. Test the maximum exhaust temperature when work is conducted. a Use a digital thermometer with PEAK mode.

Part name

1

1.

3.

4.

Testing tool for exhaust temperature

Symbol B

1

Connect adapter connector B2 to exhaust temperature sensor (1) connector and then connect digital thermometer B1. a Installation example to the front left-hand side (LF)

PC2000-8

30 Testing and adjusting

SEN02007-00

Testing exhaust color a

Tools for measuring exhaust color

Symbol J k

a

a

1.

1

Part No.

Part name

1

799-201-9001

Handy Smoke Checker

2

Commercially available

Smoke Meter

2.

Measuring with Smoke Meter J2 1) Insert probe [1] of Smoke Meter J2 into the outlet port of the exhaust pipe, and tighten the clip to secure it to the exhaust pipe.

Be careful not to touch any hot parts when removing or installing the testing tools. When measuring in the field where there is no air or electric power supply, use Handy Smoke Checker J1; when recording formal data, use Smoke Meter J2. Measure the exhaust color under the following conditions. q Coolant temperature: Within operating range Measuring with Handy Smoke Checker J1 1) Install filter paper to Handy Smoke Checker J1. 2) Insert the exhaust gas suction port into the exhaust pipe. 3) Start the engine. 4) Accelerate the engine suddenly or run at high idle, and operate the handle of Handy Smoke Checker J1 at the same time to collect the exhaust gas on the filter paper.

2)

3)

4)

5)

5) 6)

Connect the air hose and the socket of the prove hose and accelerator switch to Smoke Meter J2. a Keep the pressure of the air supply below 1.5 MPa {15 kg/cm2}. Connect the power cord to the AC100V socket. a Before connecting the cord, check that the power switch of the Smoke Meter is OFF. Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas cannot leak. Turn the power switch of Smoke Meter J2 ON.

Remove the filter paper and compare it with the scale supplied to judge the condition. After completing the measurement, remove the measuring equipment and set to the original condition.

PC2000-8

9

SEN02007-00

6) 7)

8)

9)

10

30 Testing and adjusting

Start the engine. Accelerate the engine suddenly or run at high idle, and depress the accelerator pedal of Smoke Meter J2 at the same time to collect the exhaust gas color on the filter. Place the filter paper used to catch the exhaust gas color on top of at least 10 sheets of unused filter paper inside the filter paper holder, and read the value shown. After completing the measurement, remove the measuring equipment and set to the original condition.

PC2000-8

30 Testing and adjusting

SEN02007-00

Adjusting valve clearance a

1

Adjusting tool for valve clearance

Symbol

Part No.

C

Commercially available

Part name Clearance gauge

5.

Hereafter crank the engine similar way in the firing order. Match the stamped line of the damper to the pointer and adjust the valve clearance of each cylinder. a Firing order R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 – R2 – L2 – R4 – L4

Valve clearance adjusting method 1. Remove cylinder head cover. 2.

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

3.

Loosen locknut (6) of RH No. 1 cylinder adjust screw (5). Insert a clearance gauge C of specified clearance between the crosshead (4) and rocker arm (3) and adjust the adjustment screw to the degree that the clearance gauge can be moved lightly. a Valve clearance Air Intake valve: 0.35 mm, Exhaust valve: 0.57 mm

4.

Tighten locknut (6) to secure adjustment screw. 3 Locknut: 52.9 – 64.7 Nm {5.4 – 6.6 kgm} a After tightening the locknut, check the valve clearance again.

PC2000-8

11

SEN02007-00

6.

12

30 Testing and adjusting

After finishing adjustment, return the removed parts. 3 Cylinder head cover mounting bolt: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}

PC2000-8

30 Testing and adjusting

SEN02007-00

Testing compression pressure a

Testing tools for compression pressure

Symbol 1 D k

a

1.

1

2

Part No.

Part name

795-502-1590

Compression gauge

795-471-1310

Adapter

6261-71-6150

Gasket

When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. Measure the compression pressure after the engine is warmed up. (Engine oil temperature: 40 – 60°C).

4.

Install adapter D2 to the mounting hole on the injector and compression gauge D1. a Fit the gasket to the injector end without fail. a Fix the adapter with the injector holder. 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily.

5.

Install rocker arm assembly (2) and adjust the valve clearance. 3 Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a See “Adjusting valve clearance”.

6.

Set the engine in the no-injection cranking mode. For details, see “No-injection cranking” in the Special function of machine monitor. k If the engine is not set in the no-injection cranking mode, it will start and will be dangerous. Accordingly, be sure to set the engine in this mode.

Remove cylinder head cover (1) of the cylinder to be tested for compression pressure.

2.

Bring the cylinder to be tested to the compression top dead center and remove rocker arm assembly (2). a See “Adjusting valve clearance”.

3.

Disconnect fuel high-pressure tube (3) and injector wiring harness and remove injector (4). a Disconnect the terminal of the injector wiring harness on the injector side and the bracket on the rocker housing side and r e mo v e t he i n j ec to r w i r i ng h a r n es s (Loosen the 2 terminal nuts alternately) from the injector. a Pass injector under the fuel path projected sideways and pull up the injector through wire (Do not pry the injector top up).

PC2000-8

13

SEN02007-00

7.

8.

30 Testing and adjusting

Rotate the engine with the starting motor and measure the compression pressure. a Read the pressure gauge pointer when it is stabilized.

a

After finishing testing, remove the testing tools and return the removed parts. a Install the injector and fuel high-pressure tube according to the following procedure. 1) Push in injector (11) with the hand to assemble holder (12) temporarily. 2) Tighten bolt (13) and washer (14) temporarily. 2 Spherical part of washer: Engine oil 3) Tighten sleeve nut (15) of the fuel highpressure tube temporarily. 4) Tighten bolt (13) permanently. 3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} 5) Tighten sleeve nut (15) permanently. 3 Sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm}

2)

1)

3)

4) 5)

a 6)

14

Install the injector wiring harness according to the following procedure. Install the injector wiring harness to the cylinder head and fix the connector side with the plate. Install O-ring (16). Install cap (17) with clip on the injector side of wiring harness. Press wiring harness (18) between the injector top and cap to the injector main body without slack. Tighten nut (19) on the injector side. 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}

Tighten the clamp and spacer with the bolt. Install rocker arm assembly. 3 Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} Adjust the valve clearance. For details, see “Adjusting valve clearance”. Install head cover. 3 Cylinder head cover mounting bolt: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}

PC2000-8

30 Testing and adjusting

SEN02007-00

Testing blow-by pressure a

Testing tool for blow-by pressure

Symbol E

a q q

1.

a a

1

1

Part No. 799-201-1504

Part name Gauge

Q'ty 1

Measure blow-by pressure after the engine is warmed up. Hydraulic oil temperature: 45 – 55°C Engine coolant temperature: Min. 70°C Equipped blow-by pressure sensor for VHMS control system. The blow-by signal can be checked by monitoring function equipped machine monitor. q Monitoring code: 42800 blow by pressure Operation procedure is referred to the “Special functions of machine monitor”. Monitor indication is absolute pressure.

2.

If the testing tools are used, check procedure is as follows.

a

Breather is provided to each RH and LH banks. Test the breather on either one of the banks.

3.

Install adapter [2] and nozzle [3] to the tip of each breather hose on the RH and LH.

4.

Connect tube [4] and gauge [1] to either one of the nozzles. Close the tube connecting mate of other nozzle with a piece of short cut tube, etc.

5.

Run the engine at the rated output (P mode and relieve the boom raise) and test the blowby pressure.

a

If rated output is not possible, measure the blow-by in high-idle operation. In this case, approx. 80% of blow-by pressure of the rated output can be obtained. Since blow-by pressure varies sharply depending on engine condition, if measured value is judged abnormal, investigate phenomena associated with defective blow-by such as large oil consumption, abnormal exhaust color, oil degradation and earlier contamination, etc.

a

6.

PC2000-8

After finishing testing, remove the testing tools and return the removed parts.

15

SEN02007-00

30 Testing and adjusting

Testing engine oil pressure a

2)

Testing tools for oil pressure

Symbol F

1

1 2

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic tester

1.

Equipped engine oil pressure sensor. The engine oil pressure signal can be checked by monitoring function equipped machine monitor. q Monitoring code: 37200 engine oil pressure sensor a Operation is referred to the “Special functions of machine monitor”.

2.

If the testing tool are used, check procedure is as follows. 1) Remove plug (1) (14 x P1.5) on the LH side of the cylinder block.

3)

4)

16

Install nipples [1] and [2] of hydraulic tester F1 and connect them to hydraulic tester F2. a Since the screw size of the sensor mount is 14 x P1.5, nipple (799-1015230) may be used. Run the engine at the rated output (P mode and boom raise relief) and low idle and test the oil pressure.

After finishing testing, remove the testing tools and return the removed parts.

PC2000-8

30 Testing and adjusting

Handling fuel system parts a

a

SEN02007-00

1

Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacement of fuel filter cartridge The fuel filter cartridge used must be a genuine Komatsu part. The fuel injection pump and nozzle of the common rail type fuel injection system (CRI) are consisted of more precision parts than those used for the current pumps and nozzles. This system, therefore, employs a special filter with highly efficient filtering performance to prevent mixing of foreign substances. Thus, substituting it with a non-genuine filter could cause troubles in the fuel system. It is strictly prohibited to use such part.

PC2000-8

Releasing residual pressure in fuel system a

a

a

k

1

Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)

17

SEN02007-00

30 Testing and adjusting

Testing fuel pressure a

1 2 3 4

a

k

1.

2.

18

3.

Testing tools for fuel pressure

Symbol

G

1

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

795-471-1450

Adapter

799-101-5220

Nipple

07002-11023

O-ring

799-401-2320

Gauge

Run the engine at high idle and measure the fuel pressure. a If the fuel pressure is in the following range, it is normal. Engine speed

Fuel pressure

High idle

0.15 – 0.3 MPa {1.5 – 3 kg/cm2}

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

4.

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

5.

After finishing testing, remove the testing tools and return the removed parts.

Install adapter [G2] and connect to gauge [G4].

PC2000-8

30 Testing and adjusting

SEN02007-00

Testing leakage from pressure limiter and return rate from injector

1

Type of engine having intake manifold equipped with return block

a

a

If the engine is of a type that returns the fuel spilling from the injector from the return block installed to the front of intake manifold, check the engine according to the following. Testing tools for pressure limiter leakage and injector return rate

Symbol

H

Part No.

Part name

1

6151-51-8490

Spacer

2

6141-71-1710

Joint

3

Commercially available

Hose (Inside diameter: Approx. 11 mm)

4

Commercially available

Hose (Inside diameter: Approx. 17 mm)

5

Commercially available

Measuring cylinder

6

Commercially available

Stopwatch

7

07376-70315

Plug

PC2000-8

a

Prepare an oil pan of about 20 l to receive the fuel flowing out during the test.

1.

Preparatory work (case of the LH bank) 1) Remove tube (4) between common rail (3) and supply pump (5). 2) Insert spacer H1 on supply pump (5) side and tighten the removed joint bolt again. 3) Connect the return piping to the fuel tank side again. a Make sure to install gaskets on both ends of spacer.

19

SEN02007-00

30 Testing and adjusting a

4)

5)

2.

20

Insert joint H2 on common rail (3) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the joint. Connect test hose H3 to the end of joint H2. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. a The above is the preparation work for testing the leakage from the pressure limiter.

5)

3.

If the leakage from the pressure limiter is in the following range, it is normal. Engine speed (rpm)

Leakage (cc/min)

1,600

Max. 10

After finishing testing, stop the engine.

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 (2) of return block (1) and connect test hose H4. a Apply plug H7 to the return hose side to stop oil, and fix it to the fuel tank. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. 2) Lay test hose H4 so that it will not slacken and put its end in the oil pan.

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

PC2000-8

30 Testing and adjusting

3) 4) 5)

SEN02007-00

Operate the machine monitor and set it so that it can check the engine speed. Run the engine at the rated output (With P mode and boom raise relieved). After the engine speed is stabilized, test the return rate in 1 minute with measuring cylinder H5. a You may test for 20 seconds and judge by multiplying the result by 3. a If the supply pump is not supplying fuel, the engine speed may not rise. In this case, record the engine speed, too, during the test. a If the return rate (spill) from the injector is in the following range, it is normal. Rated output speed Limit of return rate (spill) (rpm) (cc/min)

6)

1,600

960

1,700

1,020

1,800

1,080

1,900

1,140

2,000

1,200

After finishing testing, stop the engine.

4.

Work after finishing testing After finishing all testing, remove the testing tools and return the removed parts.

5.

Check the RH bank following the identical procedure.

PC2000-8

21

SEN02007-00

Bleeding air from fuel circuit a

30 Testing and adjusting

1

If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure.

Reference q The Komatsu genuine fuel filter cartridge employs a high-efficiency special filter. Always use it. q The common rail fuel injection system used on this machine consists of more precise parts than the conventional fuel injection pump and nozzle. If a filter cartridge other than the Komatsu genuine one is used, foreign matter may enter the fuel system and may cause a trouble in the system. Accordingly, never use a substitute. q When checking or servicing the fuel system, take care of entry of foreign matter more than ever. If dirt sticks, wash it off with fuel. 1.

22

2) 3) 4) 5)

6)

Set a container to receive oil under the fuel prefilter cartridge. Remove the drain hose (4) of cup (3) of the water separator. Using the filter wrench, turn filter cartridge (2) to the left to remove. Turn cup (3) of the water separator installed to the bottom of the removed cartridge to the left to remove. (This cup will be reused.) Install removed cup (3) to the new fuel prefilter cartridge. (At this time, be sure to use a new O-ring.) 3 Cup: 10 Nm {1.0 kgm}

Replacing prefilter cartridge or bleeding air from it 1) Pull fuel shut-off lever (1) installed to the front of the main pump in the pump room to close the fuel supply circuit from the fuel tank.

PC2000-8

30 Testing and adjusting

7)

Clean the filter stand. Fill the new or reused filter cartridge with clean fuel, apply oil to the packing surfaces thinly, and install the cartridge to the filter stand. a Add fuel through 8 small holes (a) on the dirty side without removing cap (b) at the center. a After adding fuel, remove cap (b) at the center and install the fuel filter. a Fill the fuel filter with clean fuel and take care that dirt will not enter it. Since the center is the clean side, do not remove cap (b) when adding fuel, and particularly take care that dirt will not enter it.

When installing the filter cartridge, tighten it 3/4 turns after its packing surface touches the seal surface of the filter stand. a If the filter cartridge is tightened too much, fuel will leak because of damage of the packing. If the filter cartridge is not tightened sufficiently, fuel will also leak through the clearance of the packing. Accordingly, observe the tightening angle. q When tightening the filter cartridge with the filter wrench, take care extremely not to scratch or dent the filter. 9) Install the drain hose. 10) Check that the drain plug at the cup bottom of the water separator is tightened securely. 3 Drain plug: 0.2 – 0.45 Nm {0.02 – 0.046 kgm} 11) When replacing the standard fuel filter cartridge (every 1,000 hours) or bleed air from it, see “Replacing main filter cartridge”.

SEN02007-00

12) Press down fuel cut lever (1) installed to the front of the main pump in the pump room to supply the fuel.

8)

PC2000-8

13) Start the engine and check the filter seal surface and water separator mounting surface for fuel leakage and then run the engine at low idle for about 10 minutes.

23

SEN02007-00

2.

30 Testing and adjusting

Replacing main filter cartridge or bleeding air from it 1) Replacing main filter cartridge 1] Pull fuel shut-off lever (1) installed to the front of the main pump in the pump room to close the fuel supply circuit from the fuel tank.

a a

5] 2] 3] 4]

Set a container to receive oil under the filter cartridge. Using the filter wrench, turn filter cartridge (5) to the left to remove. Clean the filter stand. Thinly apply oil to the packing of the new filter cartridge and install the cartridge to the filter stand.

6]

24

Do not add fuel to the fuel filter cartridge. Remove cap (b) at the center and install the fuel filter.

When installing the filter cartridge, tighten it 3/4 turns after its packing surface touches the seal surface of the filter stand. If the filter cartridge is tightened too much, fuel will leak because of damage of the packing. If the filter cartridge is not tightened sufficiently, fuel will also leak through the clearance of the packing. Accordingly, observe the tightening angle. q When tightening the filter cartridge with the filter wrench, take care extremely not to scratch or dent the filter. After replacing filter cartridge (5), loosen its air bleeding plug (6) and press down fuel shut-off lever (1) to open the fuel supply circuit from the fuel tank. a Open the circuit in the reverse order to closing.

PC2000-8

30 Testing and adjusting

2)

To bleed air when fuel is used up, perform the following air bleeding procedure taken after replacement of the main filter cartridge.

PC2000-8

SEN02007-00

3)

Bleed air according to the following procedure. 1] Fill the fuel tank with fuel (to the FULL mark of the fuel level gauge). 2] After replacing filter cartridge (5), loosen air bleeding plug (6). 3] Remove locknut (8) of priming pump lever (7), operate priming pump lever (7), and check that fuel and bubbles flow out of air bleeding plug (6). 4] Tighten air bleeding plug (6). 3 Plug: 4.9 – 6.9 Nm {0.5 – 0.7 kgm} 5] Push in priming pump lever (7) and tighten locknut (8) to lock it. 6] After replacing the filter cartridge, start the engine and check the filter seal surface for fuel leakage.

25

SEN02007-00

Bleeding air from fuel circuit (lowgrade fuel specification) 1 a

a

k

3.

Bleed air according to this procedure in the following cases. q When the fuel filter was replaced q When fuel ran out q When starting the engine for the first time after replacing the fuel piping or supply pump When replaced the fuel filter, don't feed fuel to the filters, including both the main and pre-filter. Pressure is constantly applied to the fuel circuit as long as operation of the electric priming pump is continued. Loosening the air bleeding plug from this state might allow fuel to burst out. Thus, don't try to loosen the plug while the pump is in operation.

1.

Set the starting switch to OFF position.

2.

Open the air bleeding valves (1) (one for each side). a Place the valves horizontally. q

q

26

30 Testing and adjusting

Shift switch (2) for the electric priming pump in the power container to ON position. a Lamp (3) will start flashing and operation of the electr ic priming pump will be started.

a a a

The built-in timer of this switch automatically starts or stops operation of the electric priming pump. (See the figure below) Operation of the electric priming pump is stopped as long as flashing of the lamp is continued. It is not an error. Shifting the switch to "OFF" while the lamp is flashing turns off the lamp and stops the electric priming pump, too.

Left bank

4.

As the specified duration (about 6.5 minutes) is expired, lamp (3) automatically goes off, stopping the electric priming pump. a When the fuel filter alone was replaced, above completes bleeding air.

5.

When fuel is not provided in the fuel circuit such as when run out of fuel occurred or when replacement of the fuel pipe or supply pump was done, set switch (2) to "ON" again after the electric priming pump is automatically stopped.

6.

Bleeding air, in this case, completes as lamp (3) went off.

Right bank

PC2000-8

30 Testing and adjusting

7.

8.

SEN02007-00

Close the air bleeding valves (1). a Place the valves vertically. q

Left bank

q

Right bank

Crank the engine using the starting motor and start the engine. a By cranking the engine, air in the highpressure circuit bleeds out automatically. a If the engine does not start, inappropriate bleeding air in the low-pressure circuit may be suspected. In this case, perform the followings: 1) Shift the electric priming pump switch to ON position. 2) Start the engine while the electric priming pump is operating. a If the engine does not start, repeat this. 3) After the engine starts, let the engine run for more than 5 minutes to bleed air completely from the fuel circuit.

PC2000-8

27

SEN02007-00

Testing fuel system for leakage 1 k

a

Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, test it for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage.

1.

Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.

2.

Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.

3.

Inspect the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.

4.

Run the engine at low idle.

5.

Inspect the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.

6.

Run the engine at high idle.

7.

Inspect the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.

8.

Run the engine at high idle. a Relieve the hydraulic pump.

9.

Inspect the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage.

28

30 Testing and adjusting a a

If any fuel leakage is detected, repair it and inspect again from step 1. If no fuel leakage is detected, check is completed.

PC2000-8

30 Testing and adjusting

SEN02007-00

Testing and adjusting alternator belt tension

Adjustment a Adjust the belt according to the following procedure when the belt deflection is not normal.

Testing 1. Remove V belt cover (7) on the rear side of the engine.

1.

Loosen nuts and bolts (1), (2), (3) and (4) in this order.

2.

Turn nut (5) to move alternator (6), and adjust the belt tension. a Nut (5): q It is moved to the side that belt is loosened when fastening it clockwise. q It is moved to the side that belt is tensioned when loosening it counterclockwise. a Test for breakage of each pulley, friction of V-ditch, friction of belt, and contact between belt and V-ditch. a Replace it with new belt if it was too stretched so that adjustability was lost, or cut and crack occurred.

3.

Tighten nuts and bolts (4), (3), (2) and (1) in this order. a When the belt was replaced, readjust it after one-hour operation.

2.

Measure the belt deflection (a) when pushing a point midway between the alternator pulley and the drive pulley with the finger. a Deflection (a) when pressing force is approx. 58.8 N {approx. 6 kg}: 10 – 15 mm

PC2000-8

29

SEN02007-00

Testing and adjusting air conditioner compressor belt tension

30 Testing and adjusting

1

Testing procedure 1. Dismount belt covers (7) and (8).

2.

30

Adjustment procedure a Adjust the belt according to the following procedure when the amount of belt deflection is not normal. 1.

Loosen nuts and bolts (1), (2), (3) and (4) in this order.

2.

Turn nut (5) to move air conditioner compressor (6), and adjust the belt tension. a Nut (5): q It is moved to the side that belt is loosen when fastening it clockwise. q It is moved to the side that belt is tensioned when loosening it counterclockwise. a Test for breakage of each pulley, friction of V-ditch, friction of belt, and contact between belt and V-ditch. a Replace it with new belt if it was too stretched so that adjustability was lost, or cut and crack occurred.

3.

Tighten nuts and bolts (4), (3), (2) and (1) in this order.

4.

Mount the belt cover.

Measure the belt deflection (a) when pushing a point midway between the air conditioner compressor pulley and the drive pulley with the finger. a Press force at approx. 58.8 N {Approx. 6 kg}, (a): 6 mm

PC2000-8

SEN02007-00

PC2000-8 Hydraulic excavator Form No. SEN02007-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

32

SEN02008-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

30 Testing and adjusting

1

Testing and adjusting, Part 2 Testing and adjusting, Part 2........................................................................................................................... 3 Testing swing circle bearing clearance................................................................................................. 3 Remaining pressure relief from HIC circuit .......................................................................................... 4 Gas filling in HIC circuit accumulator ................................................................................................... 4 Bleeding air from HIC circuit and supplying oil to it.............................................................................. 6 Testing and adjusting track shoe tension ............................................................................................. 8 Testing and adjusting work equipment, swing and travel circuit oil pressures ....................................11 Testing and adjusting control circuit oil pressure (output pressure of self pressure reducing valve) . 15 Testing and adjusting main pump control signal ................................................................................ 17 Measuring fan speed.......................................................................................................................... 20 Measuring fan pump EPC solenoid current ....................................................................................... 21 Measuring fan pump EPC solenoid valve output pressure ................................................................ 22 Oil pressure measuring points for pump discharge pressure or jet sensor differential pressure ....... 24 Measuring PPC valve output pressure............................................................................................... 25 Measuring solenoid valve outlet pressure.......................................................................................... 30 Adjusting work equipment and swing PPC valve ............................................................................... 32

PC2000-8

1

SEN02008-00

30 Testing and adjusting

Testing and adjusting travel deviation ................................................................................................ 33 Testing work equipment hydraulic drift cause portion......................................................................... 35 Testing oil leakage.............................................................................................................................. 36 Remaining pressure relief from hydraulic circuit ................................................................................ 39 Air bleeding from each component..................................................................................................... 40 Air bleeding from PPC circuit ............................................................................................................. 45 Testing and adjusting auto grease system ......................................................................................... 47 Adjusting mirrors ................................................................................................................................ 50

2

PC2000-8

30 Testing and adjusting

SEN02008-00

Testing and adjusting, Part 2 Testing swing circle bearing clearance a

a 1.

2.

1 1

3.

Set the dial gauge K to the zero point.

4.

Arrange the arm almost at right angles to the ground and lower the boom until the front leg of the machine body rises. a At the time, the front of the upper structure rises and its rear lowers.

5.

At the time, read the value on the dial gauge K. This value on the dial gauge indicates the swing circle bearing clearance. k During the measurement, never place hands and legs below the undercarriage.

6.

Return the work equipment to the state in Paragraph 2 and make sure that the dial gauge K has returned to the zero point. If not, repeat Steps 3 to 5.

Inspection device of swing circle bearing clearance Symbol

Part Number

K

Commercial item

Part Name Dial gauge (with magnet)

When measuring swing circle bearing clearance on a machine, follow the procedures below: 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.

Set the work equipment to the maximum reach and set the bucket tip to the height of the revolving frame lower face. a At the time, the front of the upper structure lowers and its rear rises.

PC2000-8

3

SEN02008-00

30 Testing and adjusting

Remaining pressure relief from HIC circuit 1

Gas filling in HIC circuit accumulator

a

If the HIC equipment is to be removed or the piping are to be disconnected, release the remaining pressure from the HIC circuit as follows. Lower the work equipment completely to the ground, stop the engine and use the control lever several times to relieve pressure remaining in the pipe. Then, loosen the oil filler cap of the hydraulic tank gradually to relieve pressure in the tank.

a

a

If the gas was discharged from the HIC circuit accumulator or the accumulator was replaced, charge the accumulator with gas according to the following procedure.

Loosen stop valves (1) and (2) slowly and relieve pressure remaining in the circuit. k Quick loosening will cause a high pressure in the tank circuit, so be sure to loosen the stop valves slowly. a After 1 minute elapsed, the remaining gas will have been relieved completely.

1.

Relieve pressure remaining in the HIC circuit. a Refer to the Paragraph of “Remaining pressure relief from HIC circuit” and leave 2 pieces of the stop valve loosened.

2.

Attach the plug (1) to the accumulator.

3.

Attach the valve kit [1] of the charge valve assembly M to accumulator (2) and attach the nipple [2] to nitrogen bomb (3). Then, connect the valve kit [1] and the nipple [2] with the hose [3]. a Before attaching the valve kit [1], turn the valve [4] fully to the left and turn the valve [5] to the left and keep it opened.

k

1.

2.

4

1

Device for filling gas in HIC circuit accumulator Symbol

Part Number

M

792-610-1700

Part Name Charge valve assembly

When the remaining pressure is relieved completely, retighten stop valves (1) and (2).

PC2000-8

30 Testing and adjusting

4.

Open the valve [7] of the nitrogen bomb (3) slowly, keep the pressure to the pressure gauge [6] at 0.2 – 0.3 MPa {2 – 3 kg/cm2} and tighten the valve [5]. k Quick filling high pressure gas will expand the plug suddenly and may break it, so be sure to fill nitrogen gas slowly.

5.

Screw in the valve [4] until it touches something lightly.

6.

Open the valve [7] further slowly and fill the accumulator (4) with nitrogen gas. a Close the valve [7] gradually until the pressure gauge becomes stable, and then read the value shown on the pressure gauge.

7.

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

8.

Turn the valve [4] to the left until it stops, turn the valve [5] to open it and discharge gas remaining in the valve kit [1] and the hose [3].

9.

Remove the valve kit [1] from accumulator (2) and attach plug (3) to the valve kit.

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10. After filling gas, bleed air from the HIC circuit and fill pressurized oil in the circuit. a Refer to the paragraph of “Bleeding air from HIC circuit and supplying oil to it”.

PC2000-8

5

SEN02008-00

Bleeding air from HIC circuit and supplying oil to it 1

30 Testing and adjusting

3.

Fully open stop valve (3) at the inside of the axle.

4.

Loosen air bleeding plug (4) of the cushion cylinder about 1 turn (2 places on the right and left).

Before bleeding air from the HIC circuit and supplying grease to the hydraulic grease supply cylinder, be sure to bleed air. 1.

Loosen plug (1) of the grease cylinder by 1 turn (2 places on the right and left).

2.

Fully open stop valve (2) at the inside of the axle.

6

PC2000-8

30 Testing and adjusting

5.

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Remove plug (6) under the block on the side of the relief valve and loosen air bleeding plug (5) about 1 turn.

6.

Run the engine at low idle for 2 – 3 minutes.

7.

When clear oil flows out of air bleeding plugs (4) (at 2 places on the right and left) and the hole for plug (6) under the block on the side of the relief valve, fully tighten valves (2) and (3) and plugs (4) and (5).

PC2000-8

8.

Tighten plugs (1) (at 2 places on the right and left).

9.

Tighten plug (6). 3 Plug: 81.3 ± 6.9 Nm {8.3 ± 0.7 kgm} a Be sure to tighten plug (1) last. a Fully close the stop valves and air bleeding plugs. a After bleeding air, test and adjust the track shoe tension. For details, see “Testing and adjusting track shoe tension”.

7

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30 Testing and adjusting

Testing and adjusting track shoe tension 1

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

Testing 1. Run the engine at low idle and drive the machine forward by the length of track on ground, and then stop slowly.

1.

2.

Place steel bar (b) on the track shoe between 2nd carrier roller (1) and 3rd carrier roller (2).

3.

Measure the maximum clearance between the track shoe top and the steel bar. q Maximum clearance (a): 10 – 30 mm

8

Adjusting HIC cylinder 1) Check that stop valve (4) at the inside of the axle is fully closed.

PC2000-8

30 Testing and adjusting

2)

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Open stop valve (5) at the inside of the axle.

7) 2.

Fully close stop valve (4).

Adjusting grease cylinder When tension is low 1) Add grease through plug (8). 2) To check that the tension is normal, move the machine forward slowly. 3) Check the track shoe tension again. If it is not proper, adjust it again.

3) 4)

5) 6)

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

PC2000-8

9

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4)

30 Testing and adjusting

You may adjust the track shoe tension by adding grease until projection (b) of grease cylinder (9) becomes 35 – 190 mm. a If the tension is still low, the pins and bushings may be worn much.

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

10

PC2000-8

30 Testing and adjusting

Testing and adjusting work equipment, swing and travel circuit oil pressures

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2)

1

Measurement a Measure the work equipment, swing and travel circuit oil pressures under the following conditions: q Hydraulic oil temperature : 45 – 55ºC 1.

2.

Preparatory work Turn on the starting switch and display the screen for measuring the work equipment, swing and travel circuit oil pressures on the machine monitor. a For the control method, refer to the paragraph of “Special function of machine monitor”. a Screen display on the machine monitor (Display unit : MPa, kg/cm2) q Monitoring code: 01124 P1F pump pressure 01125 P1R pump pressure 01126 P2F pump pressure 01127 P2R pump pressure

Measurement of work equipment oil pressure 1) Measurement of normal relief oil pressure Start the engine and measure the oil pressure when each cylinder is relieved individually at the stroke end at high idle. a The main relief valve of each control valve is relieved on the low pressure set side. a When the boom cylinder is lowered and relieved at the stroke end, the safety valve with suction on the boom lower side of the control valves VL1 and VR2 is relieved (because the set pressure is lower than that of the main relief valve).

PC2000-8

3)

Measurement of relief oil pressure at the time of heavy lift operation a i) Start the engine and turn on the heavy lift switch. ii) Measure the oil pressure when the boom cylinder is raised and is relieved individually at the stroke end at high idle. a The heavy lift function works only when the boom is individually raised. a The main relief valve of each control valve is relieved on the high pressure set side. Measurement of relief oil pressure at the time of machine push operation i) Start the engine and turn on the machine push-up switch. ii) Measure the oil pressure when the boom cylinder is lowered and is relieved individually at the stroke end at high idle. a When the boom cylinder is lowered and relieved at the stroke end, the safety valve with suction on the boom lower side of the control valves VL1 and VR2 is relieved (because the set pressure is lower than that of the main relief valve).

3.

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

4.

Measurement of travel oil pressure 1) Start the engine and place a pin or a block between the sprocket and the track frame or the track link to lock traveling. k Make sure that travel is certainly locked. 2) Measure the oil pressure when the travel motor is relieved at engine high idle. a The main relief valve of each control valve is relieved on the high pressure set side.

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Adjustment 1. Adjustment of main relief valve (High pressure set) of control valves VL1, VL2, VR1 and VR2 a When the work equipment oil pressure (when the machine push-up is working) is abnormal or when the travel oil pressure is abnormal, adjust the high pressure set side of the main relief valves (1), (2), (3) and (4) of each control valve according to the following procedures: q (1) : VL1 control valve (P1R pump) q (2) : VL2 control valve (P2R pump) q (3) : VR1 control valve (P1F pump) q (4) : VR2 control valve (P2F pump) q

VL valve

q

VR valve

a

12

30 Testing and adjusting

1) 2)

Loosen the locknut (5) and make the elbow (6) free. Loosen the locknut (7) and turn the holder (8) for adjustment. q Turn the holder to the right, and the pressure will rise. q Turn the holder to the left, and the pressure will lower. a Pressure adjusted by a turn of the holder: about 21.8 MPa {222 kg/cm2} 3 Locknut (7) : 93 – 123 Nm {9.5 – 12.5 kgm} a Since the low pressure set changes when the high pressure set is adjusted, the low pressure set should be adjusted.

3)

Fix the elbow (6) and tighten the locknut (5).

4)

After the adjustment, check the oil pressure again according to the above measurement procedures.

High pressure set is the state that the 2stage relief solenoid valve is ON and that a pilot pressure is applied to the changeover port.

PC2000-8

30 Testing and adjusting

2.

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

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3.

Adjustment of swing motor safety valve a When the swing oil pressure is abnormal, adjust the swing motor safety valves (11) and (12) according to the following procedures: q (11) : For the front swing motor q (12) : For the rear swing motor

Fix the elbow (6) and tighten the locknut (5).

a a 1) 4)

After the adjustment, check the oil pressure again according to the above measurement procedures. 2)

PC2000-8

The front and rear swing motors are divided from one spool. Adjust the valves in the following procedures. If swing starting power is not powerful, or if swing speed is not fast: Put match marks on the body and on adjustment screw (14) for safety valves (11) and (12) of each motor. a The match marks are for returning the screw and body to the original positions after no fault is found. Loosen locknut (14) of safety valve on one side and tighten adjustment screw (13). q Turn the adjustment screw to the right, and the pressure will rise. q Turn the adjustment screw to the left, and the pressure will lower. a Pressure adjusted by one turn of the adjustment screw : about 4.70 MPa {47.9 kg/cm2} 3 Locknut : 147 – 196 Nm {15 – 20 kgm}

13

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3) 4)

5) 6)

7)

14

30 Testing and adjusting

Start the engine, relieve the swing lock, and measure the relief oil pressure. Rise of the oil pressure shows lowering of the valve set pressure. Adjust the pressure according to the criteria. If the oil pressure is not changed, return the valves to the original positions in accordance with the match marks. Adjust the relief valves on the other side in the same steps 2) – 4) above.

After the adjustment, check the oil pressure again according to the above measurement procedures.

PC2000-8

30 Testing and adjusting

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Testing and adjusting control circuit oil pressure (output pressure of self pressure reducing valve) a

3.

Run the engine at high idle, set the work equipment/swing lever and travel lever in neutral, and measure the oil pressure.

1

Instruments for testing and adjusting control circuit oil pressure Symbol 1 P 2

Part Number

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-101-5220

Nipple (10 x 1.5 mm)

07002-11023

O-ring

Measuring a Measure the control circuit oil pressure under the following condition. q Hydraulic oil temperature: 45 – 55°C k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1.

Remove pressure measurement plug (1) of the main pump. a The plugs are installed in the same places for P1 and P2 pumps.

2.

Install nipple P2 and connect oil pressure gauge [1] of hydraulic tester P1.

Adjusting a If output pressure of self pressure reducing valve is not normal, adjust self pressure reducing valve (2) in the following procedure.

1) 2)

PC2000-8

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

15

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3)

16

30 Testing and adjusting

Fix adjustment screw (3) and then tighten locknut (4). 3 Locknut : 59 – 78 Nm {6 – 8 kgm}

PC2000-8

30 Testing and adjusting

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Testing and adjusting main pump control signal 1 a

Install nipple Q2 and connect oil pressure gauge [1] of hydraulic tester Q1. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}.

3)

Start the engine and set the working mode switch in the P-mode position. Set all the control levers in neutral and measure the EPC solenoid valve output pressure under the following condition. i) Set all the control levers in neutral. ii) Run the engine at high idle and measure the output pressure. Drive the travel motor idle and measure the EPC solenoid valve output pressure under the following condition. i) Raise the track shoe to be measured by using the boom and arm ii) Run the engine at high idle, drive the travel motor idle and measure the output pressure. a For measurement posture, see “Standard service value table”.

Devices for inspecting and measuring main pump control signal Symbol 1 Q 2

Part Number

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-101-5220

Nipple (10 × 1.5 mm)

07002-11023

O-ring

Measurement a Measure the piston pump control oil pressure under the following conditions: q Hydraulic oil temperature: 45 – 55°C k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1.

2)

Measuring EPC solenoid valve output pressure a Since the basic pressure of the EPC solenoid valve is the control circuit pressure, check that the control circuit pressure (self pressure reducing valve) is normal before measuring the EPC solenoid valve output pressure. a The EPC solenoid valve is controlled with the command current from the pump controller. (For details, see Structure, function and maintenance standard.) 1) Remove oil pressure pickup plug (1) or (2). a Plug (1) is on the front pump side and plug (2) is on the rear pump side. a The plugs are installed in the same places for P1 and P2 pumps.

PC2000-8

4)

5)

2.

Measuring EPC solenoid valve current a The EPC current can be checked with the monitoring function of the machine monitor, too. (For the operating method, see “Special functions of machine monitor”.) q Monitoring code: 01306 P1F pump EPC current 01308 P1R pump EPC current 01310 P2F pump EPC current 01312 P2R pump EPC current 1) Start the engine and set the working mode switch in the P-mode position. 2) Set all the control levers in neutral and measure the EPC current under the following condition. i) Set all the control levers in neutral. ii) Run the engine at high idle and measure the current.

17

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3)

3.

2)

18

3)

Drive the travel motor idle and measure the EPC current under the following condition. i) Raise the track shoe to be measured by using the boom and arm. ii) Run the engine at high idle, drive the travel motor idle and measure the current.

Measuring output differential pressure of jet sensor differential pressure sensor a The jet sensor output differential pressure can be checked with the monitoring function of the machine monitor, too. (For the operating method, see “Special functions of machine monitor”.) a Monitoring code: 13804 VR1 J/S differential pressure 13805 VL1 J/S differential pressure 13806 VR2 J/S differential pressure 13807 VL2 J/S differential pressure 1)

30 Testing and adjusting

Start the engine and set the working mode switch in the P-mode position. Set all the control levers in neutral and measure the jet sensor output differential pressure under the following condition. i) Set all the control levers in neutral. ii) Run the engine at high idle and measure the output differential pressure.

4.

Drive the travel motor idle 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 idle, and measure the output differential pressure.

Measuring output voltage of jet sensor differential pressure sensor a The differential pressure sensor output voltage can be checked with the monitoring function of the machine monitor. (For the operating method, see “Special functions of machine monitor”.) a Monitoring code: 13808 VR1 J/S differential pressure sensor voltage 13809 VL1 J/S differential pressure sensor voltage 13810 VR2 J/S differential pressure sensor voltage 13811 VL2 J/S differential pressure sensor voltage 1) Start the engine and set the working mode switch in the P-mode position. 2) Set all the control levers in neutral and measure the voltage under the following condition. i) Set all the control levers in neutral. ii) Run the engine at high idle and measure the voltage.

PC2000-8

30 Testing and adjusting

3)

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Drive the travel motor idle and measure the voltage under the following condition. i) Raise the track shoe to be measured by using the boom and arm. ii) Run the engine at high idle, drive the travel motor idle, and measure the voltage.

1) 2)

Adjusting 1. Adjusting jet sensors of VR1, VL1, VR2 and VL2 control valves a If the jet sensor output differential pressure is abnormal, adjust jet sensor relief valves according to the following procedure. q (17): jet sensor relief valve of VL1 control valve q (18): jet sensor relief valve of VL2 control valve q (19): jet sensor relief valve of VR1 control valve q (20): jet sensor relief valve of VR2 control valve

3)

4)

PC2000-8

Fix adjustment screw (21) and loosen locknut (22). Turn adjustment screw (21) to adjust the pressure. a If the adjustment screw is q turned to the right, the pressure rises. q turned to the left, the pressure lowers. a Pressure changed by 1 turn of adjustment screw: 0.288 MPa {2.94 kg/cm2} Fix adjustment screw (21) and tighten locknut (22). 3 Locknut: 59 – 78 Nm {6 – 8 kgm}

After finishing adjustment, check the oil pressure again according to the above described measurement procedure.

19

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30 Testing and adjusting

Measuring fan speed 1. a

Measuring fan speed (radiator) Tools for measuring fan speed Symbol

Part Number

R

799-203-8001

1) 2) 3)

4)

5)

20

1

Part Name Multitachometer

Remove the fan guard and put a sheet of reflection tape (a) on fan (1). Install the fan guard. Set probe [1] of multitachometer R with stand [2], match it to the reflection tape, and connect it to meter [3]. a Set the probe with the fan away 100 mm from it.

2.

Measuring fan speed (oil cooler) 1) Open the inspection cover of the engine hood and remove the fan guard and stick a reflection tape to the fan (1). 2) Install the fan guard. 3) Set probe [1] of multitachometer R with stand [2], match it to the reflection tape, and connect it to meter [3]. a Set the probe with the fan away 100 mm from it.

4)

Start the engine, set the fan to 100% mode, and measure the fan speed with the engine at high idle. a Stabilization of the tachometer numbers shows correct measurement. a If the fan is rotated in reverse, the measuring instruments can be sucked in. Accordingly, be sure to rotate the fan forward when measuring.

5)

After finishing measurement, remove the measuring instruments and return the removed parts.

Start the engine, set the fan to 100% mode, and measure the fan speed with the engine at high idle. a Stabilization of the tachometer numbers shows correct measurement. a If the fan is rotated in reverse, the measuring instruments can be sucked in. Accordingly, be sure to rotate the fan forward when measuring.

After finishing measurement, remove the measuring instruments and return the removed parts. PC2000-8

30 Testing and adjusting

Measuring fan pump EPC solenoid current 1. a

a

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2.

1

Measuring fan (radiator) pump EPC solenoid current The fan (radiator) pump EPC solenoid current can be checked with the monitoring function of the machine monitor. (For the operating method, see “Special functions of machine monitor”.) q Monitoring code: 31624 RAD fan pump EPC current q The current is displayed in mA. Measure the fan (radiator) pump EPC current under the following condition. q Hydraulic oil temperature: 45 – 55°C 1) Run the engine at high idle and measure the EPC current with the fan 100% speed mode.

PC2000-8

a

a

Measuring fan (radiator) pump EPC solenoid current The fan (oil cooler) pump EPC solenoid current can be checked with the monitoring function of the machine monitor. (For the operating method, see “Special functions of machine monitor”.) q Monitoring code: 31634 O/C fan pump current q The current is displayed in mA. Measure the fan (oil cooler) pump EPC current under the following condition. q Hydraulic oil temperature: 45 – 55°C 1) Run the engine at high idle and measure the EPC current with the fan 100% speed mode.

21

SEN02008-00

30 Testing and adjusting

Measuring fan pump EPC solenoid valve output pressure 1

2)

a

3)

Measuring instruments for fan pump EPC solenoid valve output pressure Symbol 1 S 2

a a

k

1.

Part Number

4)

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-101-5220

Nipple (Max. 1.5 mm)

07002-11023

O-ring

Measure the fan pump EPC solenoid valve output pressure q Hydraulic oil temperature: 45 – 55°C Since the basic pressure of the EPC solenoid valve output pressure is the control circuit pressure, check that the control circuit pressure is normal before measuring the EPC solenoid valve output pressure. Lower the work equipment to the ground and stop the engine. Then, operate the control levers several times to release the residual pressure in the piping and loosen the hydraulic tank cap gradually to release the internal pressure of the hydraulic tank.

2.

Measuring fan (oil cooler) pump EPC solenoid valve output pressure 1) Remove oil pressure pickup plug (1) from the top of the fan (oil cooler) pump.

Measuring fan (radiator) pump EPC solenoid valve output pressure 1) Remove oil pressure pickup plug (1) from the top of the fan (radiator) pump.

2)

3)

22

Install nipple S2 and connect it to oil pressure gauge [1] of hydraulic tester S1. q Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}. Run the engine at high idle and measure the solenoid output pressure. After finishing measurement, remove the measuring instruments and return the removed parts.

Install nipple S2 and connect it to oil pressure gauge [1] of hydraulic tester S1. q Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}. Run the engine at high idle and measure the solenoid output pressure.

PC2000-8

30 Testing and adjusting

4)

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After finishing measurement, remove the measuring instruments and return the removed parts.

PC2000-8

23

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30 Testing and adjusting

Oil pressure measuring points for pump discharge pressure or jet sensor differential pressure 1 q

1.

(3) Fan (Radiator) pump discharge pressure pickup plug (4) Fan (Oil cooler) pump discharge pressure pickup plug a Measuring tools for fan pump discharge pressure

The oil pressures checked with the monitoring function can be measured at the following points with “oil pressure gauges”.

Symbol 1

Measuring main pump discharge pressure (Common to pumps P1 and P2)

— 2

3.

(1) Main pump discharge pressure pickup plug (F pump) (2) Main pump discharge pressure pickup plug (R pump) a Measuring tools for main pump discharge pressure Symbol 1 — 2

2.

Part Number

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-101-5220

Nipple (M10 x 1.25 mm)

07002-11023

O-ring

Measuring fan pump discharge pressure

790-261-1204

Digital hydraulic tester

799-101-5220

Nipple (M10 x 1.25 mm)

07002-11023

O-ring

Measuring jet sensor differential pressure (Common to control valves VL and VR)

a

Measuring tools for jet sensor differential pressure Symbol 1 —

2 3

24

Part Name Hydraulic tester

(5) Jet sensor output pressure (High pressure side) [Valve 1 side] (6) Jet sensor output pressure (Low pressure side) [Valve 1 side] (7) Jet sensor output pressure (High pressure side) [Valve 2 side] (8) Jet sensor output pressure (Low pressure side) [Valve 2 side]

Part Name

799-101-5002

Part Number 799-101-5002

Part Number

Part Name

799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2701

Differential pressure gauge

799-101-5220 Nipple (M10 x 1.25 mm) 07002-11023

O-ring

PC2000-8

30 Testing and adjusting

SEN02008-00

Measuring PPC valve output pressure a

4.

Start the engine, operate the control lever of the measuring PPC circuit at high idle and measure the oil pressure. a When the oil pressure is 0 while the control lever is set at the neutral position, operate the lever to the full stroke. If the oil pressure comes almost to the oil pressure of the control circuit, the valve is normal.

5.

After the measurement, remove the measuring devices and return the valve to the original state.

1

Devices for measuring PPC valve output pressure Symbol 1 T

2 3

Part Number

Part Name

799-101-5002

Hydraulic tester

790-261-1203

Digital type hydraulic tester

799-401-3200

Adapter assembly #3

02896-11009

O-ring

799-401-3300

Adapter assembly #4

02896-11012

O-ring

a

Measure the PPC valve output pressure under the following conditions: q Hydraulic oil temperature : 45 – 55°C

1.

Disconnect the hoses (1) – (12) from the PPC circuit. Check the cab base. a See the connection drawing in the next page. a Disconnect these hoses at the PPC junction block part.

2.

Attach the adapter T2 or T3 and connect the disconnected hoses again. a #3 size for the travel and swing circuits. #4 size for the work equipment circuits.

3.

Attach the nipple [1] of the hydraulic tester T1 and connect it to the oil pressure gauge [2].

PC2000-8

25

SEN02008-00

30 Testing and adjusting

Measure the pressures inside the cab base first.

No.

Colored band

No.

1

Boom RAISE

Green

7

Swing left

2

Boom LOWER

Brown

8

Swing right

3

Bucket CURL

White

9

R.H. travel REVERSE

Black, black

4

Bucket DUMP

Black

10

R.H. travel FORWARD

Blue, black

5

Arm OUT

Yellow

11

L.H. travel REVERSE

Red, black

6

Arm IN

Blue

12

L.H. travel FORWARD

Green, black

26

PPC Circuit

PPC Circuit

Colored band Red None

PC2000-8

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28

30 Testing and adjusting

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30 Testing and adjusting

PC2000-8

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29

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30 Testing and adjusting

Measuring solenoid valve outlet pressure 1 a

Devices for measuring solenoid valve outlet pressure Symbol 1 U

2 3

Part Number

Part Name

799-101-5002

Hydraulic tester

790-261-1203

Digital type hydraulic tester

799-401-3200

Adapter assembly

02896-11009

O-ring

799-401-3300

Adapter assembly

02896-11012

O-ring

a

Measure the solenoid valve outlet pressure under the following conditions: q Hydraulic oil temperature : 45 – 55°C

1.

Disconnect the hoses (1) – (11) from the solenoid valve circuit to be measured.

30

2.

Attach the adapter U2 and connect the disconnected hoses again.

3.

Attach the nipple [1] of the hydraulic tester U2 and connect it to the oil pressure gauge [2].

4.

Start the engine, idle it at a high speed under the measuring conditions and measure the oil pressure.

5.

After the measurement, remove the measuring devices and return the valve to the original state.

PC2000-8

30 Testing and adjusting

No.

1

Solenoid valve

SEN02008-00

Measuring conditions

3

2-stage relief

4

Arm throttle (L1)

5

Arm throttle (R2)

OFF

0 {0}

All levers at neutral

The back pressure valve (Back pressure OFF) is operated

ON

Min. 2.74 {Min. 28}

OFF

0 {0}

ON

Min. 2.74 {Min. 28}

When the heavy lift switch is turned The main relief valve is set off to low pressure.

OFF

0 {0}

When the heavy lift switch is turned The main relief valve is set on and boom RAISE is operated to high pressure. independently

ON

Min. 2.74 {Min. 28}

All levers at neutral

OFF

0 {0}

ON

Min. 2.74 {Min. 28}

OFF

0 {0}

ON

Min. 2.74 {Min. 28}

OFF

0 {0}

Swing and arm or bucket

Boom RAISE and arm IN or OUT All levers at neutral Boom RAISE and arm IN or OUT All levers at neutral

6

7

8

9

10

11

Boom throttle (R1)

Straight-travel

Machine pushup

Swing holding brake

PPC oil pressure lock

— Swing priority function is operated.

— The arm throttle valve of control valve (L1) is operated. — The arm throttle valve of control valve (R2) is operated. —

Boom RAISE and swing are operated at the same time

The boom throttle valve of control valve (R1) is operated.

ON

Min. 2.74 {Min. 28}

When the travel lever is operated independently

The travel pump and work equipment/swing pump are merged.

OFF

0 {0}

When the travel lever and the work The travel pump and work equipment/swing lever are operequipment/swing pump are ated at the same time separated.

ON

Min. 2.74 {Min. 28}

When the machine push-up switch is turned on

The boom LOWER safety valve is set to high pressure.

OFF

0 {0}

When the machine push-up switch is turned off

The boom LOWER safety valve is set to low pressure.

ON

Min. 2.74 {Min. 28}

When the swing lock switch is The swing brake operates. turned on or all levers are at neutral

OFF

0 {0}

When the swing lock switch is turned off and the swing operation starts

The swing holding brake is released.

ON

Min. 2.74 {Min. 28}

When the lock lever is locked

The basic pressure circuit to the PPC valve is blocked.

OFF

0 {0}

When the lock lever is released

The basic pressure circuit to the PPC valve is opened.

ON

Min. 2.74 {Min. 28}

All levers at neutral

The bucket PPC circuit of control valve (R2) is opened.

OFF

0 {0}

Arm IN and bucket CURL

The bucket PPC circuit of control valve (R2) is blocked.

ON

Min. 2.74 {Min. 28}

Bucket Hi cancel

PC2000-8

Oil pressure (MPa {kg/cm2})

The back pressure valve (Back pressure ON) is released

Variable back pressure

Swing priority

Solenoid operation

Swing or travel

All levers at neutral 2

Machine operation

31

SEN02008-00

Adjusting work equipment and swing PPC valve a k

30 Testing and adjusting

1

When the work equipment and swing lever tip plays much, adjust according to the following procedures. Lower the work equipment completely to the ground, stop the engine and operate the work equipment control lever several times to relieve pressure remaining in the pipe. Then, loosen the hydraulic tank oil filler cap slowly and bring the safety lock lever to the lock position. a Lever play : 0.5 to 3 mm at the position of 200 mm from the center of the lever mounting pin.

1.

Remove bellows (1).

2.

Loosen the locknut (2), turn the disc (3) to adjust the lever play. a At the time, do not move the piston.

3.

Fix the disc (3) and tighten the locknut (2) by applying the specified torque. 3 Locknut : 69 – 78 Nm {7 – 9 kgm}

32

PC2000-8

30 Testing and adjusting

Testing and adjusting travel deviation

SEN02008-00

1

Measurement a Measure travel deviations under the following conditions: q Hydraulic oil temperature : 45 – 55°C q Measuring position : Horizontal hard flat ground 1.

Start the engine and bring the work equipment to the travel posture.

2.

Set the working mode to the P Mode.

3.

Run the machine 10 m with the engine at full throttle and run it further 20 m as it is, then measure the deviation (A).

PC2000-8

33

SEN02008-00

30 Testing and adjusting

Adjusting a Carry out troubleshooting for “H-16 Machine deviates by itself during travel” to find out the causal part in advance. a Adjust the deviation with the motor idle running. a If the main pump is adjusted for measures, adjust the servo piston. a Increase and decrease the maximum delivery amount of the pump. 1.

Fix adjustment screw (1) and loosen locknut (2).

2.

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

3.

Fix adjustment screw (1) and tighten locknut (2). 3 Locknut: 539 – 647 Nm {55 – 66 kgm}

34

PC2000-8

30 Testing and adjusting

Testing work equipment hydraulic drift cause portion 1 a

When a hydraulic drift occurred to the work equipment, follow the procedures below to check if the cause has come from the cylinder piston ring side or from the control valve side.

1.

Testing boom cylinder and bucket cylinder 1) Take the same posture as that for measuring hydraulic drift and stop the engine. a Place the rated load or sand in the bucket.

SEN02008-00

2.

Testing arm cylinder 1) Stop the arm cylinder about 100 mm before the IN stroke end and stop the engine.

2)

2)

In case of boom, bring the boom control lever to the “RAISE side”, or in case of bucket, bring the bucket control lever to the “CURL side”. q If the drift speed becomes faster, the cylinder piston ring is defective. q If the speed does not change, the control valve is defective. a Operate the control lever when the starting switch is ON. a When the accumulator pressure is 0, run the engine for about 10 seconds to accumulate pressure.

PC2000-8

Operate the arm control lever to the “IN side”. q If the drift speed becomes faster, the cylinder piston ring is defective. q If the speed does not change, the control valve is defective. a Operate the control lever when the starting switch is ON. a When the accumulator pressure is 0, run the engine for about 10 seconds to accumulate pressure.

[Reference] The reason why the above operation makes the drift speed faster when the cause of hydraulic drift is the cylinder piston ring: 1) In case of the above work equipment posture (the holding pressure rises on the bottom side), oil leaks from the bottom side to the head side but the head side volume is smaller than the bottom side one by the rod. So, oil flowing in from the bottom side increases the internal pressure on the head side. 2) As the internal pressure on the head side increases, both pressures come to balance at a certain pressure (depending on leakage), and the drift speed becomes slow. 3) If the head side circuit opens to the drain circuit at the time (the bottom side is closed with the check valve) by the above lever operation, oil will flow from the head side to the drain circuit. Pressure will come not to balance, and the drift speed will become faster.

35

SEN02008-00

Testing oil leakage a q

1.

30 Testing and adjusting

1

Measure oil leakage under the following conditions: Hydraulic oil temperature : within operating temperature range

2.

Measurement of leakage from arm cylinder 1) Extend the cylinder fully and stop the engine.

Measurement of leakage from boom cylinder 1) Extend the cylinder fully and stop the engine.

2)

2)

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

3)

Start the engine, operate the right control lever to the “Arm IN” side at high idling and apply the relief oil pressure to the cylinder bottom side. k Be careful not to operate the control lever to the “Arm OUT” side. After 30 seconds elapsed, measure oil leakage for 1 minute.

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

4) 3)

4)

36

Start the engine, operate the left control lever to the “Boom RAISE” side at high idle and apply the relief oil pressure to the cylinder bottom side. k Be careful not to operate the control lever to the “Boom LOWER” side. After 30 seconds elapsed, measure oil leakage for 1 minute.

PC2000-8

30 Testing and adjusting

3.

Measurement of leakage from bucket cylinder 1) Extend the cylinder fully and stop the engine.

2)

Disconnect the pipe (3) from the head side and block the pipe on the control valve side with flange. k Be careful not to disconnect the pipe on the bottom side.

SEN02008-00

4.

Measurement of leakage from swing motor k After the engine stopped, loosen the oil filler cap of the hydraulic tank slowly to relieve pressure from the tank. 1) Disconnect the drain hose (4) from the swing motor and block the hose side with plug.

2) 3) 4) a

3)

4)

Start the engine and turn the swing lock switch to the lock position. Run the engine at high idle speed and relieve the swing motor. After 30 seconds elapsed, measure oil leakage for 1 minute. Measure oil leakages several times while moving the swing motor little by little (by sliding the valve plate and the cylinder block).

Start the engine, operate the left control lever to the “Bucket CURL” side at high idling and apply the relief oil pressure to the cylinder bottom side. k Be careful not to operate the control lever to the “Bucket DUMP” side. After 30 seconds elapsed, measure oil leakage for 1 minute.

PC2000-8

37

SEN02008-00

5.

Measurement of leakage from travel motor 1) Start the engine and place a pin or a block between the sprocket and the track frame or the track link to lock the travel. k Make sure that the travel is locked certainly. k After the engine stopped, loosen the oil filler cap of the hydraulic tank slowly to relieve pressure from the tank. 2) Disconnect the drain hose (5) from the travel motor and block the hose side with plug.

3) 4)

30 Testing and adjusting

6.

Measurement of leakage from center swivel joint 1) Start the engine and place a pin or a block between the sprocket and the track frame or the track link to lock the travel. k Make sure that the travel is locked certainly. k After the engine stopped, loosen the oil filler cap of the hydraulic tank slowly to relieve pressure from the tank. 2) Disconnect the upper and lower measuring port hoses of the inspection port with the upper and lower swivels and block the hose side with plug or flange. Inspection port

Circuit

A

Right travel FORWARD

T, A

B

Right travel REVERSE

A, C

C

Left travel FORWARD

P, D

D

Left travel REVERSE

D, T

Start the engine and operate the travel on the measuring side at high idle to relieve the travel motor. After 30 seconds elapsed, measure oil leakage for 1 minute. a Measure oil leakages several times while moving the travel motor little by little (by sliding the valve plate and the cylinder block). 3)

4)

38

Measuring port

Start the engine and operate the travel of the measuring port at high idle to relieve the travel motor. k Check the inspection port and conduct the travel operation carefully. After 30 seconds elapsed, measure oil leakage for 1 minute. a Measure oil leakages from the two measuring ports of the lower swivel.

PC2000-8

30 Testing and adjusting

SEN02008-00

Remaining pressure relief from hydraulic circuit 1 k

a

When disconnecting the pipe between the control valve and the cylinder or the motor, relieve pressure remaining in the circuit according to the following procedures. No pressure remains in the travel motor circuit, but the internal pressure of the hydraulic tank influences the relief. So, open the cap of the hydraulic tank.

1.

Stop the engine and loosen the oil filler cap of the hydraulic tank slowly to relieve pressure in the tank.

2.

Free the lock lever and operate the control lever several times. a When the control lever is operated 2 or 3 times, the pressure accumulated in the accumulator is relieved completely.

3.

Start the engine, idle it at low speed for about 10 seconds to accumulate pressure in the accumulator, then stop the engine.

4.

Repeat Steps 2 and 3 several times.

PC2000-8

39

SEN02008-00

30 Testing and adjusting

Air bleeding from each component 1.

Air bleeding from hydraulic pump

a

k

1)

2) 3) 4)

40

1

After removing and installing the hydraulic pump or changing hydraulic oil, bleed air from the hydraulic pump according to the following procedures. If air was not bled or air was bled insufficiently, the pump may be broken. So, be sure to bleed air strictly according to the procedures.

5)

Loosen plug (5) for suction tube and check that oil flows out. Then, tighten the plug temporarily.

Loosen bleeders (1) – (3) of all hydraulic pump 1 or 2 turns at the same time. a Connect a tube [1] to each bleeder to prevent oil from being scattered and to receive oil in oil pan. Feed hydraulic oil up to the specified level. a Even after feeding oil to the hydraulic tank, keep the oil filler cap removed. After oil flew out from bleeder (3) of the fan pump PF, tighten bleeder (3) temporarily. After bleeders (1) and (2) of the main pumps P1 and P2 stop bleeding air, tighten only bleeder (2) of the main pump P2 temporarily. a Keep bleeder (1) of the main pump P1 loose.

PC2000-8

30 Testing and adjusting

6)

7) 8)

9) 10)

11) 12)

13)

14)

15)

16)

17) 18)

Crank the engine and make sure that oil flows out from bleeder (1) of the main pump P1. Then, tighten the bleeder temporarily. a For cranking, idle the engine at low speed for 15 seconds twice. Loosen the bleeder (2) of the main pump P2. Crank the rear engine and make sure that oil flows out of the bleeder (2) of the main pump P2. Then, tighten the bleeder temporarily. a For cranking, idle the engine at low speed for 15 seconds twice. Start the engine and keep it idle at low speed. Loosen the bleeders (1) – (3) of all hydraulic pumps and make sure that bubble-free oil flows out of them. Then, tighten these bleeders temporarily. Close the oil filler caps of the hydraulic tank. Keep the engine idling at low speed, raise the work equipment from the ground and swing the upper structure 180°. a After the swing, lower the work equipment completely to the ground. Loosen plug (5) for the suction tube and make sure that bubble-free oil flows out of it. Then, tighten the plug. 3 Plug : 58.8 – 78.4Nm {6 – 8kgm} Loosen the bleeders (1) – (3) of all hydraulic pumps and make sure that bubble-free oil flows out of them. Then, tighten these bleeders temporarily. a This work is the same as in the above Step 10. Keep the engine idling at low speed, raise the work equipment from the ground and swing the upper structure 180°. a Swing the upper structure in the reverse direction from the one in the above Step 12. After the swing, lower the work equipment completely to the ground. Loosen the bleeders (1) – (3) of all hydraulic pumps and make sure that bubble-free oil flows out of them. Then, tighten these bleeders. 3 Bleeder : 8.8 – 9.8Nm {0.9 – 1.0kgm} Stop the engine. Loosen the oil filler cap of the hydraulic tank slowly and remove it. Relieve pressure from the hydraulic tank and feed hydraulic oil up to the specified level.

PC2000-8

SEN02008-00

2.

Air bleeding from work equipment cylinder circuit

a

k

1) 2)

3) 4) 5) a

When removing and installing the work equipment cylinder or when disconnecting and connecting the cylinder circuit piping, bleed air from the work equipment cylinder according to the following procedures. If air was not bled or air was bled insufficiently, the cylinder piston ring may be broken. So, be sure to bleed air strictly according to the procedures. Start the engine and idle it at low speed for about 5 minutes. Repeat raising and lowering the boom 4 or 5 times at the low idle. a Stop the piston rod about 100mm before the stroke end and be careful not to relieve it. Execute Step 2) at high idle. Bring the piston rod to the stroke end at low idle and relieve it. Execute Steps 2) – 4) for the arm and the bucket. When the cylinder was replaced, execute the procedures before connecting the work equipment. Especially, when the boom cylinder was installed to the work equipment, the lowering side does not move to the stroke end.

41

SEN02008-00

3.

Air bleeding from swing motor circuit (Swing motor)

a

k

1) 2)

42

When removing and installing the swing motor or when disconnecting and connecting the swing motor main circuit pipes, bleed air from the swing motor according to the following procedures. If air was not bled or air was bled insufficiently, the swing motor may be damaged. So, be sure to bleed air strictly according to the procedures. Start the engine and operate it while the engine is idling at low speed. Repeat operations of swing, start, and stop 5 or 6 times.

30 Testing and adjusting

4.

Air bleeding from swing motor circuit (Parking brake circuit)

a

k

1) 2) 3)

When removing and installing the swing motor or when disconnecting and connecting the swing holding brake circuit piping, bleed air from the brake circuit according to the following procedures. If air was not bled or air was bled insufficiently, the swing holding brake may be dragged. So, be sure to bleed air strictly according to the procedures. Start the engine and loosen bleeder (11). a The bleeder is mounted on the front and rear swing motors. Turn off the swing lock switch. Swing the motor while the engine is idling at low speed and make sure that bubblefree oil flows out of bleeder (11). Then, tighten the bleeders. 3 Bleeder : 8.8 – 9.8Nm {0.9 – 1.0kgm} a The swing operation may be as faintly as the swing oil pressure switch turns on.

PC2000-8

30 Testing and adjusting

5.

Air Bleeding from travel motor circuit (Travel motor)

SEN02008-00

6.

Bleeding air from pilot selector valve circuit a k

1)

a

k

1) 2)

When removing and installing the travel motor or when disconnecting and connecting the travel motor main circuit pipes, bleed air from the travel motor according to the following procedures. If air was not bled or air was bled insufficiently, the travel motor may be damaged. So, be sure to bleed air strictly according to the procedures. Start the engine and loosen bleeder (12). a The bleeder is mounted on the LH and RH travel motors. Make sure that bubble-free oil flows out of the bleeders (12). Then, tighten the bleeder. 3 Bleeder : 8.8 – 9.8Nm {0.9 – 1.0kgm}

PC2000-8

If the pilot selector valve circuit was disconnected and connected, bleed air from it according to the following procedure. If the air bleeding operation is not performed or all air is not bled, the work equipment speed may decrease during compound operation. Therefore, be sure to bleed air according to the specified procedure.

q

Start the engine and loosen bleeders (1) and (2). a Pilot selector valves PV1 and PV2 have 1 bleeder each. Pilot selector valve PV1

q

Pilot service valve PV2

43

SEN02008-00

2)

3) 4)

44

30 Testing and adjusting

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

PC2000-8

30 Testing and adjusting

Air bleeding from PPC circuit

SEN02008-00

1

a

When removing and installing the control valve or when disconnecting and connecting PPC hose, bleed air from the PPC circuit according to the following procedures. If air was not bled or air was bled insufficiently, time lag or abnormal sound may occur. So, be sure to bleed air strictly according to the procedures.

1.

Start the engine and loosen the bleeder (13). a The bleeders are installed on the wiring harness spring case elbow of the control valve spool (28 places in total).

2.

Control each actuator while the engine is idle at low speed.

3.

Make sure that bubble-free oil flows out of bleeder (13). Then, tighten bleeder. 3 Bleeder: 8.8 – 9.8 Nm {0.9 – 1.0 kgm} k

4.

The operation of each lever should be enough to the extent that each hydraulic switch turns on.

The circuits and places to be bled are as follows. A : Arm IN circuit (3 places), Q : Boom RAISE circuit (3 places), T : Bucket CURL circuit (4 places), U : Travel REVERSE circuit (4 places), a : Arm OUT circuit (4 places), q : Boom LOWER circuit (2 places), t : Bucket DUMP circuit (4 places), u : Travel FORWARD circuit (4 places)

PC2000-8

45

SEN02008-00

q

Front side of control valve

q

Rear side of control valve

46

30 Testing and adjusting

PC2000-8

30 Testing and adjusting

SEN02008-00

Testing and adjusting auto grease system 1.

2.

1

Indication of abnormality by auto grease controller If the auto grease system has abnormality, the auto grease caution lamp lights up red and the auto grease caution mark is indicated in the machine monitor.

Lamp

Indication by machine monitor

Lighting up

Refer to figure 9JH10486

Abnormality Pump is running but pressure in grease piping does not rise.

Adjusting delivery from injector a The delivery from the injector is adjusted when shipped. If necessary, increase or decrease the delivery according to the following procedure. 1) Remove the cap from the adjustment screw and loosen locknut (3). 2) Turn adjustment screw (2) to adjust the delivery. a If the adjustment screw q is turned clockwise, the delivery is reduced. q is turned counterclockwise, the delivery is increased. a Delivery increase or decrease by 1 turn of adjustment screw: 0.17 cc/st a Limit dimension (a) of the adjustment screw to 10 mm. a If the adjustment screw is tightened fully to reduce dimension (a) to 10 mm, the delivery is 0.13 cc/st.

PC2000-8

Cause

3)

• • •

Pump trouble No grease Breakage of grease piping or leakage

Tighten locknut (3) and install the cap of the adjustment screw.

47

SEN02008-00

3.

Bleeding air from grease pump line a When a new machine is delivered or transported disassembled or when the grease can becomes empty or when the hose, pump, or injector is replaced, bleed air from the grease pump line according to the following procedure. 1) Set the grease mode selector switch to the MANUAL position. 2) Operate the grease gun to bleed air from the grease pump line. a Check that the grease discharged from the grease gun does not contain air.

4.

Bleeding air from distributor line a When a new machine is delivered or transported disassembled or when the grease can becomes empty or when the hose, pump, or injector is replaced, bleed air from the grease pump line according to the following procedure. a Perform this work after “Bleeding air from grease pump line” is finished. a Perform this work on the all distributor lines in order from the one nearest to the grease pump (Swing circle → Boom cylinder bottom → Boom → Arm). 1) Set the grease mode selector switch to the MANUAL position. 2) Remove plug (4) of the distributor.

30 Testing and adjusting

5.

Bleeding air from injector line a When a new machine is delivered or transported disassembled or when the grease can becomes empty or when the hose, pump, or injector is replaced, bleed air from the grease pump line according to the following procedure. a Perform this work after “Bleeding air from distributor line” is finished. a Perform this work on the all distributor lines. 1) Set the grease mode selector switch to the MANUAL position. 2) Remove plug (5) of the injector. 3) Using the grease gun, supply grease through service nipple (6) to the injector line.

4)

3) 4)

48

Install plug (5). 3 Plug: 3.92 – 5.88 Nm {0.4 – 0.6 kgm}

Check that the grease discharged from the plug hole does not contain air. Install plug (4). 3 Plug: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}

PC2000-8

30 Testing and adjusting

6.

Check of completion of air bleeding Check that the indicator (7) of each injector is operating normally with the auto grease system operating. a If the indicator reciprocates vertically, it is normal.

a

7.

SEN02008-00

If the indicator does not operate normally, air has not been bled completely. In this case, perform procedures 3 – 5 again.

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

4)

Install plug (5). 3 Plug: 3.92 – 5.88 Nm {0.4 – 0.6 kgm}

PC2000-8

49

SEN02008-00

Adjusting mirrors q

1.

50

30 Testing and adjusting

1

2.

Adjusting mirrors (a1) and (a2) Adjust these mirrors so that the operator can see from left side to left rear of the machine. a Angle from machine side (a) : 70°

3.

Adjusting mirror (b) Adjust this mirror so that the operator can see the catwalk. a Angle from machine side (b) : 60°

The mirrors are installed to the following 4 positions. a: Cab at left front of machine b: Floor around cab at left front of machine c: Handrail at left rear of machine d: Handrail at right center of machine

Loosen nut (1), bolt (2) and screw (3) of each mirror and adjust the mirrors to decided dimension and angle as following items. a Adjust the mirrors (c: Handrail at left rear of machine, and d: Handrail at right center of machine) so that the operator can particularly see persons at the right and left rear ends of the machine. a Adjust the mirrors so that the operator can see persons (or things 1 m high and about 30 cm in diameter) at the right and left rear ends of the machine.

PC2000-8

30 Testing and adjusting

4.

Adjusting mirrors (c1) and (c2) q c1: Adjust so that the operator can see the left rear end of the machine. q c2: Adjust so that the operator can see the left rear end of the counterweight.

q q q q

L dimension : 86 mm M dimension : 200 mm N dimension : 270 mm Angle (c) : 30°

SEN02008-00

5.

Adjusting mirrors (d1) and (d2) q d1: Adjust so that the operator can see the right lower end of the fuel tank. q d2: Adjust so that the operator can see the right rear lower end of the machine.

q q q q q

PC2000-8

P dimension : 303 mm Q dimension : 35 mm R dimension : 604 mm Angle (d) : 30° Angle (e) : 45°

51

SEN02008-00

PC2000-8 Hydraulic excavator Form No. SEN02008-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

52

SEN02009-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

30 Testing and adjusting

1

Testing and adjusting, Part 3 Testing and adjusting, Part 3........................................................................................................................... 2 Special functions of machine monitor................................................................................................... 2 Handling controller voltage circuit ...................................................................................................... 57

PC2000-8

1

SEN02009-00

30 Testing and adjusting

Testing and adjusting, Part 3

1

Special functions of machine monitor

1

For all specifications

2

PC2000-8

30 Testing and adjusting

SEN02009-00

Upper section of machine monitor (Display section) (a): Multi-display a When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, however. Upper section of machine monitor (Switch section) [F1]: F1 function switch [F2]: F2 function switch [F3]: F3 function switch [F4]: F4 function switch [F5]: F5 function switch [F6]: F6 function switch a The function of each function switch is indicated by graphic mark in the multi-display (a) above that function switch. a If the graphic mark of a function switch is not displayed, that function switch is not working. Lower section of machine monitor (Switch section) [1]: Numeral 1 input switch/Auto-decelerator switch [2]: Numeral 2 input switch/Working mode selector switch [3]: Numeral 3 input switch/Heavy lift shifting switch [4]: Numeral 4 input switch/Alarm buzzer cancel switch [5]: Numeral 5 input switch/Wiper switch [6]: Numeral 6 input switch/Windshield washer switch [7]: Numeral 7 input switch [8]: Numeral 8 input switch [9]: Numeral 9 input switch [0]: Numeral 0 input switch Switch having no numerals: No function a Each switch has the function indicated by graphic mark and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently effective, according to the display condition of multidisplay.

PC2000-8

3

SEN02009-00

30 Testing and adjusting

t Ordinary functions and special functions of machine monitor The machine monitor has the ordinary function and special functions and displays information of various types on the multi-display. Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches. 1. Ordinary functions: Operator mode The items in this mode are displayed ordinarily. The operator can display and set them by operating the switches (Display and setting of some items need special operations of the switches). 2. Special functions: Service mode The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting. t Operator mode (Outline)

Page

Page

Service mode

6p

18p

A Display of KOMATSU logo

6p

Monitoring

19p

A Display of check before starting

6p 7p

Abnormality Mechanical Systems Record Electrical Systems

27p

A Display of warning after check before starting A Display of ending of maintenance interval

7p

Maintenance Record

35p

A Display of check of working mode

7p

Maintenance Mode Change

36p

A Display of ordinary screen

7p

Phone Number Entry

38p

B Change of ordinary screen

7p

Key-on Mode

39p

A Display of end screen

8p

Unit

40p

B Selection of auto-deceleration and auto low idle

8p

Maintenance Password

41p

B Selection of working mode

8p

Camera

42p

B Selection of heavy lift

9p

ECO Display

43p

B Operation to stop alarm buzzer

9p

Pump Absorption Torque

44p

Adjustment of auto grease pump discharge pressure

45p

Interval adjustment of auto grease

45p

Operating time adjustment of auto grease pump

45p

10p

B Operation of window washer

10p

B Display of auto grease monitor

10p

B Display of truck counter

11p

B

Operation to display camera mode (if camera is installed)

11p

O (Special operation)

B Operation of windshield wiper

Default

28p

Adjustment Setting of grease start time after operation

45p

B Operation to display clock and service meter

12p

Selection of fan speed mode

46p

B Check of maintenance information

12p

Adjustment of RAD fan 100% speed

46p

B Setting and display of user mode

12p

Adjustment of O/C fan 100% speed

46p

C Display of energy-saving guidance

13p

Adjustment of RAD fan 70% speed

47p

C Display of caution monitor

13p

Adjustment of O/C fan 70% speed

47p

C Display of user code and failure code

13p

O (Special operation) D

Function of checking display of LCD (Liquid Crystal Display)

15p

D Function of checking service meter

15p

D Function of changing maintenance password

16p

4

Cylinder Cut-Out

48p

No Injection

51p

Fuel Consumption

52p

Snap shot

54p

PM clinic

55p

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30 Testing and adjusting a

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Classification of operator mode A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary screen and display after starting switch is turned OFF B: Display/Function when switch of machine monitor is operated C: Display/Function when certain condition is satisfied D: Display/Function which needs special operation of switch

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a

30 Testing and adjusting

Operator mode (Outline) Only outline of the operator mode is described in this section. For details of contents/operation of each function/display, see the “Structure, function and maintenance standard”, or “Operation and Maintenance Manual”. The following are the displays or functions of the operator mode explained in this section (including some items which need special operations). Display pattern B D E

Display of KOMATSU logo

1

1

1

Display of check before starting

2

2

2

Display of warning after check before starting — 3 — Display of ending of maintenance interval

— — 3

Display of check of working mode

3 — —

Display of ordinary screen

4

4

a

Display pattern of operator mode The contents of display from the time when starting switch is turned ON to time when screen changes to ordinary screen depends on the setting and condition of the machine. Other than D and B D : When there is abnormal item in checkbefore-starting items E : When there is maintenance item which is not maintained after specified interval

Display of KOMATSU logo When the s tarting switch is turned ON, the KOMATSU logo is displayed for 2 seconds. a After the KOMATSU logo is displayed for 2 seconds, the screen changes to “Display of check before starting”.

4

Change of ordinary screen Display of end screen Selection of auto-deceleration and auto low idle Selection of working mode Selection of heavy lift Operation to stop alarm buzzer Operation of windshield wiper Operation of wind washer Display of auto grease monitor Display of truck counter Operation to display camera mode (if camera is installed) Operation to display clock and service meter Check of maintenance information Setting and display of user mode Display of energy-saving guidance Display of caution monitor Display of user code and failure code O (Special operation) Function of checking display of LCD (Liquid Crystal Display)

Display of check before starting When the screen changes to the check-beforestarting screen, the check before starting is carried out for 2 seconds. a If any abnormality is detected by the check before starting, the screen changes to “Display of warning after check before starting” or “Display of ending of maintenance interval”. a If no abnormality is detected by the check before starting, the screen changes to “Display of check of working mode and travel speed”. a The monitors (6 pieces) displayed on the screen are the items under the check before starting.

Function of checking service meter Function of changing maintenance password

6

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Display of warning after check before starting If any abnormality is detected by the check before starting, the warning monitor is displayed on the screen. a The following figure shows that the engine oil level monitor (a) is warning of low of engine oil level.

Display of check of working mode If the check before starting is finished normally, the screen to check the working mode is displayed for 2 seconds. a After display of check of the working mode is finished, the screen changes to “Display of ordinary screen”.

Display of ending of maintenance interval When the check before starting is carried out, if a maintenance item is near or after the end of the set interval, the maintenance monitor is displayed for 30 seconds to urge the operator to maintenance. a This screen is displayed only when the maintenance function is effective. The color of the maintenance monitor (yellow or red) indicates the length of the time after the maintenance interval. a Set or change the maintenance function in the service mode. a After display of this screen is finished, the screen changes to “Display of check of working mode and travel speed”.

Display of ordinary screen If the machine monitor starts normally, the ordinary screen is displayed. a Service meter (a) or a clock is displayed at the center upper section of the screen (The service meter or clock is selected with [F4]). a ECO gauge (b) is displayed at the right end of the screen (It is turned ON and OFF in the service mode).

Change of ordinary screen In the ordinary screen, 2 screens of 1/2 and 2/2 can be selected. When the machine monitor is started, 1/2 screen is displayed. a Press F1 once to change the 1/2 or 2/2 screens alternately.

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Display of end screen When the starting switch is turned OFF, the end screen is displayed for 5 seconds. a Another message may be displayed on the end screen, depending on the message display function of KOMTRAX.

Selection of auto-deceleration and auto low idle While the ordinary screen is displayed, if the autodeceleration switch is pressed, large auto-deceleration monitor (a) is displayed for 2 seconds and the setting of the auto-deceleration is changed. a Each time the auto-deceleration switch is pressed, the auto-deceleration is turned ON and OFF alternately. a If the auto-deceleration is turned ON, large monitor (a) and auto-deceleration monitor (b) are displayed simultaneously. a If the auto-deceleration is turned OFF, autodeceleration monitor (b) goes off.

30 Testing and adjusting a

Selection of working mode Select a working mode according to the following procedure. 1. While the ordinary screen is displayed, press the working mode selector switch, and the working mode selection screen is displayed.

2.

8

If the auto low idle setting is turned “ON” from the user menu, the auto low idle function is shifted between effective and ineffective in the order of “ON” — “OFF” — “ON” each time the auto-deceleration switch is pressed.

Operate the function switches or working mode selector switch to select and confirm the working mode which you will use. Function switches q [F3]: Move to lower working mode q [F4]: Move to upper working mode q [F5]: Cancel selection and return to ordinary screen q [F6]: Confirm selection and return to ordinary screen Working mode selector switch q Press: Move to lower working mode q Hold down:Confirm selection and return to ordinary screen

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30 Testing and adjusting a

3.

If you do not touch any of the function switches and working mode selector switch for 5 seconds, the selection is confirmed and the screen changes to the ordinary screen.

SEN02009-00

Selection of heavy lift If the heavy lift switch is pressed with the ordinary screen displayed, large monitor (a) of heavy lift is displayed for 2 seconds and the heavy lift setting is changed. a Each time the heavy lift switch is pressed, the heavy lift is turned ON and OFF alternately. a If the heavy lift is turned ON, large monitor (a) and heavy lift monitor (b) are displayed simultaneously. a If the heavy lift is turned OFF, heavy lift monitor (b) goes off.

When the ordinary screen is displayed again, large working mode monitor (a) is displayed for 2 seconds, and then the setting of the working mode is changed. a When large monitor (a) is displayed, the display of working mode monitor (b) is changed, too. Operation to stop alarm buzzer While the alarm buzzer is sounding, if the alarm buzzer cancel switch is pressed, the alarm buzzer stops. a Even if the alarm buzzer cancel switch is pressed, the screen does not change.

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Operation of windshield wiper While the ordinary screen is displayed, if the wiper switch is pressed, large wiper monitor (a) is displayed for 2 seconds and the windshield wiper starts or stops. a Each time the wiper switch is pressed, the windshield wiper setting is changed to INT, ON (continuos, upper/lower), ON (continuos, upper), OFF, and INT again in order. a When large monitor (a) is displayed, the display of wiper monitor (b) is changed or turned OFF, too. a If the windshield wiper is turned OFF, large monitor (a) is not displayed.

30 Testing and adjusting

If the grease level lowers below the specified level while the normal screen is displayed, grease level caution lamp (b) lights.

If the manual grease switch on the console is pressed while the normal screen is displayed, manual grease monitor (c) is displayed at the center of the monitor and grease is supplied. When greasing is completed, manual grease monitor (c) goes off.

Operation of window washer While the ordinary screen is displayed, if the window washer switch is pressed, the washing liquid is splashed only while the switch is held down. a Even if the window washer switch is pressed, the screen does not change. Display of auto grease monitor If grease is supplied by the auto grease function while the normal screen is displayed, auto grease monitor (a) lights. When greasing is completed, auto grease monitor (a) goes off.

10

If the auto grease system has abnormality, large auto grease caution mark (d) is displayed at the center of the monitor for 2 seconds and then small caution mark (e) is displayed.

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

a

a

Operation to display camera mode (if camera is installed) When a camera is installed, if [F3] is pressed, the multi-display changes to the camera image (Set the connection of the camera in the service mode).

a a

a

PC2000-8

If a caution is generated in the camera mode, the caution monitor is displayed at the left upper of the screen (The low hydraulic oil temperature caution is not displayed there, however). When an error that there is a user code occurs in the camera mode, if you do not touch any control lever for 10 seconds, the screen changes to the ordinary screen and displays the error information. When two or more cameras are connected, the image of one of them or the images of two of them can be displayed. If 2-camera image display [F4] is selected, the image of camera 1 is displayed on the left side of the screen and the image of camera 2 is displayed on the right side. The image of camera 3 is displayed only singly. If the images of 2 cameras are displayed simultaneously, images are displayed at intervals of 1 second on the right and left screen.

11

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Operation to display clock and service meter While the ordinary screen is displayed, press [F4], and section (a) changes to the service meter and clock alternately. a When the clock is selected, adjust the time, set 12-hour or 24-hour display, and set the summer time with the user mode function.

30 Testing and adjusting

Setting and display of user mode While the ordinary screen is displayed, press [F6], and the user menu screen is displayed.

a

Check of maintenance information While the maintenance monitor or ordinary screen is displayed, press [F5], and the maintenance table screen is displayed.

a

12

There are following items in the user menu. Screen Adjustment ECO Display Clock Adjustment Language Economy Mode Adjustment Auto Low Idle Truck Counter Modification/Clear Hydraulic Fan Reserve

To reset the time left after finishing maintenance, more operations are necessary.

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30 Testing and adjusting

Display of energy-saving guidance When the machine is set in a certain operating condition, the energy-saving guidance screen is displayed automatically to urge the operator to the energy-saving operation. a The energy-saving guidance is displayed when the following condition is satisfied while the display setting is set effective in the service mode. a Condition for display: Engine is running + All levers have been in neutral for 5 minutes + Caution (Note) or user code is not generated (Note) Note: Excluding hydraulic oil low temperature caution a If any lever or pedal is operated, or [F5] is pressed, the screen returns to the ordinary screen.

Display of caution monitor If an abnormality which displays a caution monitor occurs on the ordinary screen or camera mode screen, the caution monitor is displayed large for a moment and then displayed at (a) in the screen. a On the camera mode screen, the caution monitor flashes at the left upper of the screen when the caution is generated.

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Display of user code and failure code If an abnormality which displays a user code and a failure code occurs on the ordinary screen or camera mode screen, all the information of the abnormality is displayed. (a): User code (3 digits) (b): Failure code (5 or 6 digits) (c): Telephone mark (d): Telephone No. a This screen is displayed only when an abnormality (failure code) for which a user code is set occurs. a The telephone mark and telephone No. are displayed only when the telephone No. is registered in the service mode. a If multiple abnormalities occur simultaneously, all the codes are displayed repeatedly in order. a Since the information of the displayed failure code is recorded in the abnormality record in the service mode, check the details in the service mode.

a

When the caution monitor is also displayed, the telephone mark is not displayed.

13

SEN02009-00 a

Remedies given by displayed user codes to operator to take (The following table is an excerpt from the Operation and Maintenance Manual)

User code

Failure mode

Action

Swing brake system error

Move the swing brake cancel switch up to release the brake. When applying the swing brake, operate the swing lock switch manually. Depending on the cause of the problem, it may not be possible to release it. In any case, have inspection carried out immediately.

E07

Pump control system error

An error occurs in the electronic control system of the pump. Emergency avoidance function is underway. Some functions of the machine are disabled. Move machine to the safe place, and have inspection carried out immediately.

E10

Engine controller power source error Engine controller drive system circuit error Have inspection carried out immediately. (engine stopped)

E11

Engine controller system error (Output reduced to protect engine) Fan drive system error

Operate machine to a safe posture and have inspection carried out immediately.

E14

Abnormality in throttle system

Operate machine to a safe posture and have inspection carried out immediately.

E15

Engine sensor (coolant temperature, fuel pressure, oil pressure) system error

Operations are possible, but have inspection carried out immediately.

E0E

Network error Solenoid power supply system error

Operate machine to a safe posture and have inspection carried out immediately.

E03

14

30 Testing and adjusting

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30 Testing and adjusting

Function of checking display of LCD (Liquid Crystal Display) While the ordinary screen is displayed, if the following numeral input switch and function switch are operated as follows, all the LCD (Liquid Crystal Display) lights up in white. q Operation of switches (simultaneous): [4] + [F2] a When finishing the operation of the switches, release [F2] first. a If there is a display error in the LCD, only that part is indicated in black. a The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. a To return to the former screen, press the function switch.

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SEN02009-00

Function of checking service meter To check the service meter while the starting switch is turned OFF, operate the numeral input switches as follows. At this time, only the service meter section displays. q Operation of switches (simultaneous): [4] + [1] a Since there is some time lag in start of the LCD, hold down the switches until the LCD displays normally. a After the machine monitor is used continuously, blue points (points which do not go off) may be seen on this screen. This phenomenon does not indicate a failure or a defect.

15

SEN02009-00

Function of changing maintenance password When changing the maintenance password used for the maintenance setting function, follow these procedures. 1. While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [5] o [5] o [5] a This operation of the switches is not accepted until 10 minutes pass after the starting switch is turned on.

2.

16

After the Maintenance PASSWORD screen is displayed, input the current password with the numeral input switches and confirm it with the function switch. q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral a Default password: [000000] a If the input password is correct, the screen changes to the next screen. a If the input password is incorrect, the message to input the password again is displayed.

30 Testing and adjusting

3.

After the New password input screen is displayed, input a new password with the numeral input switches and confirm it with the function switch. a Set a new password of 4 – 6 digits (If it has only 3 or less digits or has 7 or more digits, it is not accepted). q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral

4.

After the New password input screen is displayed again, input a new password again with the numeral input switches and confirm it with the function switch. q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral a If a password different from the password input before is input, the message to input again is displayed.

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30 Testing and adjusting

5.

SEN02009-00

If the screen to notify completion of setting is displayed and then the ordinary screen is displayed, the password is changed successfully.

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SEN02009-00 t Service mode To change the operator mode to the service mode, perform the following operation. This operation is always required when you use the service mode. 1.

Check of display of screen and operation of switches While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3] a This operation of the switches is accepted only while the ordinary screen is displayed.

30 Testing and adjusting a

The items which can be selected in the service menu are as follows (including some items which need special operations).

01 Monitoring 02

Abnormality Mechanical Systems Record Electrical Systems

03 Maintenance Record 04 Maintenance Mode Change 05 Phone Number Entry Key-on Mode Unit 06 Default

Maintenance Password Camera ECO Display Pump Absorption Torque Adjustment of auto grease pump discharge pressure Interval adjustment of auto grease Operation time adjustment of auto grease pump

07 Adjustment

Setting of grease start time after operation Selection of fan speed mode Adjustment of RAD fan 100% speed

2.

18

Selection of service menu When the Service menu screen is displayed, the service mode is selected. Select a service menu you use with the function switches or numeral input switches. q [F3]: Move to lower menu q [F4]: Move to upper menu q [F5]: Return to ordinary screen (operator mode) q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the menu of that code and confirm it with [F6].

Adjustment of O/C fan 100% speed Adjustment of RAD fan 70% speed Adjustment of O/C fan 70% speed 08 Snap shot 09 Cylinder Cut-Out 10 No Injection

11 Fuel Consumption 12 PM clinic

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Monitoring The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to many parts of the machine and the information from the controllers which are controlling switches, etc. 1.

Selecting menu Select “Monitoring” on the service menu screen.

3.

2.

Selecting monitoring items After the “Monitoring selection menu screen” is displayed, select items to be monitored with t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Reset input numeral/Return to service menu screen q [F6]: Confirm selection a Selection with function switches: Select an item with [F3] or [F4] and confirm it with [F6]. a Selection with numeral input switches: Enter a 5-digit code, and the item of that code is selected directly. Confirm that item with [F6]. a If the color of the selected box changes from yellow to red, selection of the item of that box is confirmed. a Up to 6 monitoring items can be selected at a time. You may not able to set up to 6 items, however, depending on the display form of those items.

PC2000-8

Deciding monitoring items After selecting monitoring items, execute monitoring with the function switch or numeral input switch. a Execution with function switch: Doubleclick or hold down [F6] (about 2 seconds). a Execution with numeral input switch: Input [99999] and press [F6]. a When monitoring only 2 items, for example, select them and confirm with [F6]. If [F6] is pressed once more at this time, monitoring is executed. a If monitoring items are selected up to the limit number, monitoring is executed automatically.

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SEN02009-00

4.

Executing monitoring After the “Executing monitoring screen” is displayed, perform the necessary operation of the machine and check the monitoring information. a Monitoring information is indicated by value, ON/OFF, or special display. a The unit of display can be set to “SI unit”, “metric unit”, or “inch unit” with the Initialization function in the service mode.

5.

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

20

30 Testing and adjusting

6.

Changing machine setting mode To change the setting of the working mode, travel speed, or auto-deceleration during monitoring, operate the corresponding switch under the current condition, and the mode setting screen is displayed. While this screen is displayed, if the corresponding switch is operated further, the corresponding mode is changed. a After finishing changing the setting, press [F6] to return to the monitoring information screen. a If the setting is changed during monitoring, the new setting is held even after the screen returns to the ordinary screen after monitoring is finished.

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Monitoring items table Code No. 00200 00201 00203 01601 12100 01002 01006 10001 10004 04206 01124 01125 01126 01127 01132 01134 07400 07500 07200 07600 07300 07301 09001 09002 13804 13805 13806 13807 13900 36400 36403 36500 37200 37400 42800 04401 04405 37501 04107 14200 14203 18400 18500 42700 30000 42600 42601 42608 42609 01307

Monitoring item Controller Model Select Machine ID Machine ID 2nd Engine Speed Command 1st Engine Speed Command Engine speed Engine speed RAD Fan Speed O/C Fan Target Speed Fuel Level P1F Pump Pressure P1R Pump Pressure P2F Pump Pressure P2R Pump Pressure RAD Fan Pump Pressure O/C Fan Pump Pressure Boom Raise PPC Pressure Boom Lower PPC Pressure Arm Curl PPC Pressure Arm Dump PPC Pressure Bucket Curl PPC Pressure Bucket Dump PPC Pressure Swing Left PPC Pressure Swing Right PPC Pressure VR1 J/S Diff Pressure VL1 J/S Diff Pressure VR2 J/S Diff Pressure VL2 J/S Diff Pressure Auto Grease Disc Pressure L/B Rail Pressure R/B Rail Pressure L/B Charge Pressure Engine Oil Pressure Ambient Pressure Blowby Pressure Hydr. Oil Temperature VHMS Hydr. Oil Temperature Ambient Temperature Coolant Temperature L/B Fuel Temperature R/B Fuel Temperature Intake Temperature Charge Temperature Engine Oil Temperature PTO Oil Temperature L/B1-3 Exhaust Temperature L/B4-6 Exhaust Temperature R/B1-3 Exhaust Temperature R/B4-6 Exhaust Temperature P1F Pump EPC Act Current

PC2000-8

Component in charge PUMP (1st) ENG (1st) ENG (2nd) PUMP (1st) PUMP (1st) ENG (1st), PUMP PUMP (2nd) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (2nd) ENG (1st) ENG (2nd) ENG (1st) ENG (1st) ENG (1st) VHMS PUMP (2nd) VHMS VHMS ENG (1st) ENG (1st) ENG (2nd) ENG (1st) ENG (1st) ENG (1st) VHMS VHMS VHMS VHMS VHMS PUMP (1st)

Unit (Initial setting: ISO) ISO meter inch — — — r/min rpm rpm r/min rpm rpm r/min rpm rpm r/min rpm rpm r/min rpm rpm r/min rpm rpm % % % psi MPa kg/cm2 MPa kg/cm2 psi 2 psi MPa kg/cm MPa kg/cm2 psi MPa kg/cm2 psi psi MPa kg/cm2 2 MPa kg/cm psi MPa kg/cm2 psi MPa kg/cm2 psi MPa kg/cm2 psi 2 MPa kg/cm psi MPa kg/cm2 psi MPa kg/cm2 psi MPa kg/cm2 psi 2 MPa kg/cm psi MPa kg/cm2 psi MPa kg/cm2 psi MPa kg/cm2 psi 2 MPa kg/cm psi MPa kg/cm2 psi psi MPa kg/cm2 kPa kg/cm2 psi 2 kPa kg/cm psi kPa kg/cm2 psi kPa kg/cm2 psi °C °C °F °C °C °F °C °C °F °C °C °F °C °C °F °C °C °F °C °C °F °C °C °F °C °C °F °C °C °F °C °C °F °C °C °F °C °C °F °C °C °F mA mA mA

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SEN02009-00

Code No. 01309 01311 01313 31624 31634 01128 01129 01130 01131 04403 04406 01133 01135 03200 04300 07201 07302 07303 07401 07501 07601 09003 09004 13808 13809 13810 13811 13901 37505 03000 03203 03206 04105 04200 14201 14202 17201 17202 18401 18501 36401 36404 36501 37201 37401 42701 30001 42603 42604 42605 42607

22

30 Testing and adjusting

Monitoring item P1R Pump EPC Act Current P2F Pump EPC Act Current P2R Pump EPC Act Current RAD Fan Pump EPC Current O/C Fan Pump EPC Current P1F Pump Press Volt P1R Pump Press Volt P2F Pump Press Volt P2R Pump Press Volt Hydr. Oil Temp Sensor Volt VHMS Hydr. Oil Temp Sens Volt RAD Fan Pump Press Sensor Volt O/C Fan Pump Press Sensor Volt Battery Volt Battery Charge Volt Arm Curl PPC Press Volt Bucket Curl PPC Press Volt Bucket Dump PPC Press Volt Boom Raise PPC Press Volt Boom Lower PPC Press Volt Arm Dump PPC Press Volt Swing Left PPC Press Volt Swing Right PPC Press Volt VR1 J/S Diff Press Volt VL1 J/S Diff Press Volt VR2 J/S Diff Press Volt VL2 J/S Diff Press Volt Auto Grease Disc Press Volt Ambient Air Temp Sens Volt Fuel Dial Pos Sens Volt L/B Battery Power Supply R/B Battery Power Supply Coolant Temp Sens Volt Fuel Level Sensor Volt L/B Fuel Temp Sens Volt R/B Fuel Temp Sens Volt L/B PCV Close Timing R/B PCV Close Timing Intake Temp Sens Volt Charge Temp Sens Volt L/B Rail Pressure Sens Volt R/B Rail Pressure Sens Volt Charge Press Sens Volt Eng Oil Press Sens Volt Ambient Press Sens Volt Eng Oil Temp Sens Volt PTO Oil Temp Sens Volt L/B1-3 Exhaust Temp Sens Volt L/B4-6 Exhaust Temp Sens Volt R/B1-3 Exhaust Temp Sens Volt R/B4-6 Exhaust Temp Sens Volt

Component in charge PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (2nd) VHMS PUMP (1st) PUMP (1st) PUMP MON PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (2nd) VHMS ENG (1st) ENG (1st) ENG (2nd) ENG (1st) MON ENG (1st) ENG (2nd) ENG (1st) ENG (2nd) ENG (1st) ENG (1st) ENG (1st) ENG (2nd) ENG (1st) ENG (1st) ENG (1st) ENG (1st) VHMS VHMS VHMS VHMS VHMS

Unit (Initial setting: ISO) ISO meter inch mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V CA CA CA CA CA CA V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V

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30 Testing and adjusting

Code No.

SEN02009-00

Monitoring item

Component in charge

42802 01307 01309 01311 01313 10002 10003 10005 10006 31623 31633 17500 18600 18700 31701 31706 36200 36300 36700 13113 13114 13115 13116 13117 13118 13119 13120 13121 13122 13123 37300

Blowby Pressure Sens Volt P1F Pump EPC Current P1R Pump EPC Current P2F Pump EPC Current P2R Pump EPC Current RAD Fan Target Speed (70%) RAD Fan Target Speed (Max) O/C Fan Target Speed (70%) O/C Fan Target Speed (Max) RAD Fan Pump EPC Current O/C Fan Pump EPC Current Engine Power Mode Inject Fueling Command Engine Output Torque Throttle Position Final Throttle Position Rail Press Command Injection Timing Command Engine Torque Ratio Pump Total Torque RAD Fan Pump Torque O/C Fan Pump Torque P1F Pump Target Torque P1F Pump Actual Torque P1R Pump Target Torque P1R Pump Actual Torque P2F Pump Target Torque P2F Pump Actual Torque P2R Pump Target Torque P2R Pump Actual Torque Fuel Rate Pressure Switch 1 Boom Lower

VHMS PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) ENG (1st) ENG (1st) ENG (1st) ENG (1st) ENG (1st) ENG (1st) ENG (1st) ENG (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) ENG (1st) ENG (1st) PUMP (2nd) PUMP (2nd)

01900

Boom Raise

PUMP (2nd)

Arm Curl

PUMP (2nd)

Arm Dump Pressure Switch 2 Bucket Curl Bucket Dump Service

01901 Pressure Switch 3

Swing Left Swing Right Travel Left Travel Right

01902

Solenoid Valve 1 02300

PC2000-8

Travel Straight Swing Brake 2-Stage Relief

Unit (Initial setting: ISO) ISO meter inch V V V mA mA mA mA mA mA mA mA mA mA mA mA r/min rpm rpm r/min rpm rpm r/min rpm rpm r/min rpm rpm mA mA mA mA mA mA — — — mg/st mg/st mg/st Nm kgm lbft % % % % % % MPa kg/cm2 psi CA CA CA % % % Nm kgm lbft Nm kgm lbft Nm kgm lbft Nm kgm lbft Nm kgm lbft Nm kgm lbft Nm kgm lbft Nm kgm lbft Nm kgm lbft Nm kgm lbft Nm kgm lbft l/h l/h gal/h

ON or OFF

PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd)

ON or OFF

ON or OFF

ON or OFF

23

SEN02009-00

Code No.

30 Testing and adjusting

Monitoring item Solenoid Valve 2

Manual Grease

PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (2nd) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st) PUMP (1st)

Fuel Level Hi

PUMP (1st)

Fuel Level Mid

PUMP (1st)

Fuel Level Low

PUMP (1st)

Grease Lo Level

PUMP (1st) PUMP (2nd)

Key Switch (ACC)

PUMP (2nd)

Swing Priority Bucket Hi Cancel Boom Throttle

02301 Solenoid Valve 3

Back Press Competing/L Arm Throttle/L Arm Throttle/R

02302 Solenoid Valve 4

RAD Fan Reverse O/C Fan Reverse Auto Grease

02303 Switch Input 1 02200

Swing Release Sw Swing Brake Sw Switch Input 2 Pump 2 Model Select 1 Pump 2 Model Select 2 Pump 2 Model Select 3 Pump 2 Model Select 4 Pump 2 Model Select 5

02205

Switch Input 3 02206

Key Switch (ACC) Key Switch (C) Switch Input 4

02307

Switch Input 5

02308

Key Switch (C)

PUMP (2nd)

Wiper Upper Sw

PUMP (2nd)

Wiper Upper Limit Sw

PUMP (2nd)

Wiper Lower Limit Sw

PUMP (2nd) PUMP (1st)

Pump 1 Model Select 1

PUMP (1st)

Pump 1 Model Select 2

PUMP (1st)

Pump 1 Model Select 3

PUMP (1st)

Pump 1 Model Select 4

PUMP (1st)

Switch Input 6

02209

Pump 1 Model Select 5

PUMP (1st)

Step Light Switch

PUMP (2nd) PUMP (2nd)

Horn Switch

PUMP (2nd)

Ladder Down Signal

PUMP (2nd)

Switch Input 7 02210

24

Component in charge

Unit (Initial setting: ISO) ISO meter inch ON or OFF

ON or OFF

ON or OFF

ON or OFF

ON or OFF

ON or OFF

ON or OFF

ON or OFF

ON or OFF

ON or OFF

PC2000-8

30 Testing and adjusting

Code No.

SEN02009-00

Monitoring item Controller Output 1

03700

Wiper Upper On

PUMP (2nd) PUMP (2nd)

Wiper Upper Brake

PUMP (2nd)

Wiper Lower On

PUMP (2nd)

Wiper Lower Brake

PUMP (2nd)

Step L. Relay

PUMP (2nd) PUMP (2nd)

Flash L. Relay

PUMP (2nd)

Controller Output 2 03701

Travel Alarm

PUMP (2nd)

Washer Relay

PUMP (2nd)

Auto Grease Caution

PUMP (1st) PUMP (1st)

Controller Output 3 03702

03703

Fan Reverse

PUMP (1st) PUMP (1st)

Battery Relay Output

PUMP (1st) MON

Controller Output 4 Monitor input 1 Key Switch

04500

MON

Preheat

MON

Light

MON

Rad. Level

MON MON

Aircleaner

MON

Engine Oil Level

MON

Battery Charge

MON MON MON VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS ENG (1st) ENG (1st) ENG (2nd) ENG (1st) ENG (2nd) ENG (1st) ENG (2nd) MON MON MON PUMP (1st) PUMP (1st) PUMP (1st)

04502

40966

99003 20216 20217 20218 18900 18902 20400 20401 20227 20402 20228 20229 20403 20230

Monitor Input 3 Swing Brake Sw VHMS Input 1 Hyd Oil Level Sw Hyd Oil Level Filter Clog Sw Truck Counter Sw1 Truck Counter Sw2 PTO Oil Lv Sw/Opt Orbcomm Communication Status Controller Power Satellite Condition Data Transmission ECM Build Version L/B ECM Calibration Data Ver R/B ECM Calibration Data Ver L/B ECM Internal Temp R/B ECM Internal Temp L/B ECM S/N R/B ECM S/N Monitor Ass'y P/N Monitor Serial No Monitor Prog. P/N Pump Con1 Ass'y P/N Pump Con1 Serial No Pump Con1 Prog. P/N

PC2000-8

Unit (Initial setting: ISO) ISO meter inch

ON or OFF

ON or OFF

ON or OFF

ON or OFF

MON

Start

Monitor Input 2 04501

Component in charge

ON or OFF

ON or OFF

ON or OFF

ON or OFF

ON or OFF

°C °C

— — — °C °C — — — — — — — —

°F °F

25

SEN02009-00

Code No. 20249 20407 20220

a a

a

26

30 Testing and adjusting

Monitoring item Pump Con2 Ass'y P/N Pump Con2 Serial No Pump Con2 Prog. P/N

Component in charge PUMP (2nd) PUMP (2nd) PUMP (2nd)

Unit (Initial setting: ISO) ISO meter inch — — —

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

PC2000-8

30 Testing and adjusting

SEN02009-00

Abnormality Record (Mechanical Systems) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems, electrical systems, and air-conditioning system or heater system. To check the mechanical system abnormality record, perform the following procedures. 1.

Selecting menu Select “Abnormality Record” on the “Service Menu” screen. 3.

2.

Selecting sub menu After the “Abnormality Record” screen is displayed, select “Mechanical Systems” with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. The heater specification and heaterless specification are different from each other in the display of “03 Air-conditioning System”, which may not be displayed in the heaterless specification.

PC2000-8

Information displayed on “abnormality record” screen On the “Mechanical Systems” screen, the following information is displayed. (a) : Occurrence order of abnormalities from latest one/Total number of records (b) : Failure code (c) : Contents of trouble (d) : Number of occurrence time (Displayable range: 0 – 65,535 times) (e) : Service meter reading at first occurrence (f) : Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F5]: Return to abnormality record screen a If no abnormality record is recorded, “No abnormality record” is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the failure codes table in “Abnormality Record (Electrical Systems)”.

27

SEN02009-00

4.

30 Testing and adjusting

Resetting abnormality record The contents of the mechanical system abnormality record cannot be reset.

Abnormality Record (Electrical Systems) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems and electrical systems. To check the electrical system abnormality record, perform the following procedures. 1.

Selecting menu Select “Abnormality Record” on the “Service Menu” Screen.

2.

Selecting sub menu After the “Abnormality Record” screen is displayed, select “Electrical Systems” with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. The heater specification and heaterless specification are different from each other in the display of “03 Air-conditioning System”, which may not be displayed in the heaterless specification.

28

3.

Information displayed on “abnormality record” screen On the “Electrical Systems” screen, the following information is displayed. (a) : Occurrence order of abnormalities from latest one/Total number of records (b) : Failure code (c) : Contents of trouble (d) : Number of occurrence time (Displayable range: 0 – 65,535 times) (e) : Service meter reading at first occurrence (f) : Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to “abnormality record” screen a If no abnormality record is recorded, “No abnormality record” is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the failure codes table.

PC2000-8

30 Testing and adjusting

4.

Resetting abnormality record 1) While the “Electrical Systems” screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3]

2)

Check that the screen is set in the reset mode, and then reset the items one by one or together with the function switches. a If the screen is set in the reset mode, [CLEAR] graphic mark is indicated at [F2]. q [F2]: Reset all items q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to abnormality record screen q [F6]: Reset selected item a To reset items one by one: Select the item to be reset with [F3] or [F4] and press [F6]. a To reset all items together: Press [F2], and all the items are reset, regardless of selection of the items. a If [E] is displayed on the left of a failure code, the resetting operation is accepted but the information is not reset.

PC2000-8

SEN02009-00

3)

After the “Electrical Sys. Error Reset” screen is displayed, operate the function switches. q [F5]: Return to “Electrical systems” screen (Reset mode) q [F6]: Execute reset a The following figure shows the screen displayed when the items are reset one by one (which is a little different from the screen displayed when all the items are reset together).

4)

If the screen to notify completion of reset is displayed and then the “Electrical Systems” (reset mode) screen is displayed, the reset of the abnormality record is completed. a After a while, the screen returns to the “Electrical Systems” screen.

29

SEN02009-00

30 Testing and adjusting

Failure code table Failure code

Failure contents

User code

Applicable equipment

History classification

0410KA

Fuel LV. Sensor Failure

—

MON

Electrical system

0410KB

Fuel LV. Sensor Failure

—

MON

Electrical system

8800ZG

Auto grease abnormally

—

PUMP

Mechanical system

7@HAZL

VR1/P1F Relief Press Abnormality

—

PUMP

Mechanical system

7@HBZL

VL1/P1R Relief Press Abnormality

—

PUMP

Mechanical system

7@HCZL

VR2/P2F Relief Press Abnormality

—

PUMP

Mechanical system

7@HDZL

VL2/P2R Relief Press Abnormality

—

PUMP

Mechanical system

AA10NX

Aircleaner Clogging

—

MON

Mechanical system

AB00KE

Change Voltage Low

—

MON

Mechanical system

B@BAZG

Eng. Oil Press. Low

—

ENG

Mechanical system

B@BAZK

Eng. Oil Level Low

—

MON

Mechanical system

B@BCNS

Eng. Water Overheat

—

ENG

Mechanical system

B@BCZK

Eng. Water Lvl Low

—

MON

Mechanical system

B@CBNS [n5o61]

High PTO Temperature

—

VHMS

VHMS [n5o61]

B@HANS

Hydr. Oil Overheat

—

PUMP

Mechanical system

CA111

ECM Critical Internal Failure

E10

ENG

Electrical system

CB111

ECM Critical Internal Failure

E10

ENG

Electrical system

CA115

Eng. Ne and Bkup Speed Sens Error

E10

ENG

Electrical system

CB115

Eng. Ne and Bkup Speed Sens Error

E10

ENG

Electrical system

CA122

Chg Air Press Sensor High Error

E11

ENG

Electrical system

CA123

Chg Air Press Sensor Low Error

E11

ENG

Electrical system

CA131

Throttle Sensor High Error

E14

ENG

Electrical system

CA132

Throttle Sensor Low Error

E14

ENG

Electrical system

CA135

Eng Oil Press Sensor High Error

E15

ENG

Electrical system

CA141

Eng Oil Press Sensor Low Error

E15

ENG

Electrical system

CA144

Coolant Temp Sens High Error

E15

ENG

Electrical system

CA145

Coolant Temp Sens Low Error

E15

ENG

Electrical system

CA153

Chg Air Temp Sensor High Error

E15

ENG

Electrical system

CA154

Chg Air Temp Sensor Low Error

E15

ENG

Electrical system

CA187

Sens Supply 2 Volt Low Error

E15

ENG

Electrical system

CB187

Sens Supply 2 Volt Low Error

E15

ENG

Electrical system

CA212

Eng Oil Temp Sensor High Error

E15

ENG

Electrical system

CA213

Eng Oil Temp Sensor Low Error

E15

ENG

Electrical system

CA221

Ambient Press Sens High Error

E15

ENG

Electrical system

CA222

Ambient Press Sens Low Error

E15

ENG

Electrical system

CA227

Sens Supply 2 Volt High Error

E15

ENG

Electrical system

CB227

Sens Supply 2 Volt High Error

E15

ENG

Electrical system

CA234

Eng Over Speed

E15

ENG

Electrical system

CA238

Ne Speed Sens Supply Volt Error

E15

ENG

Electrical system

CB238

Ne Speed Sens Supply Volt Error

E15

ENG

Electrical system

CA263

Fuel Temp Sensor High Error

E15

ENG

Electrical system

CB263

Fuel Temp Sensor High Error

E15

ENG

Electrical system

30

PC2000-8

30 Testing and adjusting

Failure code

SEN02009-00

Failure contents

User code

Applicable equipment

History classification

CA265

Fuel Temp Sensor Low Error

E15

ENG

Electrical system

CB265

Fuel Temp Sensor Low Error

E15

ENG

Electrical system

CA271

IMV/PCV1 Short Error

E10

ENG

Electrical system

CB271

IMV/PCV1 Short Error

E10

ENG

Electrical system

CA272

IMV/PCV1 Open Error

E10

ENG

Electrical system

CB272

IMV/PCV1 Open Error

E10

ENG

Electrical system

CA273

PCV2 Short Error

E10

ENG

Electrical system

CB273

PCV2 Short Error

E10

ENG

Electrical system

CA274

PCV2 Open Error

E10

ENG

Electrical system

CB274

PCV2 Open Error

E10

ENG

Electrical system

CA322

Inj #1(L#1) Open/Short Error

E11

ENG

Electrical system

CA323

Inj #5(L#5) Open/Short Error

E11

ENG

Electrical system

CA324

Inj #3(L#3) Open/Short Error

E11

ENG

Electrical system

CA325

Inj #6(L#6) Open/Short Error

E11

ENG

Electrical system

CA331

Inj #2(L#2) Open/Short Error

E11

ENG

Electrical system

CA332

Inj #4(L#4) Open/Short Error

E11

ENG

Electrical system

CA342

Calibration Code Incompatibility

E10

ENG

Electrical system

CB342

Calibration Code Incompatibility

E10

ENG

Electrical system

CA351

Injectors Drive Circuit Error

E10

ENG

Electrical system

CB351

Injectors Drive Circuit Error

E10

ENG

Electrical system

CA352

Sens Supply 1 Volt Low Error

E15

ENG

Electrical system

CB352

Sens Supply 1 Volt Low Error

E15

ENG

Electrical system

CA386

Sens Supply 1 Volt High Error

E15

ENG

Electrical system

CB386

Sens Supply 1 Volt High Error

E15

ENG

Electrical system

CA441

Battery Voltage Low Error

E10

ENG

Electrical system

CB441

Battery Voltage Low Error

E10

ENG

Electrical system

CA442

Battery Voltage High Error

E10

ENG

Electrical system

CB442

Battery Voltage High Error

E10

ENG

Electrical system

CA449

Rail Press Very High Error

E11

ENG

Electrical system

CB449

Rail Press Very High Error

E11

ENG

Electrical system

CA451

Rail Press Sensor High Error

E11

ENG

Electrical system

CB451

Rail Press Sensor High Error

E11

ENG

Electrical system

CA452

Rail Press Sensor Low Error

E11

ENG

Electrical system

CB452

Rail Press Sensor Low Error

E11

ENG

Electrical system

CA553

Rail Press High Error

E15

ENG

Electrical system

CB553

Rail Press High Error

E15

ENG

Electrical system

CA554

Rail Press Sensor In Range Error

E11

ENG

Electrical system

CB554

Rail Press Sensor In Range Error

E11

ENG

Electrical system

CA559

Rail Press Low Error

E15

ENG

Electrical system

CB559

Rail Press Low Error

E15

ENG

Electrical system

CA689

Eng Ne Speed Sensor Error

E15

ENG

Electrical system

CB689

Eng Ne Speed Sensor Error

E15

ENG

Electrical system

CA691

Intake Air Temp Sens High Error

E15

ENG

Electrical system

CA692

Intake Air Temp Sens Low Error

E15

ENG

Electrical system

PC2000-8

31

SEN02009-00

Failure code

30 Testing and adjusting

Failure contents

User code

Applicable equipment

History classification

CA731

Eng Bkup Speed Sens Phase Error

E15

ENG

Electrical system

CB731

Eng Bkup Speed Sens Phase Error

E15

ENG

Electrical system

CA757

All Persistent Data Lost Error

E10

ENG

Electrical system

CB757

All Persistent Data Lost Error

E10

ENG

Electrical system

CA778

Eng Bkup Speed Sensor Error

E15

ENG

Electrical system

CB778

Eng Bkup Speed Sensor Error

E15

ENG

Electrical system

CA781

CEN Communication Error

E0E

ENG

Electrical system

CB781

CEN Communication Error

E0E

ENG

Electrical system

CA1117

Persistent Data Lost Error

E10

ENG

Electrical system

CB1117

Persistent Data Lost Error

E10

ENG

Electrical system

CA1257

Harness Key Error

E0E

ENG

Electrical system

CB1257

Harness Key Error

E0E

ENG

Electrical system

CB1548

Inj #7(R#1) Open/Short Error

E11

ENG

Electrical system

CB1549

Inj #8(R#2) Open/Short Error

E11

ENG

Electrical system

CB1551

Inj #9(R#3) Open/Short Error

E11

ENG

Electrical system

CB1552

Inj #10(R#4) Open/Short Error

E11

ENG

Electrical system

CB1553

Inj #11(R#5) Open/Short Error

E11

ENG

Electrical system

CB1622

Inj #12(R#6) Open/Short Error

E11

ENG

Electrical system

CA1633

KOMNET Data link Time out Error

E0E

ENG

Electrical system

CA2185

Throt Sens Sup Volt High Error

E14

ENG

Electrical system

CA2186

Throt Sens Sup Volt Low Error

E14

ENG

Electrical system

CA2249

Rail Press Very Low Error

E11

ENG

Electrical system

CB2249

Rail Press Very Low Error

E11

ENG

Electrical system

CA2555

Grid Heater Relay Volt Low Error

E15

ENG

Electrical system

CA2556

Grid Heater Relay Volt High Error

E15

ENG

Electrical system

D110KB

Battery Relay Drive S/C

—

PUMP

Electrical system

D163KB

Flash Light Relay S/C

—

PUMP

Electrical system

D195KA

Step Light Relay Disc

—

PUMP

Electrical system

D195KY

Step Light Relay S/C

—

PUMP

Electrical system

D1E9KB

Wiper Drive Relay 1 S/C

—

PUMP

Electrical system

D1EAKB

Wiper Drive Relay 2 S/C

—

PUMP

Electrical system

D1EBKB

Low Wiper Brake Relay Short Circuit

—

PUMP

Electrical system

D1ECKB

Upper Wiper Brake Relay Short Circuit

—

PUMP

Electrical system

DA22KK

Pump 1 Solenoid Power Low Error

E0E

PUMP

Electrical system

dA22KK

Pump 2 Solenoid Power Low Error

E0E

PUMP

Electrical system

DA25KP

Pump 1 Sens Supply Vol Low Error

E07

PUMP

Electrical system

dA25KP

Pump 2 Sens Supply Vol Low Error

—

PUMP

Electrical system

DA26KP

5V Sensor 2 Power Abnormality

E07

PUMP

Electrical system

DA29KQ

Pump 1 Model Select Abnormality

—

PUMP

Electrical system

dA29KQ

Pump 2 Model Select Abnormality

—

PUMP

Electrical system

DA2RMC

CAN Discon (Pump 1 Con Detected)

E0E

PUMP

Electrical system

dA2RMC

CAN Discon (Pump 2 Con Detected)

E0E

PUMP

Electrical system

DA2TMC

Pump Comm. ECM Child Abnormality

—

PUMP

Electrical system

DH25KX

VR1/P1F J/S Dif Press Sensor Abnormality

E07

PUMP

Electrical system

32

PC2000-8

30 Testing and adjusting

Failure code

SEN02009-00

Failure contents

User code

Applicable equipment

History classification

DH26KX

VL1/P1R J/S Dif Press Sensor Abnormality

E07

PUMP

Electrical system

DH27KX

VR2/P2F J/S Dif Press Sensor Abnormality

E07

PUMP

Electrical system

DH28KX

VL2/P2R J/S Dif Press Sensor Abnormality

E07

PUMP

Electrical system

DHPEKX

VR1/P1F Pump P. Sensor Abnormality

E07

PUMP

Electrical system

DHPFKX

VL1/P1R Pump P. Sensor Abnormality

E07

PUMP

Electrical system

DHPGKX

VR2/P2F Pump P. Sensor Abnormality

E07

PUMP

Electrical system

DHPHKX

VL2/P2R Pump P. Sensor Abnormality

E07

PUMP

Electrical system

DHPSKX

Auto Grease Press Sensor Abnormality

—

PUMP

Electrical system

DHPTKX

Fan(RAD) Pump P. Sensor Open Circuit

—

PUMP

Electrical system

DHPUKX

Fan(O/C) Pump P. Sensor Open Circuit

—

PUMP

Electrical system

DHS3KX

Arm Dig PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHS4KX

Bucket Curl PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHS8KX

Boom Raise PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHS9KX

Boom Lower PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHSAKX

Swing Right PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHSBKX

Swing Left PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHSCKX

Arm Dump PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHSDKX

Bucket Dump PPC Press Sensor Abnormality

—

PUMP

Electrical system

DUM3KB

Auto Grease Caution LED Short Circuit

—

PUMP

Electrical system

DUM4KB

FAN Reverse LED Short Circuit

—

PUMP

Electrical system

DV20KB

Travel Alarm S/C

—

PUMP

Electrical system

DW41KA

Swing Priority Sol Open Circuit

—

PUMP

Electrical system

DW41KB

Swing Priority Sol Short Circuit

—

PUMP

Electrical system

DW45KA

Swing Brake Sol. Disc.

E03

PUMP

Electrical system

DW45KB

Swing Brake Sol. S/C

E03

PUMP

Electrical system

DW91KA

Straight-Travel Sol. Disc.

PUMP

Electrical system

DW91KB

Straight-Travel Sol. S/C

—

PUMP

Electrical system

DW4XKA

Bucket Curl Hi Cancel Sol. Disc.

—

PUMP

Electrical system

DW4XKB

Bucket Curl Hi Cancel Sol. S/C

—

PUMP

Electrical system

DW7BKA

Fan Motor(RAD) Reverse Sol Open Circuit

—

PUMP

Electrical system

DW7BKB

Fan Reverse Sol S/C

—

PUMP

Electrical system

DW7HKA

Fan Motor(O/C) Reverse Sol Open Circuit

—

PUMP

Electrical system

DW7HKB

Fan Motor(O/C) Reverse Sol Short Circuit

—

PUMP

Electrical system

DWA3KA

Arm throttle Valve/L Sol Open Circuit

—

PUMP

Electrical system

DWA3KB

Arm throttle Valve/L Sol Short Circuit

—

PUMP

Electrical system

DWA4KA

Arm throttle Valve/R Sol Open Circuit

—

PUMP

Electrical system

DWA4KB

Arm throttle Valve/R Sol Short Circuit

—

PUMP

Electrical system

DWA5KA

Auto Grease Sol Open Circuit

—

PUMP

Electrical system

DWA5KB

Auto Grease Sol Short Circuit

—

PUMP

Electrical system

DWA6KA

Boom throttle Valve Sol Open Circuit

—

PUMP

Electrical system

DWA6KB

Boom throttle Valve Sol Short Circuit

—

PUMP

Electrical system

DWK0KA

2-stage Relief Sol. Disc.

—

PUMP

Electrical system

DWK0KB

2-stage Relief Sol. S/C

—

PUMP

Electrical system

DWK2KA

Back Press Comp Valve Sol Open Circuit

—

PUMP

Electrical system

PC2000-8

33

SEN02009-00

Failure code

30 Testing and adjusting

Failure contents

User code

Applicable equipment

History classification

—

PUMP

Electrical system

DWK2KB

Back Press Comp Valve Sol Short Circuit

DWN5KA

Fan(RAD) Pump Epc Sol Open Circuit

E11

PUMP

Electrical system

DWN5KB

Fan(RAD) Pump Epc Sol Short Circuit

E11

PUMP

Electrical system

DWNCKA

Fan(O/C) Pump Epc Sol Open Circuit

E11

PUMP

Electrical system

DWNCKB

Fan(O/C) Pump Epc Sol Short Circuit

E11

PUMP

Electrical system

DXAAKA

P1F EPC Sol Disc

E07

PUMP

Electrical system

DXAAKB

P1F EPC Sol S/C

E07

PUMP

Electrical system

DXABKA

P1R EPC Sol Disc

E07

PUMP

Electrical system

DXABKB

P1R EPC Sol S/C

E07

PUMP

Electrical system

DXACKA

P2F EPC Sol Disc

E07

PUMP

Electrical system

DXACKB

P2F EPC Sol S/C

E07

PUMP

Electrical system

DXADKA

P2R EPC Sol Disc

E07

PUMP

Electrical system

DXADKB

P2R EPC Sol S/C

E07

PUMP

Electrical system

DY2CKB

Washer Drive S/C

—

PUMP

Electrical system

DY20MA

Low Wiper Working Abnormality

—

PUMP

Electrical system

DY2FMA

Upper Wiper Working Abnormality

—

PUMP

Electrical system

LA10ZL

RAD Fan Pump Relief Press Abnormality

—

PUMP

Mechanical system

LA20ZL

O/C Fan Pump Relief Press Abnormality

—

PUMP

Mechanical system

34

PC2000-8

30 Testing and adjusting

SEN02009-00 a

Maintenance Record The machine monitor records the maintenance information of the filters, oils, etc., which the operator can display and check by the following operations. When maintenance is carried out, if the data are reset in the operator mode, the number of the times of maintenance is recorded in this section. 1.

01 Engine oil change 02 Engine oil filter change 03 Fuel main filter change 41 Fuel pre-filter change 04 Hydraulic oil filter change 05 Hydraulic tank breather change 06 Corrosion resistor change 07 PTO case oil change 08 Final drive case oil change 09 Machinery case oil change 10 Hydraulic oil change 30 Hydraulic oil pilot filter change 31 Hydraulic oil drain filter change 42 Oil cooler accumulator change

Selecting menu Select “Maintenance Record” on the “Service Menu” screen.

3.

2.

The following items can be selected in the maintenance record.

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

Selecting maintenance record item After the “Maintenance Record” screen is displayed, select an item to be checked with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code.

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30 Testing and adjusting a

Maintenance Mode Change The operating condition for maintenance function in the operation mode can be set and changed with this menu. q Set function effective or ineffective q Change set replacement interval (by items) q Initialize all set replacement intervals 1.

01 Engine oil change 02 Engine oil filter change 03 Fuel main filter change 41 Fuel pre-filter change 04 Hydraulic oil filter change 05 Hydraulic tank breather change 06 Corrosion resistor change 07 PTO case oil change 08 Final drive case oil change 09 Machinery case oil change 10 Hydraulic oil change 30 Hydraulic oil pilot filter change 31 Hydraulic oil drain filter change 42 Oil cooler accumulator change

Selecting menu Select of “Maintenance Mode Change” on the “Service Menu” screen.

3.

2.

36

Selecting sub menu After the “Maintenance Mode Change” screen is displayed, select an item to change the setting with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code and confirm it with [F6].

The following items can be selected on the Change of maintenance mode screen.

Contents of setting of Maintenance mode on/ off After selecting “Maintenance Mode On/Off”, if the screen is displayed, set ON or OFF with the function switches. q ON: Functions of all maintenance items are set effective in operator mode q OFF: Functions of all maintenance items are set ineffective in operator mode q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Maintenance mode change screen q [F6]: Confirm selection and return to Maintenance mode change screen a Even if ON/OFF of each item has been set, if the above setting is changed, it is applied.

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30 Testing and adjusting

4.

Contents of setting of each maintenance item After selecting each maintenance item, if the screen is displayed, set the item with the function switches. q Initial value: Maintenance interval set in machine monitor (Recommended by manufacturer and not changeable). q Set value: Maintenance interval which can be set freely. Maintenance functions in operator mode operate on basis of this set time (which is increased or decreased by 50 hours). q ON: Maintenance function of this item is set effective in operator mode. q OFF: Maintenance function of this item is set ineffective in operator mode. q [F3]: Select Reduce set value (Upper) or OFF (Lower). q [F4]: Select Increase set value (Upper) or ON (Lower). q [F5]: Cancel setting before confirmation and return to Maintenance mode change screen. q [F6]: Confirm setting of upper or lower line. a After the setting of the upper and lower lines is confirmed with [F6] and the screen changes to the Maintenance mode change screen with [F5], the setting is effective. a If the set value of an item set to “ON” is changed after 1 or more operating hours since the start of setting, the change is recognized as a resetting operation.

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5.

Function of initializing all items After selecting “All Default Value”, if the screen is displayed, set with the function switches. q If this operation is executed, the set values of all the maintenance items are initialized. q [F5]: Return to Maintenance mode change screen q [F6]: Execute initialization a A while after [F6] is pressed, the initialization completion screen is displayed. Then, if the “Maintenance Mode Change” screen is displayed, initialization is completed.

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SEN02009-00

Phone Number Entry The telephone No. displayed when the user code/ failure code is displayed in the operator mode can be input and changed according to the following procedure. If a telephone No. is not input with this function, no telephone No. is displayed in the operator mode. 1.

Selecting menu Select “Phone Number Entry” on the “Service Menu” screen.

2.

Registering and changing telephone No. After the “Phone Number Entry” screen is displayed, register or change the telephone No. q [F2]: Reset all input No. q [F3]: Move to left position (if not blank) q [F4]: Move to right position (if not blank) q [F5]: Reset input digit/Return to service menu q [F6]: Confirm input

a a

38

30 Testing and adjusting a

If [F6] is pressed without inputting a digit, there is not information of telephone No. Accordingly, no telephone No. is displayed in the operator mode.

Up to 14 digits can be input from the left. Input nothing in the surplus positions. If one of the input digits is wrong, move to that digit (orange background) and overwrite it with the correct digit.

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30 Testing and adjusting

Default (Key-on Mode) Check or change various settings related to the machine monitor and machine by “Default”. The function of working mode with key ON is used to set the working mode displayed on the machine monitor when the starting switch is turned ON. 1.

Selecting menu Select “Default” on the “Service Menu” screen.

2.

Selecting sub menu After the “Default” screen is displayed, select “Key-on Mode” with the function switches or numeral input switches. a Select this item similarly to an item on the “Service Menu” screen.

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3.

Selecting mode After the “Key-on Mode” screen is displayed, select the mode to be set with the function switches. q Power Mode: [P] is displayed when key is ON q Economy Mode: [E] is displayed when key is ON q Mode at Previous Key-off: Final mode in previous operation is displayed when key is ON q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to “Default” screen q [F6]: Confirm selection and return to “Default” screen a When the machine is delivered, Mode at previous key-OFF is set.

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SEN02009-00

Default (Unit) Check or change various settings related to the machine monitor and machine by “Default”. The unit selecting function is used to select the unit of the data displayed for monitoring, etc. 1.

Selecting menu Select “Default” on the “Service Menu” screen.

2.

Selecting sub menu After the “Default” screen is displayed, select “Unit” with the function switches or numeral input switches. a Select this item similarly to an item on the “Service Menu” screen.

40

30 Testing and adjusting

3.

Selecting unit After the “Unit” screen is displayed, select the unit to be set with the function switches. q [F3]: Move to lower unit q [F4]: Move to upper unit q [F5]: Cancel selection and return to “Default” screen q [F6]: Confirm selection and return to “Default” screen a When the machine is delivered, the SI unit system is set.

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30 Testing and adjusting

Default (Maintenance Password) Check or change various settings related to the machine monitor and machine by “Default”. The function of setting maintenance password is used to set the display of the password screen when the functions related to the maintenance are used in the operator mode. 1.

Selecting menu Select “Default” on the “Service Menu” screen.

2.

Selecting sub menu After the “Default” screen is displayed, select “Maintenance Password” with the function switches or numeral input switches. a Select this item similarly to an item on the “Service Menu” screen.

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3.

Selecting Disable/Enable After the Maintenance Password screen is displayed, select the setting with the function switches. q Disable : Password screen is not displayed q Enable : Password screen is displayed q [F3] : Move to lower item q [F4] : Move to upper item q [F5] : Cancel selection and return to “Default” screen q [F6] : Confirm selection and return to “Default” screen

4.

Displaying maintenance password screen When the following operation is performed, the password screen is displayed in the operator mode. q Maintenance mode: The Maintenance table screen is changed to the Maintenance interval reset screen.

5.

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

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Default (Camera) Check or change various settings related to the machine monitor and machine by “Default”. The camera setting function is used to set installation and removal of a camera. 1.

Selecting menu Select “Default” on the “Service Menu” screen.

2.

Selecting sub menu After the “Default” screen is displayed, select “Came ra ” wi th t he func tio n swi tch es or numeral input switches. a Select this item similarly to an item on the “Service Menu” Screen.

42

30 Testing and adjusting

3.

Selecting camera setting After the “Camera” setting screen is displayed, select the setting with the function switches. q OFF: Camera is not used q Original Image: Image of connected camera is displayed in original position (as in mirror, used as back monitor) q Reverse Image: Image of connected camera is displayed in reverse position (as seen directly, used as front or side monitor) q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel setting before confirmation and return to “Default” screen q [F6]: Confirm selection in each line a After “Camera” screen is displayed, camera 1 can be always set. When 2 or more cameras are connected, if camera 1 is set, the screen changes to setting of camera 2 automatically. a After confirming the setting of each line with [F6], return to the “Default” screen with [F5], and the setting is effective. a If a camera is connected but not set normally with this function, the graphic mark of camera is not displayed at [F3] in the operator mode. Accordingly, the image of the camera cannot be used. a If 2 or more cameras are connected, be sure to set the use of them from camera 1 in order. a The function of displaying 2 images simultaneously is effective when use of camera 1 and camera 2 is set. a When a camera is installed, check that the displayed image is not inverted horizontally.

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30 Testing and adjusting

Default (ECO Display) Check or change various settings related to the machine monitor and machine by “Default”. The ECO display setting function is used to set the display of the ECO gauge and energy saving guidance. 1.

2.

3.

SEN02009-00 a

If ECO display is turned ON, ECO is displayed when the screen changes to the ordinary screen. Even if the energy saving guidance is turned ON, however, it is not displayed if the condition for display is not satisfied on the ordinary screen.

a

Display of ECO gauge (a)

a

Display of energy saving guidance

Selecting menu Select “Default” on the “Service Menu” screen.

Selecting sub menu After the “Default” screen is displayed, select “ECO Display” with the function switches or numeral input switches. a Select this item similarly to an item on the “Service Menu” screen.

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

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Adjustment (Pump Absorption Torque) The operator can adjust various items related to the machine with the machine monitor. The pump absorption torque (F) function is used to finely adjust the absorption torque on the front side of the hydraulic pump. 1.

Selecting menu Select “Adjustment” on the “Service Menu” screen.

2.

Selecting sub menu After the “Adjustment” screen is displayed, select “Pump Absorption Torque (F)” with the function switches or numeral input switches. a Select this item similarly to an item on the “Service Menu” screen.

30 Testing and adjusting

3.

Selecting absorption torque After the “Pump Absorption Torque (F)” screen is displayed, select a set value on the right side with the function switches. q Set value: For actual torque adjustment value, see table q [F3]: Increase set value q [F4]: Decrease set value q [F6]: Confirm setting and return to Adjustment menu screen a The 3 digits on the left side do not vary since they are the code of this function.

a

Relationship between set value torque adjustment value Code

021

44

Set value 000 001 002 003 004 005 006 007 008

and

Torque adjustment value +39.2 Nm {+4 kgm} +29.4 Nm {+3 kgm} +19.6 Nm {+2 kgm} +9.8 Nm {+1 kgm} 0 Nm {0 kgm} –9.8 Nm {–1 kgm} –19.6 Nm {–2 kgm} –29.4 Nm {–3 kgm} –39.2 Nm {–4 kgm}

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30 Testing and adjusting

SEN02009-00

For the adjustment items, codes and set values, see the following table. Item Main pump absorption torque

Code

Default

022

Q

Auto grease pump discharge pressure adjustment

080

Q

Auto grease interval setting

081

Q

Auto grease pump operating time adjustment

082 Q

After-start first greasing time setting

083

Q

PC2000-8

Set value

Adjustment value

000

40.0 kgm

001

30.0 kgm

002

20.0 kgm

003

10.0 kgm

004

0.0 kgm

005

–10.0 kgm

006

–20.0 kgm

007

–30.0 kgm

008

–40.0 kgm

000

20 kg/cm2

001

15 kg/cm2

002

10 kg/cm2

003

5 kg/cm2

004

0 kg/cm2

005

–5 kg/cm2

006

–10 kg/cm2

007

–15 kg/cm2

008

–20 kg/cm2

000

30 min

001

25 min

002

20 min

003

15 min

004

10 min

005

5 min

006

4 min

007

3 min

008

2 min

000

5 min

001

4 min

002

3 min

003

2 min

004

1 min

005

45 sec

006

30 sec

000

5 min

001

4 min

002

3 min

003

2 min

004

1 min

005

45 sec

006

30 sec

45

SEN02009-00

30 Testing and adjusting

Item Fan speed mode selection

Code

Default

055

Q

Set value

Adjustment value

000

Normal

001

Fixed to 70% speed

002

Fixed to 100% speed

000

105 rpm

Speed adjustment mode: 100%

001

90 rpm

Set speed: 840 rpm

002

75 rpm

003

60 rpm

004

45 rpm

005

30 rpm

006

15 rpm

007

0 rpm

008

–15 rpm

009

–30 rpm

010

–45 rpm

011

–60 rpm

012

–75 rpm

013

–90 rpm

014

–105 rpm

000

105 rpm

001

90 rpm

Radiator fan 100% speed adjustment

056

Q

O/C fan 100% speed adjustment

058

Speed adjustment mode: 100% Set speed: 760 rpm

Q

46

002

75 rpm

003

60 rpm

004

45 rpm

005

30 rpm

006

15 rpm

007

0 rpm

008

–15 rpm

009

–30 rpm

010

–45 rpm

011

–60 rpm

012

–75 rpm

013

–90 rpm

014

–105 rpm

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30 Testing and adjusting

Item Radiator fan 70% speed adjustment

SEN02009-00

Code

Default

057

Set value

Adjustment value

000

105 rpm

Speed adjustment mode: 70%

001

90 rpm

Set speed: 590 rpm

002

75 rpm

003

60 rpm

004

45 rpm

005

30 rpm

006

15 rpm

007

0 rpm

008

–15 rpm

009

–30 rpm

010

–45 rpm

011

–60 rpm

012

–75 rpm

013

–90 rpm

014

–105 rpm

000

105 rpm

Speed adjustment mode: 70%

001

90 rpm

Set speed: 550 rpm

002

75 rpm

003

60 rpm

004

45 rpm

005

30 rpm

006

15 rpm

007

0 rpm

008

–15 rpm

009

–30 rpm

010

–45 rpm

011

–60 rpm

012

–75 rpm

013

–90 rpm

014

–105 rpm

Q

O/C fan 70% speed adjustment

059

Q

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Cylinder Cut-Out The operator can perform “Cylinder Cut-Out” operation with the machine monitor. “Cylinder Cut-Out” operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (combustion in it is abnormal). 1.

Selecting menu Select “Cylinder Cut-Out” on the “Service Menu” screen.

30 Testing and adjusting

Menu

Right bank

Left bank

01

All right cylinders drive

All cylinders are driven

Specified cylinders are stopped

02

All left cylinders drive

Specified cylinders are stopped

All cylinders are driven

03

All right cylinders stop

All cylinders are stopped

Specified cylinders are stopped

04

All left cylinders stop

Specified cylinders are stopped

All cylinders are stopped

2) q

2.

When “01” (All right cylinder drive) is selected Shaded side is stopped and on the actual machine, the stopped side is indicated by light blue and driven side is indicated by dark blue.

Setting of cylinders to be reduced 1) Since the V-type 12 cylinders are divided into the r ight and l eft bank s for the reduced cylinder mode operation, the conditions of both banks are specified as follows. q

48

The left-bank cylinders are indicated as L1 – L6 and the right-bank ones as R1 – R6. In this case, L1 – L6 can be reduced. a Since “All right cylinder drive” is selected, R1 – R6 cannot be reduced.

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30 Testing and adjusting

3) q

q q q q q q

a a a

a a

When “02” (All left cylinder drive) is selected Shaded side is stopped and on the actual machine, the stopped side is indicated by light blue and driven side is indicated by dark blue. a The condition is reverse to “All right cylinder drive”.

[F1]: Move selection mark (R) to left [F2]: Move selection mark (R) to right [F3]: Reset holding [F4]: Hold [F5]: Return to service menu screen [F6]: Confirm selection This operation may be performed while the engine is running. When [F6] is pressed, if background (a) of the selected cylinder No. becomes white, the cylinder is Cut-Out. If the machine monitor Cut-Out a cylinder but the engine controller cannot Cut-Out that cylinder, the background (a) of the cylinder No. becomes yellow. One or more cylinders can be Cut-Out. In the cylinder Cut-Out operation, the auto-deceleration function can be selected. If the auto-deceleration is turned ON, auto-deceleration monitor (b) is displayed.

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4)

When “03” (All right cylinder stop) is selected The screen changes to the reduced cylinder mode operation screen and then injection is stopped in the order of the groups of R1, R3 and R5 and that of R2, R4 and L6. 1] Screen displayed while R1, R3 and R5 are stopped. q L1 to L6 cylinders are the drive side (indicated by light blue on the actual machine). Injection in the crossed cylinders (indicated by gray on the actual machine) is stopped.

2] q

q

Screen displayed while R2, R4 and R6 are stopped. Injection in the crossed cylinders, which are indicated by gray on the actual machine, is stopped. Cylinder No. in the crossed cylinders is stopped already.

49

SEN02009-00

5)

If stopping process of R1 – R6 is completed, the cursor is displayed and the en gi ne c an b e s tar te d wi th L1 – L 6 stopped. a The above process takes several seconds to protect the fuel injection system.

6)

When “04” (All left cylinder stop) is selected The condition is reverse to “All right cylinder stop”.

a 3.

50

Resetting Cut-Out cylinder When changing a cylinder to be Cut-Out or when Cylinder Cut-Out operation is finished, select a Cut-Out cylinder to be reset with the function switches. a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes blue, the cylinder is reset. a The Cut-Out operation is not automatically reset after the screen returns to the operator mode. Accordingly, be sure to perform the resetting operation after the cylinder cut-out operation is finished.

30 Testing and adjusting

4.

Function of holding displayed information If [F4] is pressed during the cylinder Cut-Out operation, the displayed information is newly held (c) (The real-time information is kept displayed on the left side). While the information is held, if [F3] is pressed, the holding function is reset. a The holding function is effective, regardless of setting of the reduced cylinder mode operation.

[Reference] q If a normally operating cylinder is Cut-Out, the following phenomena occur. 1) Lowering of engine speed 2) Increase of final injection rate command (quantity) q If the engine is running near the high idle, however, the engine speed may not lower for the reason of engine control. q In this case, lower the engine speed with the fuel control dial and judge by increase of the injection rate command.

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30 Testing and adjusting

No Injection If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with oil. To prevent this, the function to lubricate the engine before starting it by cranking it without injecting fuel is installed. Set the no-injection cranking while the engine is stopped. 1.

2.

SEN02009-00

3.

Starting no injection cranking If no injection cranking (Fuel injection in no cylinders) becomes effective, that is displayed on the screen. Under this condition, crank the engine with the starting motor. a While the screen is changing to the following screen, the screen of “Setting is being prepared” is displayed. a Limit the cranking time to 20 seconds to protect the starting motor.

4.

Finishing no injection cranking After completing the no injection cranking operation, press [F6], and finish of no injection cranking is displayed and the screen returns to the “Service Menu” screen automatically.

Selecting menu Select “No Injection” on the “Service Menu” screen.

Displaying check screen If the “No injection” screen is displayed, the machine monitor asks the operator if no injection cranking should be performed. Answer with the function switch. q [F5]: Do not perform (Return to Service menu screen) q [F6]: Perform a While the screen is changing to the following screen, the screen of “Communication between controllers is being checked” is displayed.

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5.

Prohibiting no injection cranking If the operator tries to perform the no injection cranking while the engine is running, the message that the engine is running is displayed and the no injection cranking is not set effective. a This function can be selected even while the engine is running. If the no injection cranking is performed, however, the message of “Engine is running” is displayed on the screen.

30 Testing and adjusting

Fuel Consumption This function calculates the hourly fuel consumption from the actual fuel consumption in a measuring period and indicates it. 1. Selecting menu Select “Fuel Consumption” on the “Service Menu” screen.

2.

Starting measurement After the screen of “Fuel Consumption” is displayed, start measurement with the function switches. q [F1]: Start q [F2]: Clear q [F5]: Return to Service menu screen a When the screen of Fuel consumption is displayed, if a data is indicated, it is the data of the previous measurement. This data is not an obstacle to new measurement and can be reset by pressing [F2]. a If [F1] is pressed, the data is displayed on the starting date and time side and measurement starts.

a

52

The display unit of the fuel changes according to the unit set with the default (unit setting) function. SI and meter: l/h inch: gal/h

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30 Testing and adjusting

3.

Display and function during measurement Clock mark (a) flashes during measurement. a While the fuel consumption is being measured, the operator can work with the operator mode and other functions. Measurement is not finished until this screen is displayed again and [F1] is pressed (Even if the starting switch is turned OFF, this function is kept effective, although fuel consumption is measured only while the engine is running).

4.

Finishing measurement Press [F1], and measurement is finished and the data are displayed on the finishing date and time side.

5.

Displaying fuel consumption If the measurement is finished, the hourly fuel consumption calculated from the fuel consumption calculated by the engine controller and the elapsed time are displayed.

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Setting of snap shot This function sends a snap shot trigger command to the VHMS controller to execute the snap shot. 1. Selection of menu On the “Service menu” screen, select “Snap shot”.

2.

Start of snap shot After the “Snap shot” screen is displayed, press the “F1” switch, and the snap shot starts. a The VHMS controller takes 7 minutes 30 seconds to complete the process. This time can be checked with the bar graph and the executing time displayed at the bottom of the screen.

3.

Finish of snap shot The bar graph becomes full in 7 minutes and 30 seconds. After 5 seconds, the screen returns to the normal screen automatically and the snap shot finishes. If the “F6” switch is pressed, the screen changes to the service screen.

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30 Testing and adjusting

Setting of PM-clinic This function is used to perform the PM-clinic service 1. Selection of menu On the “Service menu” screen, select “PMclinic”.

a

There are 12 PM-clinic screen pages. q If the “F1” switch is pressed, the next page is displayed. q If the “F2” switch is pressed, the previous page is displayed. q If the “F4” switch is pressed, the current page is held. q If the “F3” switch is pressed, the current page is released.

2.

Start of PM-clinic If a page is displayed and the specified operation is performed, the measured values of the displayed items are displayed.

3.

Finish of PM-clinic If the [ ] switch is pressed, the screen changes to the service screen and the PMclinic finishes.

4.

For the contents of the 12 pages of the PMclinic, see the table in the following page.

54

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30 Testing and adjusting

SEN02009-00

m

inch

Component in charge

r/min

rpm

rpm

ENG

°C

°C

°F

ENG (L/B)

Item

1/12

1

Engine speed

2

Engine coolant temperature

3

Engine oil pressure

4

Engine oil temperature

5

PTO oil temperature

°C

°C

°F

VHMS

6

Hydraulic oil temperature

°C

°C

°F

PUMP (2)

1

Engine speed

r/min

rpm

rpm

ENG

2

Intake air temperature

°C

°C

°F

ENG (L/B)

3

R/B 1-3 exhaust temperature

°C

°C

°F

VHMS

4

R/B 4-6 exhaust temperature

°C

°C

°F

VHMS

5

L/B 1-3 exhaust temperature

°C

°C

°F

VHMS

6

L/B 4-6 exhaust temperature

°C

°C

°F

VHMS

1

Engine speed

r/min

rpm

rpm

ENG

2

Intake air temperature

°C

°C

°F

ENG (L/B)

3

L/B common rail pressure

MPa

kg/cm2

psi

ENG

4

L/B boost pressure

kPa

kg/cm2

psi

ENG

5

Boost temperature

°C

°C

°F

ENG

6

L/B 1-3 exhaust temperature

°C

°C

°F

VHMS

1

Engine speed

r/min

rpm

rpm

ENG

2

Ambient temperature

°C

°C

°F

VHMS

3

L/B fuel temperature

°C

°C

°F

ENG

4

R/B fuel temperature

°C

°C

5

L/B common rail pressure

MPa

6

R/B common rail pressure

MPa

1

Engine speed

2

Ambient temperature

3

Ambient pressure

4

L/B fuel temperature

5

2/12

3/12

4/12

5/12

6/12

7/12

PM-clinic display item

ISO

Page

kPa

kg/cm

psi

PUMP (1)

°C

°C

°F

ENG

2

°F

ENG

2

psi

ENG

2

kg/cm

psi

ENG

r/min

rpm

rpm

ENG

°C

°C

°F

VHMS

kg/cm

kPa

kg/cm

psi

ENG

°C

°C

°F

ENG

R/B common rail pressure

MPa

kg/cm2

psi

ENG

6

Blow-by pressure

MPa

kg/cm2

psi

VHMS

1

Engine speed

r/min

rpm

rpm

ENG

2

Ambient temperature

°C

°C

°F

VHMS

3

Ambient pressure

4

R/B fuel temperature

5

R/B common rail pressure

MPa

6

Blow-by pressure

MPa

1

Engine speed

2

Hydraulic oil temperature

3

2

kPa

kg/cm

psi

ENG

°C

°C

2

°F

ENG

2

psi

ENG

2

kg/cm

psi

VHMS

r/min

rpm

rpm

ENG

°C

°C

°F

PUMP (2)

P1F pump pressure

MPa

kg/cm2

psi

PUMP (1)

4

P1R pump pressure

MPa

kg/cm2

psi

PUMP (1)

5

P2F pump pressure

MPa

kg/cm2

psi

PUMP (1)

6

P2R pump pressure

MPa

kg/cm2

psi

PUMP (1)

PC2000-8

kg/cm

55

SEN02009-00

30 Testing and adjusting

m

inch

Component in charge

r/min

rpm

rpm

ENG

°C

°C

Item

8/12

1

Engine speed

2

Hydraulic oil temperature

3

P1F pump pressure

MPa

4

P1R pump pressure

MPa

5

VR1 J/S differential pressure

MPa

6

VL1 J/S differential pressure

MPa

1

Engine speed

2

Hydraulic oil temperature

3

P2F pump pressure

MPa

4

P2R pump pressure

MPa

5

VR2 J/S differential pressure

MPa

6

VL2 J/S differential pressure

MPa

1

Engine speed

2

Hydraulic oil temperature

3

P1F pump pressure

MPa

2

4

P1R pump pressure

5

9/12

10/12

11/12

12/12

56

PM-clinic display item

ISO

Page

°F

PUMP (2)

2

psi

PUMP (1)

2

psi

PUMP (1)

2

psi

PUMP (1)

2

kg/cm

psi

PUMP (1)

r/min

rpm

rpm

ENG

°C

°C

kg/cm

kg/cm kg/cm

°F

PUMP (2)

2

psi

PUMP (1)

2

psi

PUMP (1)

2

psi

PUMP (1)

2

kg/cm

psi

PUMP (1)

r/min

rpm

rpm

ENG

°C

°C

°F

PUMP (2)

kg/cm

psi

PUMP (1)

MPa

kg/cm2

psi

PUMP (1)

P1F pump EPC current

mA

mA

mA

PUMP (1)

6

P1R pump EPC current

mA

mA

mA

PUMP (1)

1

Engine speed

r/min

rpm

rpm

ENG

2

Hydraulic oil temperature

°C

°C

°F

PUMP (2)

3

P2F pump pressure

MPa

psi

PUMP (1)

4

P2R pump pressure

MPa

kg/cm

psi

PUMP (1)

5

P2F pump EPC current

mA

mA

mA

PUMP (1)

6

P2R pump EPC current

mA

mA

mA

PUMP (1)

1

Engine speed

r/min

rpm

rpm

ENG

2

Ambient temperature

°C

°C

3

O/C fan pulley pressure

MPa

4

RAD fan pump pressure

MPa

5

RAD fan pump control EPC current

6

O/C fan pump control EPC current

kg/cm kg/cm kg/cm

2

kg/cm

2

°F

VHMS

2

psi

PUMP (1)

2

kg/cm

psi

PUMP (1)

mA

mA

mA

PUMP (1)

mA

mA

mA

PUMP (1)

kg/cm

PC2000-8

30 Testing and adjusting

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.

PC2000-8

SEN02009-00

1

57

SEN02009-00

PC2000-8 Hydraulic excavator Form No. SEN02009-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

58

SEN02010-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

30 Testing and adjusting

1

Testing and adjusting, Part 4 Testing and adjusting, Part 4........................................................................................................................... 2 VHMS controller initial setting procedure ............................................................................................. 2 Precautions for replacing VHMS controller ........................................................................................ 19 Preparation work for troubleshooting of electrical system.................................................................. 25 Pm-clinic service ................................................................................................................................ 27 Measurement procedure .................................................................................................................... 28

PC2000-8

1

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30 Testing and adjusting

Testing and adjusting, Part 4

1

VHMS controller initial setting procedure

1

a

Equipment used for VHMS controller initial setting

Symbol 1 W 2

a

a

a

a

a

a a

2

Part No.

Part name

799-608-3211 Diskette 799-608-3220 Wiring harness Note type PC Commercially (Windows 98/2000/Me/XP), available with RS232C terminal

Initial setting of VHMS controller shall be done according to the following procedure. This operation is needed prior to a full-scale operation of a machine being delivered and assembled in the field, or prior to resumption of its operation after a long time of storage. Machine data collected with VHMS controller are stored and managed on WebCARE database. In order to endure smooth data processing on WebCARE , consistency must be provided among the settings done on VHMS controller. Inconsistencies in the settings obstruct loading of data to WebCARE, hampering appropriate use of VHMS data. The initial setting, therefore, is a must. For the installation procedure of the VHMS initial setting program to a PC, refer to the operation and maintenance manual being bundled with the service kit W1. In the procedure, service menus of the machine monitor are used. Thus, it is advisable to reference the information contained in the “Special functions of machine monitor” to understand their procedure beforehand. The initial setting procedure is described in the “ORBCOMM installation specification” and the “ORBCOMM-less specification”. When using the “ORBCOMM installation specification”, implement the procedures needed for VHMS alone, bypassing those prepared only for ORBCOMM installation specification. Check each step of the setting work referencing the “VHMS initial setting work check sheet”. Information such as models shown in the figures may not be identical with actual ones.

1.

Confirmation of machine information, engine information, transmission controller information and controller information a This confirmation procedure is targeted at the entire machine. Confirm and record the machine information, engine information, VHMS controller information and ORBCOMM terminal information. No.

Information to be confirmed

1

Model name

2

Machine serial No.

3

Current service meter hour

4

Engine serial No.

5

VHMS controller serial No.

6

ORBCOM terminal serial No. [Only for machines equipped with ORBCOMM]

a

VHMS controller (1) and ORBCOMM terminal (2) are installed in the cab base inner the distribution board.

PC2000-8

30 Testing and adjusting

2.

Connecting a PC a This work is done inside the cab. 1) Make sure the starting switch is at OFF position. k Before connecting or disconnecting a PC, be sure to turn off the starting switch. 2) Using harness [1] of service kit W1, connect the PC W2 and download connector C53. a Then connect the PC to RS232C terminal.

a

SEN02010-00

3.

Confirming VHMS controller operation and confirming satellite capturing state a This work is done inside the cab. a Confirmation of capturing of the satellite is done for [ORBCOMM installation specification]. 1) Turn the starting switch ON. 2) Check the controller for normal operation referencing 7-segment LED of VHMS controller. a VHMS controller is fed with switch power supply. Thus, its operation is judged normal if its 7-segment LED starts flashing while rotating as the starting switch is turned on and then if the controller starts counting in the ascending order.

Download connector C53 is installed in the front side of the right stand of operator seat. 3)

PC2000-8

Among the 7-segment LED situated in the right side of VHMS controller, refer to the one that represents the decimal point to check whether or not ORBCOMM controller has captured the communication satellite. [ORBCOMM installation specification] a Check whether or not ORBCOMM controller is capturing the communication satellite from VHMS controller. a It is successfully capturing the satellite when the LED representing the decimal point in the right side 7-segment LED is flashing.

3

SEN02010-00 a

4.

It can be checked with monitoring function of the machine monitor, too.

Starting the VHMS initial setting tool a This work is done inside the cab (from PC). 1) Turn on the PC power and start the OS. 2) Operating [VHMS initial setting tool] icon on the PC, start up the VHMS initial setting tool.

3) 4) 5)

4

30 Testing and adjusting

Important a Appearance of the setup screen of the VHMS setting tool depends its tool. a When using Ver.3.5.2.1 or older version (CD-ROM), the setting procedure shall conform to that described in Section 5. a When using an update version (Ver.3.5.2.1 or after), the procedure in Section 6 shall be used. a It is recommended to download the latest VHMS version from WebCARE to update the currently used version. (Related material: PARTS & SERV IC E O PE RAT IO N T IP S S EK N5052) Enter the 10-digit service ID to [Service ID]. a Service ID: 7826117000 Select [Data clear and Set up] from [Select Function] item. Click [OK] button to proceed to the setup screen.

5.

Initial setting of VHMS controller (Ver. 3. 5. 2. 1 or older version) a This work is done inside the cab (from PC). a It is prohibited in the initial setting to modify the data of service meter [SMR]. [Machine Information] 1) Open [Machine Information] tab. a [Data clear and Set up] menu displays [Machine Information] tab first. 2) Check every data for correctness.

PC2000-8

30 Testing and adjusting

3)

When [Date/Time] information is not appropriate, correct it in the following manner. 1] Press [Edit] button in the lower right side of [Date/Time] box to display the correction screen. 2] After correcting it to the correct information, press [OK] button.

4)

When [Machine Information] information is not appropriate, correct it in the following manner. 1] Press [Edit] button in the lower right side of [Machine Information] dialog box to display the correction screen. 2] After correcting it to the correct information, press [OK] button.

SEN02010-00

5)

As every data in [Machine Information] has been checked and corrected, press [Apply] button to settle the setting. a As [Apply] button is pressed, a message confirming above setting will appear on the screen. Check the setting again and, if the setting is correct, press [OK] button. a ORBCOMM installation specification requires the settlement operation after [Communication Setting] is completed.

[Communication Setting] [ORBCOMM installation specification only] a This setting shall be implemented after the request for station opening has been made and station of ORBCOMM has been opened. 6) Open [Communication Setting] tab. 7) Check every data for correctness.

PC2000-8

5

SEN02010-00

8)

30 Testing and adjusting

10) When modifying the setting of [Satellite Setting], employ the following procedure. 1] Press [Edit] button in the [Satellite Setting] block to display the correction screen. 2] Set the GCC code to the region applied and, as setting is completed, press [OK] button.

When modifying the setting of [SHORT FAULT HISTORY], employ the following procedure. 1] Select [SHORT FAULT HISTORY] from the screen and then press [Edit] button in the lower left side of [File Transfer Setting] block to display the setup screen. 2] Correct the setting and, as it is completed, press [OK] button. a In the initial setting, select [Occurrence] from [Timing] item and then set the function to ON.

GCC codes and applicable regions

9)

6

When modifying the setting of [SHORT TREND ANALYSIS], employ the following procedure. 1] Select [SHORT TREND ANALYSIS] from the screen and then press [Edit] button in the lower left side of [File Transfer Setting] block to display the setup screen. 2] Correct the setting and, as it is completed, press [OK] button. a In the initial setting, enter [20h] to [SMR] and then set the function to ON.

Code

Applicable region

Code

Applicable region

1

America

122

Korea

120

Italy

130

Japan

121

Malaysia

11) As every data in [Communication Setting] has been checked and corrected, press [Apply] button to settle the setting. a As [Apply] button is pressed, a message confirming above setting will appear on the screen. Check the setting again and, if the setting is correct, press [OK] button.

PC2000-8

30 Testing and adjusting

SEN02010-00

12) As every data in [Machine Information] and [Communication Setting] has been checked and corrected, press [Exit] button to end [VHMS initial setting tool].

13) After the initial setting of the VHMS controller is completed, initialize the machine monitor maintenance information, too. q Maintenance information initialization procedure 1] While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Switch operations: While pressing [4], perform [4] + [1] o [2] o [3] in order. a This operation of the switches is accepted only while the ordinary screen is displayed.

PC2000-8

2]

When the service menu screen appears, move the yellow cursor onto "04 Maintenance Mode Change" using [F3] or [F4] and then press [F6].

7

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3]

When the maintenance mode change screen appears, move the yellow cursor onto "99 Use Default Value" using [F3] or [F4] and then press [F6].

30 Testing and adjusting

6.

Initial setting of VHMS controller (Ver. 3. 5. 2. 1 or later version) a This work is done inside the cab (from PC). a It is prohibited in the initial setting to modify the data of service meter [SMR]. 1) Select [VHMS Setting] and then press [Next] button.

2)

4]

8

Select [Set up & All clear] and press [Next] button.

The maintenance information is initialized.

PC2000-8

30 Testing and adjusting

3)

SEN02010-00

Confirm the machine information and, if they are correct, press [Next] button.

a

4) 5) 6)

Select the time zone. Enter the local time. When DST (Daylight Saving Time) (or summer time) is currently used, press [Next] button. a Selecting DST advances the clock by an hour. Thus, correction of the time is needed again.

7)

Set the GCC code to the target region of application and, as setting is completed, press [Next] button.

When VHMS has been installed later, it is required to enter the information such as [Serial No.].

GCC codes and applicable regions

PC2000-8

Code

Applicable region

Code

Applicable region

1

America

122

Korea

120

Italy

123

Brazil

121

Malaysia

130

Japan

9

SEN02010-00

8)

If there is no problem in the setting displayed last, press [Apply] button.

9)

A screen message will confirm whether or not the data before the setting is to be saved. If the data is not necessary, select [NO].

30 Testing and adjusting

7.

Performing Quick Pm a Perform the following procedure in the cab. a The Quick Pm means the Pm clinic performed by using the snap shot (manual) function of the machine monitor. 1) Run the engine at low idle and set the machine in the following position. q Swing the boom 90° to right (with the idler on the front side). q Set the arm vertically. q Lower the bucket bottom to the ground and set it horizontally. 2) Set the switches and lever in the following positions. q Working mode switch: P-mode q Heavy lift switch: ON q Auto-decelerator switch: ON q Swing lock switch: OFF q PCC lock lever: Free 3) Set the machine monitor to display the service menu. a For the operating method, see “Special function of machine monitor”.

4)

On the initial screen of the service menu, select “10 Snap shot” menu.

10) As correction of the first setting is completed, press [OK] button to end the program.

10

PC2000-8

30 Testing and adjusting

5)

6)

7)

SEN02010-00

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

After 5 seconds passes since the bar graph is completed (7 minutes 30 seconds passes after the snap shot is starts), the initial screen of the service menu is displayed again.

PC2000-8

11

SEN02010-00

30 Testing and adjusting

Operating procedure for Quick Pm *: Operation mode (P) No.

Elapsed time

Time on snap data

Fuel dial

Swing lock switch

MIN (Low)

OFF

1

Start O Finish

0:00 O 0:30

–330.00 O –300.00

2

Start O Finish

0:30 O 1:00

–300.00 O –270.00

MAX (High)

3

Start O Finish

1:00 O 1:30

–270.00 O –240.00

4

Start O Finish

1:30 O 2:30

5

Start O Finish

6

Data read in Pm clinic after data are downloaded

Operation of lever Set all levers in neutral.

• Engine speed (Low idle) • Engine oil pressure (Low idle) • Ambient temperature

OFF

Set all levers in neutral (Turn decelerator on).

• • • • •

MAX (High)

OFF

Move levers finely [Note] (Turn decelerator off).

• Engine speed (Auto deceleration)

–240.00 O –180.00

MAX (High)

OFF

Raise right-hand track shoe and drive it idle (Set lever to stroke end).

• Pump pressure (actuating pressure)

2:30 O 3:30

–180.00 O –120.00

MAX (High)

OFF

Swing 180°. Raise left-hand track shoe • Pump pressure and drive it idle (Set lever (actuating pressure) to stroke end).

Start O Finish

3:30 O 4:00

–120.00 O 0–90.00

MAX (High)

ON

R.H. swing relief.

• Swing oil pressure (relief pressure)

7

Start O Finish

4:00 O 4:30

0–90.00 O 0–60.00

MAX (High)

ON

L.H. swing relief.

• Swing oil pressure (relief pressure)

8

Start O Finish

4:30 O 5:00

0–60.00 O 0–30.00

MAX (High)

ON

Arm OUT relief.

• Arm OUT oil pressure

9

Start O Finish

5:00 O 5:30

0–30.00 O 0–00.00

MAX (High)

ON

Bucket DUMP relief.

• Bucket DUMP oil pressure

10

Start O Finish

5:30 O 6:00

0–00.00 O 0–30.00

MAX (High)

ON

Bucket CURL relief.

• Bucket CURL oil pressure

11

Start O Finish

6:00 O 6:30

0–30.00 O 0–60.00

MAX (High)

ON

Arm IN relief.

• Arm IN oil pressure

12

Start O Finish

6:30 O 7:00

0–60.00 O 0–90.00

MAX (High)

ON

Boom RAISE relief.

• Boom RAISE oil pressure

13

Start O Finish

7:00 O 7:30

0–90.00 O –120.00

MAX (High)

ON

Set all levers in neutral (1st deceleration o 2nd deceleration)

• Engine speed (1st deceleration speed)

14

—

7:30

–120.00

MIN (Low)

ON

Finish

Engine speed (High idle) Engine oil pressure (High idle) J/S differential pressure Pump oil pressure Fan pump oil pressure

Note: To turn off the decelerator and set the engine speed to high idle, move one of both work equipment control levers and both travel levers to a degree that the work equipment does not move or the machine does not swing or travel. (If the PPC oil pressure switch is turned ON, the auto-decelerator is turned OFF.)

12

PC2000-8

30 Testing and adjusting

SEN02010-00

Snap shot item table No.

Item

Unit

No.

Item

Unit

Sampling time

sec

43 Arm throttle selector valve L

—

1

Engine speed

rpm

44 Arm throttle selector valve R

—

2

Fuel injection rate

mm3/st

45 Swing brake valve

—

3

Blow-by pressure

kPa

46 Swing priority selector valve

—

4

Left-bank front exhaust temperature

°C

47 Travel back pressure valve

—

48 Swing back pressure valve

—

5

Left-bank rear exhaust temperature

°C

6

Right-bank front exhaust temperature

°C

7

Right-bank rear exhaust temperature

°C

8

Engine oil pressure

9

engine oil temperature

°C

10 Engine coolant temperature

°C

11 Intake air pressure 12 Intake air temperature

MPa

kPa °C

13 Ambient temperature

°C

14 Pump 1F oil pressure

MPa

15 Pump 1R oil pressure

MPa

16 Pump 2F oil pressure

MPa

17 Pump 2R oil pressure

MPa

18 Fan pump F pressure

MPa

19 Fan pump R pressure

MPa

20 Hydraulic oil temperature

°C

21 Pump 1F control current

mA

22 Pump 1R control current

mA

23 Pump 2F control current

mA

24 Pump 2R control current

mA

25 Engine speed command value

V

26 Auto-deceleration command value

V

27 Fuel injection timing

deg

28 Fuel injection pressure

MPa

29 PTO oil temperature

°C

30 Boom raise oil pressure

MPa

31 Boom lower oil pressure

MPa

32 Arm in oil pressure

MPa

33 Arm out oil pressure

MPa

34 Bucket curl oil pressure

MPa

35 Bucket dump oil pressure

MPa

36 Right travel oil pressure switch 37 Left travel oil pressure switch

— —

38 Right swing oil pressure

MPa

39 Left swing oil pressure

MPa

40 Service valve pressure switch

—

41 Straight travel valve

—

42 2-stage main relief signal

—

PC2000-8

13

SEN02010-00

8.

30 Testing and adjusting a a

Download of setting data 1) Using harness [1] of service kit W1, connect PC W2 to download connector C53 in the cab or download connector VDL on the ground.

3)

a

Download connector C53 in the cab is installed in the front side of the right stand of operator seat.

9.

2)

Operating [VHMS analysis tool] on PC, start up the VHMS analysis tool.

Using [Download] function, download the data currently recorded on VHMS to PC. a For the operating procedure, see the VHMS analysis tool operation and maintenance manual. a After making sure the download is complete, proceed to the next step.

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

2)

14

Enter [User Name] and [Password]. For the operating procedure, see the VHMS analysis tool operation and maintenance manual.

As check of the setting data is finished, end [VHMS analysis tool].

PC2000-8

30 Testing and adjusting

10. Disconnecting the PC 1) Make sure the starting switch is at OFF position. k Before connecting or disconnecting a PC, be sure to turn off the starting switch. 2) End the OS of PC W2 and then turn off the PC power.

SEN02010-00

11. Report to Komatsu As steps 1 – 9 are completed, send VHMS/ WebCARE setting report to VHMS/WebCARE Support Center in Komatsu Headquarters. a This report is a must since setting on the receiving end in the satellite communication must be done by Komatsu. a In this case, send VHMS data via Notes (LAN) or E-mail (WAN). Komatsu VHMS/WebCARE Support Center

2-3-6, Akasaka Minato-Ku Tokyo, Japan FAX: 81-3-5561-4766 (from outside of Japan) FAX: 03-5561-4766 (Domestic user) E-mail: [email protected]

3)

When the data was download into the cab, disconnect harness [1] of service kit W1 from download connector C53.

PC2000-8

15

SEN02010-00

30 Testing and adjusting

[For storage] VHMS initial setting work check sheet

Date of setting: DB/branch office name Data entered by:

Setup step

Check item

Result

Model name 1

Confirmation of machine body and component nameplates

Serial No. Engine serial No. VHMS controller serial No.

2

Connection between PC and VHMS controller

Is the connection secure?

yes

no

3

VHMS controller check for normal operation

Is it operating normally? (Displays counting in ascending-order succeeding to rotation)

yes

no

Is “Data Clear and Set up” selected for the setting tool mode?

yes

no

Is model name identical with machine body?

yes

no

Is machine body serial No. correctly entered?

yes

no

4 Starting of VHMS initial setting tool

Initial setting of VHMS controller (Setting of machine body informa5 tion) In this step, basic machine body information are set on VHMS controller

Is engine serial No. correctly entered?

yes

no

Is today's date entered?

yes

no

Is current time entered?

yes

no

Is SMR correctly entered?

yes

no

6 Saving of settings

Is LED (7-segment) turned off?

yes

no

7 Confirmation of VHMS function

Is LED operation normal?

yes

no

8 Execution of quick Pm

Is service mode “SNAPSHOT” turned on and is the switch hit?

yes

no

9 Data storing operation on VHMS

Is LED (7-segment) turned off?

yes

no

10 Download

Is LED operation normal?

yes

no

Are all files downloaded?

yes

no

The time downloaded (Reference wrist watch) 11 Confirmation of download data

12 Data storing operation on VHMS

16

Hour, minute:

[Confirmation of data] Is [MFA0] error present in Fault History?

yes

no

Are SMR and time in Fault History consistent with settings?

yes

no

Is any data missing in Snap Shot0?

yes

no

Is LED (7-segment) turned off?

yes

no

PC2000-8

30 Testing and adjusting

SEN02010-00

[For storage] ORBCOMM station opening work check sheet Setup step

Date of setting: DB/branch office name Data entered by: Check item

Result

Model name Confirmation of machine body and 1 component nameplates

Serial No. Engine serial No. VHMS controller serial No. ORBCOMM terminal serial No.

2

Connection between PC and VHMS controller

Is the connection secure?

yes

no

3

VHMS controller check for normal operation

Is it operating normally? (Displays counting in ascending-order succeeding to rotation)

yes

no

Is “Set up” selected for the setting tool mode?

yes

no

On

Off

On

Off

On

Off

4 Starting of VHMS initial setting tool

Entry of setting to S.Fault History Initial setting of VHMS controller 1. Setting of communication (Setting of machine body information and PLM are completed)

Presence/absence of communication Number of cases (Default is 8 cases) Entry of setting of S.Trend Analysis setting Presence/absence of communication Interval (Default is 20H)

5

Entry of setting of S.Payload data Presence/absence of communication Tabulation start time Interval of tabulation (in days) 2. Setting for start of communication

6 Saving of settings 7

ORBCOMM controller performance check

PC2000-8

day

Is GCC code set? (130 for Japan)

yes

no

Is LED (7-segment) turned off after data was stored?

yes

no

How is decimal point display in VHMS monitor (7-segment)? (OFF, ON, long/short flashing)

yes

no

17

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18

30 Testing and adjusting

PC2000-8

30 Testing and adjusting

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Precautions for replacing VHMS controller 1 a

Care should be paid to the following equipment when replacing VHMS controller

Symbol 1 W 2

a

a

a a

Part No.

Part name

799-608-3211 Diskette 799-608-3220 Wiring harness Note type PC Commercially (Windows 98/2000/Me/XP), available with RS232C terminal

When it is required to replace a VHMS controller, setup of the replacing VHMS controller shall be conducted before and after the replacement according to the following procedure. Machine data collected with VHMS controller are stored and managed on WebCARE database. In order to endure smooth data processing on WebCARE , consistency must be provided among the settings done on VHMS controller. Inconsistencies in the settings obstruct loading of data to WebCARE, hampering appropriate use of VHMS data. Setting work after replacement, therefore, is a must. Check each step of the setting work referencing the “VHMS initial setting work check sheet”. Information such as models shown in the figures may not be identical with actual ones.

[Operations needed prior to replacement of VHMS controller] 1. Download of the remaining data a This work is done inside the cab (from PC). a Using [Download] function, download the currently recorded and remained data on VHMS to PC. a For the operating procedure, refer to “8. Download of setting data” in “VHMS controller initial setting procedure”.

PC2000-8

2.

Confirmation, saving and loading of VHMS controller setting information (Ver. 3. 5. 2. 1 or older version) a This work is done inside the cab (from PC). a Setting information is saved from the VHMS controller to be replaced to the PC and the saved information is loaded to the new VHMS controller after the replacement. 2-1. Confirmation and saving of VHMS controller setting information prior to replacement 1) Connect the PC and start the VHMS initial setting tool. a See the “VHMS controller initial setting procedure” for this operation. 2) Select [Save/Load] and press [OK] button.

3) 4)

Confirm every information before the replacement. Select [Save] from [File] of the menu.

19

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5) 6) 7)

8) 9)

Reconfirm the information and then press [OK] button to save the information. Select [Exit] from [File] of the menu to end the VHMS setting tool. Disconnect the PC. a Refer to “10. Disconnecting the PC” in “VHMS controller initial setting procedure”. Turns the PC power off. Proceed to replacement of VHMS controllers.

30 Testing and adjusting

3)

Select [Load] from [File] of the menu.

4)

Currently saved information will be displayed. Press [OK] button.

5)

Display the saved information on another screen. Press [Edit] button and adjust the time.

2-2. Loading the setting information to the replacing VHMS controller 1) Connect the PC again and start the VHMS initial setting tool. a See the “VHMS controller initial setting procedure” for this operation. 2) Select [Save/Load] and press [OK] button.

6)

20

PC2000-8

30 Testing and adjusting

7)

After adjusting time, press [OK] button.

SEN02010-00

9) a

8)

The confirmation screen will ask whether or not the data before the above setup is to be saved. Press [NO] button. It is not necessary to save the data before the setting.

Press [Apply] button to display contents of the setting. Check the setting again and, if it is acceptable, press [OK] button.

10) The setup result is displayed. Confirm the contents and press [Close] button.

11) Select [Exit] from [File] of the menu to end the VHMS initial setting tool.

PC2000-8

21

SEN02010-00

3.

Confirmation, saving and loading of VHMS controller setting information (Ver. 3. 5. 2. 1 or later version) a This work is done inside the cab (from PC). a Setting information is saved from the VHMS controller to be replaced to the PC and the saved information is loaded to the new VHMS controller after the replacement. 3-1. Confirmation of VHMS controller setting information prior to replacement 1) Connect the PC and start the VHMS initial setting tool. a See the “VHMS controller initial setting procedure” for this operation. 2) Select [When VHMS needs to be replaced] and then press [Next] button.

30 Testing and adjusting

4)

Confirm every information before the replacement and then press [Save] button.

5)

Select [Exit] from [File] of the menu to end the VHMS initial setting tool. Disconnect the PC. a Refer to “10. Disconnecting the PC” in “VHMS controller initial setting procedure”. Turns the PC power off. Proceed to replacement of VHMS controllers.

6)

7) 8)

3)

22

Select [Save current setting before replacement of VHMS controller] and press [Next] button.

3-2. Loading the setting information to the replacing VHMS controller 1) Connect the PC again and start the VHMS initial setting tool. a See the “VHMS controller initial setting procedure” for this operation. 2) Select [When VHMS needs to be replaced] and then press [Next] button.

PC2000-8

30 Testing and adjusting

3)

Select [Use previous setting after replacement of VHMS controller] and press [Next] button.

4)

Currently saved information will be displayed. Press [Next] button.

5)

SEN02010-00

6)

The confirmation screen will ask whether or not the data before the above setup is to be saved. Press [NO] button. a It is not necessary to save the data before the setting.

7)

The above completes modification of the setting. Press [OK] button to end the VHMS initial setting tool.

Adjust the time and press [Apply] button.

PC2000-8

23

SEN02010-00

30 Testing and adjusting

[Operations needed after replacement of VHMS controller] a Execute the quick Pm referring “7. Executing quick Pm” in “VHMS controller initial setting procedure”. a Download the data referring “8. Download of setting data” in “VHMS controller initial setting procedure”. a After the replacement, send VHMS/WebCARE setting report sheet to VHMS/WebCARE Support Center in Komatsu Headquarters. a Also send two sets of data, the downloaded before and after the VHMS replacement, via Notes (LAN) or E-mail (WAN). Komatsu VHMS/WebCARE Support Center

2-3-6, Akasaka Minato-Ku Tokyo, Japan FAX: 81-3-5561-4766 (from outside of Japan) FAX: 03-5561-4766 (Domestic user) E-mail: [email protected]

24

PC2000-8

30 Testing and adjusting

Preparation work for troubleshooting of electrical system

SEN02010-00

2.

1

a

When carrying out troubleshooting of an electric circuit related to the machine monitor, engine controller, or VHMS controller, expose the related connectors according to the following procedure.

1.

Machine monitor 1) Remove controller cover on the rear side of machine monitor. 2) Insert or connect troubleshooting T-adapters in or to connectors CM01 and CM02 on the rear side of machine monitor (1).

Engine controller 1) Remove controller cover (3). q Left bank

q

Right bank

2)

Insert or connect troubleshooting T-adapters in or to connectors ENG, CE05 and CE06 of right bank engine controller (1). Right bank

q

PC2000-8

25

SEN02010-00

3.

Pump controller 1) Remove the controller cover bolts and controller cover in the operator's cab. 2) Insert or connect troubleshooting T-adapters in or to connectors CP01, CP02 and CP03 of pump controller 1. 3) Insert or connect troubleshooting T-adapters in or to connectors CP04, CP05 and CP06 of pump controller 2.

4.

VHMS controller 1) Open the distribution board cover. 2) Insert or connect troubleshooting T-adapters in or to connectors CV01, CV02A, CV02B, CV03A, CV04A and CV04B of the VHMS controller (1).

26

30 Testing and adjusting

PC2000-8

30 Testing and adjusting

SEN02010-00

Pm-clinic service

1

PC2000-8

27

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Measurement procedure

30 Testing and adjusting

1

Outline of measurement procedure for PMclinic There are the following 3 types of measurement procedure for PM clinic of PC2000-8. a Basically, apply measurement procedure 1 or 2. 1.

3.

Measurement procedure by oil pressure gauge, fan tachometer, etc. Measure each data with an oil pressure gauge, fan tachometer, etc.

4.

Measurement procedure by downloading data in VHMS controller Connect a personal computer to the VHMS controller and execute the quick PM clinic with the machine monitor, and then download the PM clinic data to the personal computer. a The following tools are necessary to this measurement procedure.

Measurement procedure by machine monitor Read the data on the PM clinic screen with “PM clinic function” of the machine monitor.

Symbol 1 W 2

2.

28

Part No.

Part name

799-608-3211

• Diskette

790-608-3220

• Wiring harness

Commercially available

Notebook personal computer OS: Windows98/2000/Me/XP with “RS232C terminal”

Measurement procedure by stopwatch, scale, etc. Measure each data with a stopwatch, scale, etc.

PC2000-8

30 Testing and adjusting

Preparation for measurement for PM clinic 1. Check safety around the machine and start the engine. 2.

Set the machine monitor to display the service menu selection screen, and then select the “PM clinic” menu and display “PM clinic (1/12)” screen. a For the operating method, see “Testing an d a dj u s t i ng , Sp ec i a l f un c t i on s o f machine monitor”

SEN02010-00

Measurement procedure by machine monitor 1. Start of engine 1) Check that the machine monitor is not displaying the abnormality screen. 2) Prepare the PM clinic sheet. Check safety around the machine, sound the horn, and start the engine. 3) Turn the swing lock switch in the OFF position. 4) Set the lock lever in the FREE position. 2.

3.

Warm up the engine to increase the engine coolant temperature and hydraulic oil temperature. q Engine coolant temperature: Min. 40ºC q Hydraulic oil temperature: Min. 40ºC

4.

Stop the machine on a level ground.

5.

Prepare for locking the travel system. k When measuring the travel relief pressure, lock the sprocket on the side to be measured. k When measuring the no-load travel speed, push up the track shoe on the side to be measured.

6.

Lower the work equipment to the ground and stop the engine.

PC2000-8

Check of indication of engine coolant temperature gauge and PTO oil temperature gauge 1) Set the machine monitor to display the monitor screen (1/2). 2) Check the indication of the engine coolant temperature gauge and PTO oil temperature gauge.

29

SEN02010-00

3.

Change of display of machine monitor Set the machine monitor to display the service menu and select the “PM clinic” menu. a For the operating method, see “Functions and operation of machine monitor”.

4.

Measuring with “PM clinic (1/12)” 1) Display “PM clinic (1/12)”. 2) Measure the engine speed, engine coolant temperature, engine oil pressure, engine oil temperature, PTO oil temperature and hydraulic oil temperature. a For the measurement conditions, see the check sheet.

30

30 Testing and adjusting

5.

Measuring with “PM clinic (2/12)” 1) Display “PM clinic (2/12)”. 2) Measure the engine speed, intake air pressure and exhaust temperature (at the front and rear of the right bank and left bank). a For the measurement conditions, see the check sheet.

6.

Measuring with “PM clinic (3/12)” 1) Display “PM clinic (3/12)”. 2) Measure the engine speed, intake air temperature, left-bank common rail pressure, left-bank boost pressure and exhaust temperature (at the front of the left bank). a For the measurement conditions, see the check sheet.

PC2000-8

30 Testing and adjusting

7.

Measuring with “PM clinic (4/12)” 1) Display “PM clinic (4/12)”. 2) Measure the engine speed, ambient temperature, left-bank fuel temperature, rightbank fuel temperature and common rail pressure (of the right and left banks). a For the measurement conditions, see the check sheet.

8.

Measuring with “PM clinic (5/12)” 1) Display “PM clinic (5/12)”. 2) Measure the engine speed, ambient temperature, left-bank fuel temperature, leftbank common rail pressure and blow-by pressure. a For the measurement conditions, see the check sheet.

PC2000-8

SEN02010-00

9.

Measuring with “PM clinic (6/12)” 1) Display “PM clinic (6/12)”. 2) Measure the engine speed, ambient temperature, right-bank fuel temperature, right-bank common rail pressure and blow-by pressure. a For the measurement conditions, see the check sheet.

10. Measuring with “PM clinic (7/12)” 1) Display “PM clinic (7/12)”. 2) Measure the engine speed, hydraulic oil temperature, P1F pump pressure, P1R pump pressure, P2F pump pressure and P2R pump pressure. a For the measurement conditions, see the check sheet.

31

SEN02010-00

30 Testing and adjusting

11. Measuring with “PM clinic (8/12)” 1) Display “PM clinic (8/12)”. 2) Measure the engine speed, hydraulic oil temperature, P1F pump pressure, P1R pump pressure, VR1 J/S differential pressure and VL1 J/S differential pressure. a For the measurement conditions, see the check sheet.

13. Measuring with “PM clinic (10/12)” 1) Display “PM clinic (10/12)”. 2) Measure the engine speed, hydraulic oil temperature, P1F pump pressure, P1R pump pressure, P1F pump control EPC current and P1R pump control EPC current. a For the measurement conditions, see the check sheet.

12. Measuring with “PM clinic (9/12)” 1) Display “PM clinic (9/12)”. 2) Measure the engine speed, hydraulic oil temperature, P2F pump pressure, P2R pump pressure, VR2 J/S differential pressure and VL2 J/S differential pressure. a For the measurement conditions, see the check sheet.

14. Measuring with “PM clinic (11/12)”

32

1) 2)

Display “PM clinic (11/12)”. Measure the engine speed, hydraulic oil temperature, P2F pump pressure, P2R pump pressure, P2F pump control EPC current and P2R pump control EPC current. a For the measurement conditions, see the check sheet.

PC2000-8

30 Testing and adjusting

15. Measuring with “PM clinic (12/12)” 1) Display “PM clinic (12/12)”. 2) Measure the engine speed, ambient temperature, fan pump pressure (O/C), fan pump pressure (RAD), fan pump control EPC (RAD) current and fan pump control EPC (O/C) current a For the measurement conditions, see the check sheet.

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17. Measuring fan speed Using a tachometer, measure the RAD and O/C fan speeds. a See “Testing and adjusting (Part 2)”, Measuring fan speed.

16. Measuring PPC basic pressure a For the measurement conditions, see the check sheet. a Connect a pressure gauge to the PPC basic pressure pickup coupler to measure the PPC basic pressure.

18. Measuring work equipment speed and hydraulic drift Using a stopwatch, scale, etc., measure the work equipment speed and hydraulic drift.

PC2000-8

33

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Measurement procedure by downloading data in VHMS controller 1.

2.

34

30 Testing and adjusting

3.

Change of display of machine monitor 1) Set the machine monitor to display the service menu selection screen. a See “Functions and operation of machine monitor”. 2) Select “Snap shot”.

4.

Execution of snap shot 1) Continue the operation on the screen to start the snap shot. a While the screen at right is displayed, press the F1 button, and the check message is displayed. a Before starting the snap shot, fully understand the operating procedure for the snap shot.

Connection of personal computer 1) Check that the starting switch is in the OFF position. k Be sure to connect and disconnect the personal computer while starting switch is in the OFF position. 2) Connect personal computer W2 and download connector C53 by wiring harness [1] of service kit W1. a Download connector C53 is installed to the top of the left console. a Connect the personal computer to the RS232C terminal.

Start of engine 1) Check that the machine monitor is not displaying the abnormality screen. 2) Prepare the PM clinic sheet. Check safety around the machine, sound the horn, and start the engine. 3) Turn the swing lock switch in the OFF position. 4) Set the PPC lock lever in the FREE position.

PC2000-8

30 Testing and adjusting

2)

SEN02010-00

Operate the switches and levers at each execution time according to the “Operating procedure for quick PM clinic” shown in the following table. a The execution times are displayed on the machine monitor. k Since the work equipment and machine are operated actually during the quick PM clinic, take care of the safety around the machine extremely during the work.

PC2000-8

35

SEN02010-00

30 Testing and adjusting

Operating procedure for Quick Pm No.

Elapsed time

Time on snap data

Fuel dial

Swing lock switch

MIN (Low)

OFF

1

Start O Finish

0:00 O 0:30

–330.00 O –300.00

2

Start O Finish

0:30 O 1:00

–300.00 O –270.00

MAX (High)

3

Start O Finish

1:00 O 1:30

–270.00 O –240.00

4

Start O Finish

1:30 O 2:30

5

Start O Finish

6

Data read in Pm clinic after data are downloaded

Operation of lever Set all levers in neutral.

• Engine speed (Low idle) • Engine oil pressure (Low idle) • Ambient temperature

OFF

Set all levers in neutral (Turn decelerator on).

• • • • •

MAX (High)

OFF

Move levers finely [Note] (Turn decelerator off).

• Engine speed (Auto deceleration)

–240.00 O –180.00

MAX (High)

OFF

Raise right-hand track shoe and drive it idle (Set lever to stroke end).

• Pump pressure (actuating pressure)

2:30 O 3:30

–180.00 O –120.00

MAX (High)

OFF

Swing 180°. Raise left-hand track shoe • Pump pressure and drive it idle (Set lever (actuating pressure) to stroke end).

Start O Finish

3:30 O 4:00

–120.00 O 0–90.00

MAX (High)

ON

R.H. swing relief.

• Swing oil pressure (relief pressure)

7

Start O Finish

4:00 O 4:30

0–90.00 O 0–60.00

MAX (High)

ON

L.H. swing relief.

• Swing oil pressure (relief pressure)

8

Start O Finish

4:30 O 5:00

0–60.00 O 0–30.00

MAX (High)

ON

Arm OUT relief.

• Arm OUT oil pressure

9

Start O Finish

5:00 O 5:30

0–30.00 O 0–00.00

MAX (High)

ON

Bucket DUMP relief.

• Bucket DUMP oil pressure

10

Start O Finish

5:30 O 6:00

0–00.00 O 0–30.00

MAX (High)

ON

Bucket CURL relief.

• Bucket CURL oil pressure

11

Start O Finish

6:00 O 6:30

0–30.00 O 0–60.00

MAX (High)

ON

Arm IN relief.

• Arm IN oil pressure

12

Start O Finish

6:30 O 7:00

0–60.00 O 0–90.00

MAX (High)

ON

Boom RAISE relief.

• • • •

13

Start O Finish

7:00 O 7:30

0–90.00 O –120.00

MAX (High)

ON

Set all levers in neutral (1st deceleration o 2nd deceleration)

• Engine speed (1st deceleration speed)

14

—

7:30

–120.00

MIN (Low)

ON

Finish

Engine speed (High idle) Engine oil pressure (High idle) J/S differential pressure Pump oil pressure Fan pump oil pressure

Boom RAISE oil pressure Blow-by pressure Exhaust temperature Boost pressure

Note: To turn off the decelerator and set the engine speed to high idle, move one of both work equipment control levers and both travel levers to a degree that the work equipment does not move or the machine does not swing or travel. (If the PPC oil pressure switch is turned ON, the auto-decelerator is turned OFF.)

36

PC2000-8

30 Testing and adjusting

5.

SEN02010-00

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

3)

Use the [Download] function to download the data recorded in the VHMS controller to the personal computer. a For the operation procedures and data analyzing method, see the operation manual for VHMS Analysis Tool.

PC2000-8

37

Pm-Clinic service Chassis serial No.

PC2000-8 Backhoe

Engine serial No. (SAA12V140E-3)

Hour inspection Work direction No.

Service meter

Date of execution

Inspector

Interview with operator and walk-around inspection Is there any abnormality before starting inspection?

Accepted Rejected

Max. level of (F) coolant temperature

Max. (F) PTO oil temperature

Blue 3 4 5 6 7 (During work)

Blue 3 4 5 6 7 (During work)

1

2

Red 8 9

Max. level of (R) coolant temperature

1. Engine

1

2

Blue 3 4 5 6 7 (During work)

Red 8 9

1

2

Max. (R) PTO oil temperature 1

2

Blue 3 4 5 6 7 (During work)

Measurement Condition items After starting engine Engine: Low idle 1-1 Engine: High idle Engine: Full throttle Boom: Raise relief Engine Engine: Full throttle speed (in DH mode) Boom: Raise relief + Heavy lift: ON Auto-deceleration switch: ON Fuel control dial: Max. Control lever: Neutral 1-2 At rated horsepower Blow-by pressure

1-3 Engine lubricating oil pressure

Engine: Low idle (SAE30)

Unit

rpm

kPa {mmAq}

MPa {kg/cm2}

Engine: High idle (SAE30)

2. PTO

At rated horsepower At all speed range

kPa {mmHg} °C

Ambient temperature

2-1 Visual check of filter 2-2 Check of center bearing thermo-label 2-3 PTO oil temperature

—

°C

3. Work equipment speed

38

Engine: Full throttle DH mode Hydraulic oil temperature: 45 - 55°C

5. Bucket CURL Swing: Measure time for 6. Bucket DUMP 5 turns after 1 turn. 7. Swing 5 turns Travel: Raise each track and measure 5 turns with no load after 1 turn. 8. Drive right track 5 turns 9. Drive left track 5 turns

°C

Min.

°C

Altitude

m

Standard value Service limit for new machine value 775 – 875 1930 – 2030

775 – 875 1930 – 2030

1680 – 1880

1680 – 1880

1680 – 1880

1680 – 1880

1300 – 1500

1300 – 1500

Max. 2.94 {Max. 300} Min. 0.08 {Min. 0.8} Min. 0.08 {Min. 0.8} 0.29 – 0.44 {3.0 – 4.5}

Min. 5.88 {Min. 600} Min. 0.06 {Min. 0.6} Min. 0.06 {Min. 0.6} Min. 0.2 {Min. 2.0}

Min. 125.7 {Min. 950}

Limit is not set

Max. 700

Max. 750

20

20

sec

Measurement Accepted Rejected result

—

—

Metal powder must not be collected. 120°C range must not be black. Max. 120°C

1. Boom RAISE 2. Boom LOWER 3. Arm IN 4. Arm OUT

Max.

Red 8 9

Engine: Low idle (SAE10)

1-4 Boost pressure 1-5 Exhaust temperature

Ambient temperature

Red 8 9

Max. 120°C

6.7 – 8.3

Max. 9.0

4.8 – 5.8

Max. 6.4

6.7 – 8.3 4.7 – 5.7

Max. 9.0 Max. 6.2

4.5 – 5.5

Max. 6.0

3.5 – 4.3

Max. 4.7

57.5 – 67.5

Max. 70.0

90.5 – 110.5

90.5 – 110.5

90.5 – 110.5

90.5 – 110.5

PC2000-8

4 Hydraulic drift

Measurement items

Condition

Set work equipment in measuring posture and stop engine. Hydraulic drift of Whole work equipment Work equipment bucket tooth tip posture: Boom and arm in level, bucket Boom cylinder Cylinder retraction curled, rated load on work equipment [no Arm cylinder Cylinder extension load] Hydraulic oil temperature: 45 – 55ºC Cylinder retraction Bucket cylinder

Measurement items

Condition

5-1 Control pressure (PPC basic pressure)

Unit

mm/15 min

Unit

Control lever: Neutral Control lever: Neutral Right travel lever: Stroke end Track: Turning with no load Left travel lever: Stroke end Track: Turning with no load Control lever: Neutral Right travel lever: Stroke end Track: Turning with no load Left travel lever: Stroke end Track: Turning with no load Boom: Raise relief (Normal) Boom: Raise relief (Heavy lift ON)

5-2 Jet sensor differential pressure

5-3 Pump EPC current

MPa {kg/cm2}

mA

5 Hydraulic system

Swing: Relief Boom: Raise relief (Normal) Boom: Raise relief (Heavy lift ON) Arm: In relief Arm: Out relief Bucket: Curl relief

MPa {kg/cm2}

Boom: Raise relief (Normal) Boom: Raise relief (Heavy lift ON) 5-6 P2F pump pressure

Arm: In relief Arm: Out relief Bucket: Curl relief Boom: Raise relief (Heavy lift ON)

5-7 P2R pump pressure

Arm: In relief Arm: Out relief Bucket: Curl relief

5-8 Fan pump EPC (Radiator) current 5-9 Fan pump EPC (Oil cooler) current 5-10 Fan speed (Radiator) 5-11 Fan speed (Oil cooler) 5-12 Hydraulic oil temperature

PC2000-8

Accepted Rejected

Max. 1,800 {Max. 1000} Max. 90 {Max. 50} Max. 250 {Max. 105} Max. 80 {Max. 30}

Standard value for Service limit value Measurement result Accepted Rejected new machine F engine R engine 3.04 – 3.73 {31 – 38}

Max. 0.17 MPa Max. 0.17 MPa {Max. 1.7 kg/cm2} {Max. 1.7 kg/cm2} Max. 0.17 MPa Max. 0.17 MPa {Max. 1.7 kg/cm2} {Max. 1.7 kg/cm2}

Bucket: Curl relief

5-5 P1R pump pressure

Measurement result

Min. 1.28 MPa Min. 1.28 MPa {Min. 13.1 kg/cm2} {Min. 13.1 kg/cm2}

Arm: Out relief

Hydraulic oil temperature: 45 – 55ºC Mode: P Engine: Full throttle Fan: 100% speed mode Auto-decelerator: OFF

Max. 1,200 {Max. 650} Max. 60 {Max. 35} Max. 165 {Max. 70} Max. 50 {Max. 15}

3.24 – 3.73 {33 – 38}

Arm: In relief

5-4 P1F pump pressure

Standard value for Service limit value new machine

Control lever: Neutral

160 – 280

160 – 280

P1 : 390 – 510 P2 : 615 – 735

P1 : 390 – 510 P2 : 615 – 735

P1 : 390 – 510 P2 : 615 – 735

P1 : 390 – 510 P2 : 615 – 735

28.4 – 30.4 {290 – 310} 31.1 – 33.1 {317 – 337} 28.4 – 30.4 {290 – 310} 28.4 – 30.4 {290 – 310} 28.4 – 30.4 {290 – 310} 28.4 – 30.4 {290 – 310} 28.4 – 30.4 {290 – 310} 31.1 – 33.1 {317 – 337} 28.4 – 30.4 {290 – 310} 28.4 – 30.4 {290 – 310} 28.4 – 30.4 {290 – 310} 28.4 – 30.4 {290 – 310} 31.1 – 33.1 {317 – 337} 28.4 – 30.4 {290 – 310} 28.4 – 30.4 {290 – 310} 28.4 – 30.4 {290 – 310} 31.1 – 33.1 {317 – 337} 28.4 – 30.4 {290 – 310} 28.4 – 30.4 {290 – 310} 28.4 – 30.4 {290 – 310}

27.4 – 30.4 {280 – 310} 30.1 – 33.1 {307 – 337} 27.4 – 30.4 {280 – 310} 27.4 – 30.4 {280 – 310} 27.4 – 30.4 {280 – 310} 27.4 – 30.4 {280 – 310} 27.4 – 30.4 {280 – 310} 30.1 – 33.1 {307 – 337} 27.4 – 30.4 {280 – 310} 27.4 – 30.4 {280 – 310} 27.4 – 30.4 {280 – 310} 27.4 – 30.4 {280 – 310} 30.1 – 33.1 {307 – 337} 27.4 – 30.4 {280 – 310} 27.4 – 30.4 {280 – 310} 27.4 – 30.4 {280 – 310} 30.1 – 33.1 {307 – 337} 27.4 – 30.4 {280 – 310} 27.4 – 30.4 {280 – 310} 27.4 – 30.4 {280 – 310}

STD : 575 – 675 55ºC : 505 – 605

STD : 575 – 675 55ºC : 505 – 605

STD : 600 – 700 55ºC : 505 – 605

STD : 600 – 700 55ºC : 505 – 605

mA Control lever: Neutral Control lever: Neutral Control lever: Neutral Mode: P Engine: Full throttle Bucket: Dump relief Fan: 100% speed mode

rpm

ºC

STD : 790 – 890 STD : 790 – 890 55ºC : 1050 – 1150 55ºC : 1050 – 1150 STD : 710 – 810 STD : 710 – 810 55ºC : 1050 – 1150 55ºC : 1050 – 1150 Max. 100ºC

Max. 100ºC

39

6

Visual check of hydraulic tank strainer (Every 2,000 H)

There must not be excessive metal powder or foreign matter.

Memo: Enter phenomena and information you noticed during today's check.

40

PC2000-8

PC2000-8

Pm-Clinic service

Visual check of welded structures (For PC2000-8) If any crack is found, draw its shape below.

Arm

Boom

Revolving frame

1. Arm cylinder bracket Left Right 2. Arm foot Left Right End plate 3. Arm top boss Left Right 4. Arm cylinder bracket Left Right

5. Boom top bracket Left Right 6. Boom cylinder bracket Left Right 7. Boom lower plate Left Right 8. Boom foot Left Right

9. Boom bracket Left Right

PC2000-8

Track frame 10. Circle bracket Front Rear Right Left 11. Track frame mounting section Front Rear Right Left

41

SEN02010-00

PC2000-8 Hydraulic excavator Form No. SEN02010-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

42

SEN02011-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

40 Troubleshooting

1

Failure code table and fuse locations Failure code table................................................................................................................................. 2 Before carrying out troubleshooting of electrical system...................................................................... 9

PC2000-8

1

SEN02011-00

40 Troubleshooting

Failure code table and fuse locations Failure code table Failure code

1 User code

Applicable equipment

History classification

0410KA

Fuel LV. Sensor Failure

—

MON

Electrical system

0410KB

Fuel LV. Sensor Failure

—

MON

Electrical system

6014NX [n5o51]

Hydraulic Oil Filter Clogging

—

VHMS

Mechanical system

8800ZG

Auto grease abnormally

—

PUMP

Mechanical system

7@HAZL

VR1/P1F Relief Press Abnormality

—

PUMP

Mechanical system

7@HBZL

VL1/P1R Relief Press Abnormality

—

PUMP

Mechanical system

7@HCZL

VR2/P2F Relief Press Abnormality

—

PUMP

Mechanical system

7@HDZL

VL2/P2R Relief Press Abnormality

—

PUMP

Mechanical system

AA10NX

Aircleaner Clogging

—

MON

Mechanical system

AB00KE

Change Voltage Low

—

MON

Mechanical system

aB00KE [n9o11]

Low Upper ALR Charge Voltage

—

VHMS

VHMS [n9o11]

B@BAZG

Eng. Oil Press. Low

—

ENG

Mechanical system

B@BAZK

Eng. Oil Level Low

—

MON

Mechanical system

B@BCNS

Eng. Water Overheat

—

ENG

Mechanical system

B@BCZK

Eng. Water Lvl Low

—

MON

Mechanical system

B@CBNS [n5o61]

PTO Oil Overheat

—

PUMP

VHMS [n5o61]

B@HANS

Hydr. Oil Overheat

—

MON

Mechanical system

B@HAZK [n5o52]

Low Hydraulic Oil Level

—

VHMS

VHMS [n5o52]

ECM Critical Internal Failure

E10

ENG

Electrical system

CA111

2

Failure contents

1

CB111

ECM Critical Internal Failure

E10

ENG

Electrical system

CA115

Eng. Ne and Bkup Speed Sens Error

E10

ENG

Electrical system

CB115

Eng. Ne and Bkup Speed Sens Error

E10

ENG

Electrical system

CA122

Chg Air Press Sensor High Error

E11

ENG

Electrical system

CA123

Chg Air Press Sensor Low Error

E11

ENG

Electrical system

CA131

Throttle Sensor High Error

E14

ENG

Electrical system

CA132

Throttle Sensor Low Error

E14

ENG

Electrical system

CA135

Eng Oil Press Sensor High Error

E15

ENG

Electrical system

CA141

Eng Oil Press Sensor Low Error

E15

ENG

Electrical system

CA144

Coolant Temp Sens High Error

E15

ENG

Electrical system

CA145

Coolant Temp Sens Low Error

E15

ENG

Electrical system

CA153

Chg Air Temp Sensor High Error

E15

ENG

Electrical system

CA154

Chg Air Temp Sensor Low Error

E15

ENG

Electrical system

CA187

Sens Supply 2 Volt Low Error

E15

ENG

Electrical system

CB187

Sens Supply 2 Volt Low Error

E15

ENG

Electrical system

CA212

Eng Oil Temp Sensor High Error

E15

ENG

Electrical system

CA213

Eng Oil Temp Sensor Low Error

E15

ENG

Electrical system

Reference document No.

Troubleshooting by failure code, Part 1 SEN02096-00

PC2000-8

40 Troubleshooting

SEN02011-00

Failure contents

User code

Applicable equipment

History classification

CA221

Ambient Press Sens High Error

E15

ENG

Electrical system

CA222

Ambient Press Sens Low Error

E15

ENG

Electrical system

CA227

Sens Supply 2 Volt High Error

E15

ENG

Electrical system

CB227

Sens Supply 2 Volt High Error

E15

ENG

Electrical system

CA234

Eng Over Speed

E15

ENG

Electrical system

CA238

Ne Speed Sens Supply Volt Error

E15

ENG

Electrical system

CB238

Ne Speed Sens Supply Volt Error

E15

ENG

Electrical system

CA263

Fuel Temp Sensor High Error

E15

ENG

Electrical system

CB263

Fuel Temp Sensor High Error

E15

ENG

Electrical system

CA265

Fuel Temp Sensor Low Error

E15

ENG

Electrical system

CB265

Fuel Temp Sensor Low Error

E15

ENG

Electrical system

CA271

IMV/PCV1 Short Error

E10

ENG

Electrical system

CB271

IMV/PCV1 Short Error

E10

ENG

Electrical system

CA272

IMV/PCV1 Open Error

E10

ENG

Electrical system

CB272

IMV/PCV1 Open Error

E10

ENG

Electrical system

CA273

PCV2 Short Error

E10

ENG

Electrical system

CB273

PCV2 Short Error

E10

ENG

Electrical system

CA274

PCV2 Open Error

E10

ENG

Electrical system

CB274

PCV2 Open Error

E10

ENG

Electrical system

CA322

Inj #1(L#1) Open/Short Error

E11

ENG

Electrical system

CA323

Inj #5(L#5) Open/Short Error

E11

ENG

Electrical system

CA324

Inj #3(L#3) Open/Short Error

E11

ENG

Electrical system

CA325

Inj #6(L#6) Open/Short Error

E11

ENG

Electrical system

CA331

Inj #2(L#2) Open/Short Error

E11

ENG

Electrical system

CA332

Inj #4(L#4) Open/Short Error

E11

ENG

Electrical system

CA342

Calibration Code Incompatibility

E10

ENG

Electrical system

CB342

Calibration Code Incompatibility

E10

ENG

Electrical system

CA351

Injectors Drive Circuit Error

E10

ENG

Electrical system

CB351

Injectors Drive Circuit Error

E10

ENG

Electrical system

CA352

Sens Supply 1 Volt Low Error

E15

ENG

Electrical system

CB352

Sens Supply 1 Volt Low Error

E15

ENG

Electrical system

CA386

Sens Supply 1 Volt High Error

E15

ENG

Electrical system

CB386

Sens Supply 1 Volt High Error

E15

ENG

Electrical system

CA441

Battery Voltage Low Error

E10

ENG

Electrical system

CB441

Battery Voltage Low Error

E10

ENG

Electrical system

CA442

Battery Voltage High Error

E10

ENG

Electrical system

CB442

Battery Voltage High Error

E10

ENG

Electrical system

CA449

Rail Press Very High Error

E11

ENG

Electrical system

CB449

Rail Press Very High Error

E11

ENG

Electrical system

Failure code

PC2000-8

Reference document No.

Troubleshooting by failure code, Part 2 SEN02097-00

3

SEN02011-00

Failure code

4

40 Troubleshooting

Failure contents

User code

Applicable equipment

History classification

CA451

Rail Press Sensor High Error

E11

ENG

Electrical system

CB451

Rail Press Sensor High Error

E11

ENG

Electrical system

CA452

Rail Press Sensor Low Error

E11

ENG

Electrical system

CB452

Rail Press Sensor Low Error

E11

ENG

Electrical system

CA553

Rail Press High Error

E15

ENG

Electrical system

CB553

Rail Press High Error

E15

ENG

Electrical system

CA554

Rail Press Sensor In Range Error

E11

ENG

Electrical system

CB554

Rail Press Sensor In Range Error

E11

ENG

Electrical system

CA559

Rail Press Low Error

E15

ENG

Electrical system

CB559

Rail Press Low Error

E15

ENG

Electrical system

CA689

Eng Ne Speed Sensor Error

E15

ENG

Electrical system

CB689

Eng Ne Speed Sensor Error

E15

ENG

Electrical system

CA691

Intake Air Temp Sens High Error

E15

ENG

Electrical system

CA692

Intake Air Temp Sens Low Error

E15

ENG

Electrical system

CA731

Eng Bkup Speed Sens Phase Error

E15

ENG

Electrical system

CB731

Eng Bkup Speed Sens Phase Error

E15

ENG

Electrical system

CA757

All Persistent Data Lost Error

E10

ENG

Electrical system

CB757

All Persistent Data Lost Error

E10

ENG

Electrical system

CA778

Eng Bkup Speed Sensor Error

E15

ENG

Electrical system

CB778

Eng Bkup Speed Sensor Error

E15

ENG

Electrical system

CA781

CEN Communication Error

E0E

ENG

Electrical system

CB781

CEN Communication Error

E0E

ENG

Electrical system

CA1117

Persistent Data Lost Error

E10

ENG

Electrical system

CB1117

Persistent Data Lost Error

E10

ENG

Electrical system

CA1257

Harness Key Error

E0E

ENG

Electrical system

CB1257

Harness Key Error

E0E

ENG

Electrical system

CB1548

Inj #7(R#1) Open/Short Error

E11

ENG

Electrical system

CB1549

Inj #8(R#2) Open/Short Error

E11

ENG

Electrical system

CB1551

Inj #9(R#3) Open/Short Error

E11

ENG

Electrical system

CB1552

Inj #10(R#4) Open/Short Error

E11

ENG

Electrical system

CB1553

Inj #11(R#5) Open/Short Error

E11

ENG

Electrical system

CB1622

Inj #12(R#6) Open/Short Error

E11

ENG

Electrical system

CA1633

KOMNET Data link Time out Error

E0E

ENG

Electrical system

CA2185

Throt Sens Sup Volt High Error

E14

ENG

Electrical system

CA2186

Throt Sens Sup Volt Low Error

E14

ENG

Electrical system

CA2249

Rail Press Very Low Error

E11

ENG

Electrical system

CB2249

Rail Press Very Low Error

E11

ENG

Electrical system

CA2555

Grid Heater Relay Volt Low Error

E15

ENG

Electrical system

CA2556

Grid Heater Relay Volt High Error

E15

ENG

Electrical system

Reference document No.

Troubleshooting by failure code, Part 3 SEN02098-00

PC2000-8

40 Troubleshooting

Failure code

SEN02011-00

Failure contents

User code

Applicable equipment

History classification

D110KB

Battery Relay Drive S/C

—

PUMP

Electrical system

D163KB

Flash Light Relay S/C

—

PUMP

Electrical system

D195KA

Step Light Relay Disc

—

PUMP

Electrical system

D195KY

Step Light Relay S/C

—

PUMP

Electrical system

D1E9KB

Wiper Drive Relay 1 S/C

—

PUMP

Electrical system

D1EAKB

Wiper Drive Relay 2 S/C

—

PUMP

Electrical system

D1EBKB

Low Wiper Brake Relay Short Circuit

—

PUMP

Electrical system

D1ECKB

Upper Wiper Brake Relay Short Circuit

—

PUMP

Electrical system

DA22KK

Pump 1 Solenoid Power Low Error

E0E

PUMP

Electrical system

dA22KK

Pump 2 Solenoid Power Low Error

E0E

PUMP

Electrical system

DA25KP

Pump 1 Sens Supply Vol Low Error

E07

PUMP

Electrical system

dA25KP

Pump 2 Sens Supply Vol Low Error

DA26KP

5V Sensor 2 Power Abnormality

—

PUMP

Electrical system

E07

PUMP

Electrical system

DA29KQ

Pump 1 Model Select Abnormality

—

PUMP

Electrical system

dA29KQ

Pump 2 Model Select Abnormality

—

PUMP

Electrical system

DA2RMC

CAN Discon (Pump 1 Con Detected)

E0E

PUMP

Electrical system

dA2RMC

CAN Discon (Pump 2 Con Detected)

E0E

PUMP

Electrical system

DA2TMC

Pump Comm. ECM Child Abnormality

—

PUMP

Electrical system

DBB0KK [n9o01]

VHMS Source Voltage Error

—

VHMS

VHMS [n9o01]

DBB0KQ [nFo11]

VHMS Connector Mismatch

—

VHMS

VHMS [nFo11]

DBB5KP [n9o04]

VHMS 5V source sys Error

—

VHMS

VHMS [n9o04]

DBB6KP [n9o02]

VHMS 24V source sys Error

—

VHMS

VHMS [n9o02]

DBBQKR [n8o02]

KOM-NET/c error

—

VHMS

VHMS [n8o02]

DGE5KX [n4o01]

Ambient Air Temp Sensor Failure

—

VHMS

VHMS [n4o01]

DGH2KB

Hydr. Oil Temp. Sensor S/C

—

PUMP

Electrical system

DGT3KZ [n5o01]

PTO Temp Sensor Failure

—

VHMS

VHMS [n5o01]

PC2000-8

Reference document No.

Troubleshooting by failure code, Part 4 SEN02099-00

5

SEN02011-00

Failure code

6

40 Troubleshooting

Failure contents

User code

Applicable equipment

History classification

DGT5KA [n3o12]

Exhaust Temp. Sensor LBF Failure

—

VHMS

VHMS [n3o12]

dGT5KA [n3o22]

Exhaust Temp. Sensor LBR Failure

—

VHMS

VHMS [n3o22]

DGT5KB [n3o11]

Exhaust Temp. Sensor LBF Failure

—

VHMS

VHMS [n3o11]

dGT5KB [n3o21]

Exhaust Temp. Sensor LBR Failure

—

VHMS

VHMS [n3o21]

DGT6KA [n3o24]

Exhaust Temp. Sensor RBF Failure

—

VHMS

VHMS [n3o24]

dGT6KA [n3o25]

Exhaust Temp. Sensor RBR Failure

—

VHMS

VHMS [n3o25]

DGT6KB [n3o23]

Exhaust Temp. Sensor RBF Failure

—

VHMS

VHMS [n3o23]

dGT6KB [n3o26]

Exhaust Temp. Sensor RBR Failure

—

VHMS

VHMS [n3o26]

DH25KX

VR1/P1F J/S Dif Press Sensor Abnormality

E07

PUMP

Electrical system

DH26KX

VL1/P1R J/S Dif Press Sensor Abnormality

E07

PUMP

Electrical system

DH27KX

VR2/P2F J/S Dif Press Sensor Abnormality

E07

PUMP

Electrical system

E07

PUMP

Electrical system

DH28KX

VL2/P2R J/S Dif Press Sensor Abnormality

DHE5KB [n3o32]

Blowby Pres. Sensor Failure

VHMS [n3o32]

DHE5KY [n3o31]

Blowby Pres. Sensor Failure

VHMS [n3o31]

DHH2KA [n3o53]

Hydraulic oil filter Sensor Failure

VHMS [n3o53]

DHPEKX

VR1/P1F Pump P. Sensor Abnormality

E07

PUMP

Electrical system

DHPFKX

VL1/P1R Pump P. Sensor Abnormality

E07

PUMP

Electrical system

DHPGKX

VR2/P2F Pump P. Sensor Abnormality

E07

PUMP

Electrical system

DHPHKX

VL2/P2R Pump P. Sensor Abnormality

E07

PUMP

Electrical system

DHPSKX

Auto Grease Press Sensor Abnormality

—

PUMP

Electrical system

DHPTKX

Fan(RAD) Pump P. Sensor Open Circuit

—

PUMP

Electrical system

DHPUKX

Fan(O/C) Pump P. Sensor Open Circuit

—

PUMP

Electrical system

DHS3KX

Arm Dig PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHS4KX

Bucket Curl PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHS8KX

Boom Raise PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHS9KX

Boom Lower PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHSAKX

Swing Right PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHSBKX

Swing Left PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHSCKX

Arm Dump PPC Press Sensor Abnormality

—

PUMP

Electrical system

DHSDKX

Bucket Dump PPC Press Sensor Abnormality

—

PUMP

Electrical system

Reference document No.

Troubleshooting by failure code, Part 5 SEN02100-00

PC2000-8

40 Troubleshooting

Failure code

SEN02011-00

Failure contents

User code

Applicable equipment

History classification

DUM3KB

Auto Grease Caution LED Short Circuit

—

PUMP

Electrical system

DUM4KB

FAN Reverse LED Short Circuit

—

PUMP

Electrical system

DV20KB

Travel Alarm S/C

—

PUMP

Electrical system

DW41KA

Swing Priority Sol Open Circuit

—

PUMP

Electrical system

DW41KB

Swing Priority Sol Short Circuit

—

PUMP

Electrical system

DW45KA

Swing Brake Sol. Disc.

E03

PUMP

Electrical system

DW45KB

Swing Brake Sol. S/C

E03

PUMP

Electrical system

DW91KA

Straight-Travel Sol. Disc.

PUMP

Electrical system

DW91KB

Straight-Travel Sol. S/C

—

PUMP

Electrical system

DW4XKA

Bucket Curl Hi Cancel Sol. Disc.

—

PUMP

Electrical system

DW4XKB

Bucket Curl Hi Cancel Sol. S/C

—

PUMP

Electrical system

DW7BKA

Fan Motor(RAD) Reverse Sol Open Circuit

—

PUMP

Electrical system

DW7BKB

Fan Reverse Sol S/C

—

PUMP

Electrical system

DW7HKA

Fan Motor(O/C) Reverse Sol Open Circuit

—

PUMP

Electrical system

DW7HKB

Fan Motor(O/C) Reverse Sol Short Circuit

—

PUMP

Electrical system

DWA3KA

Arm throttle Valve/L Sol Open Circuit

—

PUMP

Electrical system

DWA3KB

Arm throttle Valve/L Sol Short Circuit

—

PUMP

Electrical system

DWA4KA

Arm throttle Valve/R Sol Open Circuit

—

PUMP

Electrical system

DWA4KB

Arm throttle Valve/R Sol Short Circuit

—

PUMP

Electrical system

DWA5KA

Auto Grease Sol Open Circuit

—

PUMP

Electrical system

DWA5KB

Auto Grease Sol Short Circuit

—

PUMP

Electrical system

DWA6KA

Boom throttle Valve Sol Open Circuit

—

PUMP

Electrical system

DWA6KB

Boom throttle Valve Sol Short Circuit

—

PUMP

Electrical system

DWK0KA

2-stage Relief Sol. Disc.

—

PUMP

Electrical system

DWK0KB

2-stage Relief Sol. S/C

—

PUMP

Electrical system

DWK2KA

Back Press Comp Valve Sol Open Circuit

—

PUMP

Electrical system

DWK2KB

Back Press Comp Valve Sol Short Circuit

—

PUMP

Electrical system

PC2000-8

Reference document No.

Troubleshooting by failure code, Part 6 SEN02101-00

7

SEN02011-00

Failure code

Failure contents

User code

Applicable equipment

History classification

DWN5KA

Fan(RAD) Pump Epc Sol Open Circuit

E11

PUMP

Electrical system

DWN5KB

Fan(RAD) Pump Epc Sol Short Circuit

E11

PUMP

Electrical system

DWNCKA

Fan(O/C) Pump Epc Sol Open Circuit

E11

PUMP

Electrical system

DWNCKB

Fan(O/C) Pump Epc Sol Short Circuit

E11

PUMP

Electrical system

DXAAKA

P1F EPC Sol Disc

E07

PUMP

Electrical system

DXAAKB

P1F EPC Sol S/C

E07

PUMP

Electrical system

DXABKA

P1R EPC Sol Disc

E07

PUMP

Electrical system

DXABKB

P1R EPC Sol S/C

E07

PUMP

Electrical system

DXACKA

P2F EPC Sol Disc

E07

PUMP

Electrical system

DXACKB

P2F EPC Sol S/C

E07

PUMP

Electrical system

DXADKA

P2R EPC Sol Disc

E07

PUMP

Electrical system

DXADKB

P2R EPC Sol S/C

E07

PUMP

Electrical system

DY2CKB

Washer Drive S/C

—

PUMP

Electrical system

DY20MA

Low Wiper Working Abnormality

—

PUMP

Electrical system

DY2FMA

Upper Wiper Working Abnormality

—

PUMP

Electrical system

F@BBZL [n3o38]

High Blowby Pressure

—

VHMS

VHMS [n3o38]

F@BYNR [n3o62]

Very High LBF CYL Exhaust Temp

—

VHMS

VHMS [n3o62]

f@BYNR [n3o72]

Very High LBR CYL Exhaust Temp

—

VHMS

VHMS [n3o72]

F@BYNS [n3o61]

High LBF CYL Exhaust Temp

—

VHMS

VHMS [n3o61]

f@BYNS [n3o71]

High LBR CYL Exhaust Temp

—

VHMS

VHMS [n3o71]

F@BZNR [n3o82]

Very High RBF CYL Exhaust Temp

—

VHMS

VHMS [n3o82]

f@BZNR [n3o92]

Very High RBR CYL Exhaust Temp

—

VHMS

VHMS [n3o92]

F@BZNS [n3o81]

High RBF CYL Exhaust Temp

—

VHMS

VHMS [n3o81]

f@BZNS [n3o91]

High RBR CYL Exhaust Temp

—

VHMS

VHMS [n3o91]

LA10ZL

RAD Fan Pump Relief Press Abnormality

—

PUMP

Mechanical system

LA20ZL

O/C Fan Pump Relief Press Abnormality

—

PUMP

Mechanical system

a a a

a

8

40 Troubleshooting

Reference document No.

Troubleshooting by failure code, Part 7 SEN02102-00

This table lists the failed sections in the order of the failure code. Those failure codes to which the corresponding number is not indicated in the action code space are not displayed on the ordinary screen if a failure is found. They are just recorded in the abnormality record (electrical system and mechanical system) of the service menu. The category of record is used for indicating to which of the electrical and mechanical system of the service menu's abnormality record a given failure is classified. VHMS failure codes, which are available only in VHMS specifications, are stored only in VHMS controller; therefore, they are not recorded in the abnormality record. In addition, four-digit codes in the (bracket) of VHMS indicate the failure codes (displayed two digits each) displayed by the 7-segment LED of VHMS controller. E at the head of the action code indicates the following state: q With E: The failure still remains without being resolved. q Without E: The failure is already resolved.

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40 Troubleshooting

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Before carrying out troubleshooting of electrical system

1

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

Circuit breaker (B) (Large capacity breaker) Type of power supply

Circuit breaker (B) Terminal numbers are shown in brackets ( ).

Destination of power 30A (B21A-B21B) 30A (B22A-B22B)

Switch power supply (battery relay M terminal)

(1) 60A (B11-B12)

20A (B23A-B23B) Fuse (6) – (10) 20A (B24A-B24B) 20A (B25A-B25B) 20A (B26A-B26B)

(2) 60A (B13-B14)

Fuse (1) – (5) (11) – (13) Connector B05 (Optional power supply) 20A (B27A-B27B)

Constant power supply (battery relay B terminal)

(3) 60A (B17-B18)

30A (B28A-B28B) 30A (B29A-B29B) 30A (B30A-B30B) Fuse (16) – (20)

Switch power supply (battery relay M terminal)

*

(4) 105A (B6A-B6B)

Intake air heater relay (1)

(5) 105A (B5A-B5B)

Intake air heater relay (2)

Figure in the ( ) shows a circuit breaker number in the circuit diagram

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40 Troubleshooting

Circuit breaker (A)

q

Type of power supply

Circuit breaker (2) for switch power supply 60A

Constant power supply circuit breaker (3) 60A

Circuit breaker (A) Terminal numbers are shown in brackets ( ).

Destination of power

(1) 20A (B25A-B25B)

Pump controller 2

(2) 20A (B24A-B24B)

Pump controller 1

(3) 20A (B23A-B23B)

*

10

Working lamp power supply (R08 relay)

(4) 30A (B22A-B22B)

Right working lamp power supply (R10 relay)

(5) 30A (B21A-B21B)

Left working lamp power supply (R11 relay)

(6) 30A (B30A-B30B)

Engine right controller

(7) 30A (B29A-B29B)

Engine left controller

(8) 30A (B28A-B28B) (9) 20A (B27A-B27B)

Switch power supply circuit breaker (1) 60A

PPC lock solenoid valve

(10) 20A (B26A-B26B)

Starting switch Machine monitor Pump controller 1 Pump controller 2 VHMS controller ORBCOM controller VHMS controller

Figure in the ( ) shows a circuit breaker number in the circuit diagram

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40 Troubleshooting

Location of circuit breakers 1. Circuit breaker (B) (Large capacity breaker) Located in the box (2) on the side of battery room (1).

PC2000-8

SEN02011-00

2.

Circuit breaker (A) (Arranged to the downstream of circuit breaker (B)) Located in the distribution board inside the cab base.

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40 Troubleshooting

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

Switch power supply circuit breaker (B) (2) (60A) (B13-B14)

Switch power supply circuit breaker (B) (1) (60A) (B11-B12) Switch power supply circuit breaker (B) (2) (60A) (B13-B14) Fuse in the circuit diagram

Constant power supply circuit breaker (B) (3) (60A) (B17-B18)

*

12

Fuse No.

Fuse capacity

Destination of power

1

10A

2

10A

3

10A

4

10A

5

10A

6

10A

Bottom dump solenoid valve

7

10A

Rotary lamp

Emergency swing holding brake solenoid valve Machine push-up switch Boom damping solenoid valve PPC oil pressure lock solenoid valve Starter cut relay Cigarette lighter Horn Flash light

8

10A

Auxiliary lamp

9

10A

Radio

10

30A

Wiper Windshield washer

11

20A

Air conditioner unit (upper)

12

20A

Air conditioner unit (lower)

13

20A

12 V power supply

14

5A

Left bank engine controller (ACC) circuit

15

5A

Right bank engine controller (ACC) circuit

16

10A

Radio backup, room lamp

17

10A

Network bus power supply Engine controller

18

20A

Pump controller Room lamp (cab base)

19

20A

20

10A

Room lamp (cab) Emergency stop circuit Step light

The bracket ( ) under the breaker shows a breaker terminal number

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40 Troubleshooting

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Location of fuse Located in the distribution board inside the cab base.

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13

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PC2000-8 Hydraulic excavator Form No. SEN02011-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

14

SEN02012-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

40 Troubleshooting

1

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

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40 Troubleshooting

General information on troubleshooting

1

Points to remember when troubleshooting

1

k k k k k k

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.

2.

3.

4.

5.

6.

2

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

40 Troubleshooting

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Sequence of events in troubleshooting

1

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3

SEN02012-00

40 Troubleshooting

Checks before troubleshooting Item

Lubricating oil, Coolant

Criterion

Remedy

1. Check of level and type of fuel

—

Add fuel

2. Check of fuel for foreign matter

—

Clean and drain

3. Check of fuel filter

—

Replace

4. Check of hydraulic oil level

—

Add oil

5. Check of hydraulic oil strainer

—

Clean and drain

6. Check of swing machinery oil level

—

Add oil

7. Check of level and type of engine oil (in oil pan)

—

Add oil

8. Check of coolant level

—

Add coolant

9. Check of dust indicator for clogging

—

Clean or replace

—

Replace

1. Check of battery terminals and wiring for looseness and corrosion

—

Retighten or replace

2. Check of alternator terminals and wiring for looseness and corrosion

—

Retighten or replace

3. Check of starting motor terminals and wiring for looseness and corrosion

—

Retighten or replace

1. Check for abnormal noise and smell

—

Repair

2. Check of oil leakage

—

Repair

3. Bleeding air

—

Bleed air

20 – 30 V

Replace

2. Check of electrolyte level

—

Add or replace

3. Check of wires for discoloration, burn, and removal of cover

—

Replace

4. Check for released wire clamp and drooping wire

—

Repair

5. Check of wires for wetness (Check connectors and terminals for wetness, in particular)

—

Disconnect the connectors and dry

6. Check of fuse for disconnection and corrosion

—

Replace

10. Check of hydraulic oil filter

Electrical equipment

Hydraulic, Mechanical equipment

1. Check of battery voltage (with engine stopped)

Electric, electrical equipment

1

7. Check of alternator voltage (while engine speed is at After operating for several minutes: middle or higher)

Replace

27.5 – 29.5 V

8. Check of battery relay for operating sound (When starting switch is turned ON or OFF)

4

—

Replace

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40 Troubleshooting

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Classification and procedures of troubleshooting

1

Classification of troubleshooting code Troubleshooting code Code display

Contents Troubleshooting by [electrical system] or [mechanical system] failure code

E-mode

Troubleshooting of electrical system

H-mode

Troubleshooting of hydraulic and mechanical system

S-mode

Troubleshooting of engine

Troubleshooting procedures If a problem occurs on the machine, or if it is felt that there is a problem, carry out troubleshooting as follows. 1.

When machine monitor displays user code If a user code is displayed on the machine monitor at the same time as the problem occurs, check the content of the display, then go to the applicable troubleshooting chart for the failure code.

2.

When machine monitor does not display failure code, but failure history is recorded If a problem occurs but the user code display cannot be checked on the machine monitor, use the failure history display function in the machine monitor service mode to check for a failure code. If a failure code is recorded, there is a high probability that this is the cause, so go to the applicable troubleshooting chart.

3.

When a user code is not displayed and failure history is not recorded either If a problem occurs but the user code display cannot be checked on the machine monitor, and also the problem is not recorded by the failure history display function in the machine monitor service mode, the problem of the electrical, hydraulic or mechanical system that cannot be detected by a controller may have occurred. In this case, check the symptom of the trouble and go to the applicable troubleshooting chart.

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40 Troubleshooting

Failure-looking Phenomenon and Troubleshooting No. Troubleshooting No.

Failure-looking phenomenon

Code display

E-mode H-mode S-mode

Action to be taken concerning user code and failure code 1

Display user code in machine monitor

2

Display failure code in electrical system after checking failure history

3

Display failure code in mechanical system after checking failure history

4

Engine does not start up easily. (It always takes some time to start up the engine)

5

Engine does not rotate

According to displayed code

Engine-related failure

6 7

Engine does not start

S-1 E-3

S-2 1)

Engine rotates, but there is no exhaust gas

S-2 2)

There is exhaust gas, but engine does not start

S-2 3)

8

Engine pickup is poor. (Engine does not follow acceleration)

9

Engine stops while in operation

S-3 S-4

10 Engine rotation is irregular. (There is hunting)

S-5

11 Engine is short of output, or lacks power

S-6

12 Color of exhaust gas is too dark. (Incomplete combustion)

S-7

13 Excessive engine oil consumption, or color of exhaust gas is blue

S-8

14 Premature engine oil contamination

S-9

15 Excessive fuel consumption

S-10

16 Engine coolant is mixed with engine oil, spurts out or decreases

S-11

17 Engine oil amount increases. (Coolant or fuel gets in)

S-13

18 Abnormal noises are heard

S-15

19 Excessive vibrations are caused

S-16

20 Auto-decelerator does not work

E-4

21 Engine auto warming-up device does not work

E-5

22 Engine preheater does not work

E-6

Failure related to work equipment, swing and travel 23 Speed or power of all work equipment, travel, and swing is low 24 Engine speed lowers remarkably or engine stalls 25 All work equipment, travel, and swing systems do not work 26 Abnormal sound is heard from around pump

6

E-7

H-1

S-6

H-2

S-4

H-3 H-4

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40 Troubleshooting

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Troubleshooting No.

Failure-looking phenomenon

Code display

E mode H mode S mode

Work equipment-related failure 27 Speed or power of boom is low

H-5

28 Speed or power of arm is low

H-6

29 Speed or power of bucket is low

H-7

30 Boom does not move

H-8

31 Arm does not move

H-9

32 Bucket does not move

H-10

33 Hydraulic drift of work equipment is large

H-11

34 Time lag of work equipment is large

H-12

35 Machine push-up circuit does not work

E-8

36 Heavy lift function does not work or is not reset 37 Boom shockless function cannot be turned ON or OFF

H-14 H-13

E-9

H-15

Travel-related failure 38 Machine deviates in one direction

H-16

39 Machine deviates largely at start

H-17

40 Machine deviates largely during compound operation

H-18

41 Travel speed or power is low

H-19

42 Machine does not travel (only one track)

H-20 Swing-related failure

43 Machine does not swing

H-21

44 Swing speed or acceleration is low

H-22

45

Swing speed or power is low in compound operation of travel and bucket

H-23

46 Upper structure overruns largely

H-24

47 Large shocks are made when upper structure stops swinging

H-25

48

Large abnormal sounds are made when upper structure stops swinging

H-26

49 Hydraulic drift of swing is large

H-27

Fan rotation is abnormal (large noise or vibration of fans, or fan over50 heating)

H-28

Machine monitor-related failure (Operator's Menu: ordinary display) 51 When starting switch turned ON, machine monitor displays nothing

E-1

When starting switch turned ON (before starting engine), basic check 52 item lights up

E-2

53 Machine monitor does not display some items

E-10

54

Contents of display by machine monitor are different from applicable machine

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E-11

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40 Troubleshooting

Troubleshooting No.

Failure-looking phenomenon

Code display

E mode H mode S mode

55 While engine is running, fuel level monitor lamp lights up red

E-12

56 Hydraulic oil temperature gauge does not display correctly

E-13

57 Fuel gauge does not display correctly

E-14

58 Swing lock monitor does not display correctly

E-15

59 When operating monitor switch, no display appears

E-16

60 Windshield wiper does not work

E-17

Monitor panel-related failure (Service Menu: Special Function Display) 61 In monitoring function, “Travel” cannot be displayed correctly

E-18

Other failure 62 Travel alarm does not sound

E-19

63 Any of room lamp, head lamp, working lamp does not light up

E-20

64 Air conditioner does not work

E-21

65 Step light does not light up or light off

E-22

66

8

Radiator fan rotation is abnormal (Fan noise or vibration is excessively large or overheats)

H-28

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40 Troubleshooting

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Connection table for connector pin numbers

(Rev. 2006.11)

a

The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing.

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10

40 Troubleshooting

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11

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12

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13

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14

40 Troubleshooting

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15

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16

40 Troubleshooting

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17

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18

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19

SEN02012-00

20

40 Troubleshooting

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21

SEN02012-00

22

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23

SEN02012-00

24

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25

SEN02012-00

26

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27

SEN02012-00

28

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29

SEN02012-00

30

40 Troubleshooting

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31

SEN02012-00

32

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33

SEN02012-00

34

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35

SEN02012-00

36

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37

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38

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SEN02012-00

40

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40 Troubleshooting

T-adapter box and T-adapter table a

(Rev. 2006.11)

799-601-2600 T-box (for ECONO)

21

799-601-3100 T-box (for MS)

37

799-601-3200 T-box (for MS)

37

q

q

q q

Out of kit

799-601-4200

799-601-4100

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification symbol

799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

Number of pins

The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.

q

q

799-601-3380 • Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS)

24

MS-24P

q

799-601-3420 Adapter for BENDIX (MS)

24

MS-24P

q

799-601-3430 Adapter for BENDIX (MS)

17

MS-17P

q

799-601-3440 Adapter for BENDIX (MS)

17

MS-17P

q

799-601-3450 Adapter for BENDIX (MS)

5

MS-5P

q

799-601-3460 Adapter for BENDIX (MS)

10

MS-10P

q

799-601-3510 Adapter for BENDIX (MS)

5

MS-5S

q

799-601-3520 Adapter for BENDIX (MS)

17

MS-17P

q

799-601-3530 Adapter for BENDIX (MS)

19

MS-19P

q

799-601-2910 Adapter for BENDIX (MS)

14

MS-14P

q

799-601-2710 Adapter for MIC

5

MIC-5P

q q

799-601-2720 Adapter for MIC

13

MIC-13P

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

799-601-2760 Adapter for ECONO

3

ECONO3P

q q

799-601-2770 Adapter for ECONO

4

ECONO4P

q q

799-601-2780 Adapter for ECONO

8

ECONO8P

q q

799-601-2790 Adapter for ECONO

12 ECONO12P q q

q

799-601-3470 Case

799-601-2810 Adapter for DLI

8

DLI-8P

q q

799-601-2820 Adapter for DLI

12

DLI-12P

q q

799-601-2830 Adapter for DLI

16

DLI-16P

q q

799-601-2840 Extension cable (ECONO type)

12 ECONO12P q q

q

q

q

799-601-2850 Case 799-601-4210 Adapter for DRC

q

50

q

DRC50

799-601-7010 Adapter for X (T-adapter)

1

q

q

799-601-7020 Adapter for X

2

X2P

q q q

q

799-601-7030 Adapter for X

3

X3P

q q q

q q

799-601-7040 Adapter for X

4

X4P

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

799-601-7070 Adapter for SWP

14

SW14P

799-601-7320 Adapter for SWP

16

SW16P

q q

q q

799-601-7080 Adapter for M (T-adapter)

1

q

q

799-601-7090 Adapter for M

2

M2P

q q q

q

799-601-7110 Adapter for M

3

M3P

q q q

q

42

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40 Troubleshooting

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q q q

q q

Out of kit

S8P

799-601-4200

8

799-601-4100

799-601-7140 Adapter for S

799-601-9300

q

799-601-9200

q q q

M8P

799-601-9100

M6P

8

799-601-9000

6

799-601-7340 Adapter for M

799-601-8000

799-601-7130 Adapter for M

799-601-7500

q

799-601-7400

q q q

799-601-7100

M4P

799-601-7000

4

799-601-2800

799-601-7120 Adapter for M

Part name

799-601-2700

Identification symbol

Part No.

799-601-2500

Number of pins

T-adapter kit

q

799-601-7150 Adapter for S (White)

10

S10P

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

799-601-7330 Adapter for S (White)

16

S16PW

799-601-7350 Adapter for S (White)

12

S12PW

799-601-7180 Adapter for AMP040

8

A8P

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

q q q

q

q q

799-601-7240 Case

q

799-601-7270 Case 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

799-601-9010 Adapter for DTM

2

DTM2

q

q

799-601-9020 Adapter for DT

2

DT2

q

q

799-601-9030 Adapter for DT

3

DT3

q

q

799-601-9040 Adapter for DT

4

DT4

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

q

799-601-9090 Adapter for DT (Brown)

8

DT8BR

q

q

799-601-9110 Adapter for DT (Gray)

12

DT12GR

q

q

799-601-9120 Adapter for DT (Black)

12

DT12B

q

q

799-601-9130 Adapter for DT (Green)

12

DT12G

q

q

799-601-9140 Adapter for DT

12

DT12BR

q

q

799-601-9210 Adapter for HD30-18

8

D18-8

q q

799-601-9220 Adapter for HD30-18

14

D18-14

q q

799-601-9230 Adapter for HD30-18

20

D18-20

q q

799-601-9240 Adapter for HD30-18

21

D18-21

q q

799-601-9250 Adapter for HD30-24

9

D24-9

q q

799-601-9260 Adapter for HD30-24

16

D24-16

q q

799-601-9270 Adapter for HD30-24

21

D24-21

q q

799-601-9280 Adapter for HD30-24

23

D24-23

q q

799-601-9290 Adapter for HD30-24

31

D24-31

q q

799-601-9310 Plate for HD30 (24-pin)

PC2000-8

q q

q q q q

q

43

799-601-9320 T-box (for DT/HD)

q q

12

Out of kit

799-601-4200

799-601-4100

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification symbol

799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

40 Troubleshooting

Number of pins

SEN02012-00

q

q

799-601-9330 Case

q

799-601-9340 Case 799-601-9350 Adapter for DRC

40

DRC-40

q q

799-601-9360 Adapter for DRC

24

DRC-24

799-601-9410* Socket for engine (CRI-T2)

2

G

Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL

3

A3

q q

2

P

q q

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) Temperature sensor

2

C

q q

2

A

q q

799-601-9430*

795-799-5540*

Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV

Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM

q

795-799-5460 Cable for engine (HPI-T2)

3

q

795-799-5470 Cable for engine (HPI-T2)

3

q

795-799-5480 Cable for engine (HPI-T2)

3

q

799-601-4110 Adapter for engine (140-T3) PIM

4

ITT3N

799-601-4130 Adapter for engine (CRI-T3) NE, CAM

3

FCIN

q q

3

FCIG

q q

3

FCIB

q q

2

4160

q q

3

4180

q q

799-601-4140

Adapter for engine (CRI-T3) Atomosphere pressure

799-601-4150 Adapter for engine (CRI-T3) POIL 799-601-4160

Adapter for engine (CRI-T3) Oil pressure switch

799-601-4180 Adapter for engine (CRI-T3) PEVA

q

799-601-4190*

Socket for engine (CRI-T3) Commonrail pressure

3

1,2,3L

q q

799-601-4230*

Socket for engine (CRI-T3) Air intake pressure/temperature

4

1,2,3,4C

q q

799-601-4240* Socket for engine (CRI-T3) PAMB

3

1,2,3A

q q

799-601-4250* Socket for engine (CRI-T3) PIM

3

1,2,3B

q q

799-601-4330* Socket for engine (CRI-T3) G

3

1,2,3,G

q q

Socket for engine (CRI-T3) 799-601-4340* Pump actuator

2

2,PA

q q

4

1,2,3,4T

799-601-4380*

Socket for engine (CRI-T3)(95) Air intake pressure/temperature

q q q

799-601-4260 Adapter for controller (ENG)

4

DTP4

799-601-4211 Adapter for controller (ENG)

50

DRC50

q

DRC60

q

799-601-4220 Adapter for controller (ENG)

60

799-601-4390* Socket for controller (95 ENG)

60

q

799-601-4280 Box for controller (PUMP)

121

q

799-601-9720 Adapter for controller (HST)

16

HST16A

q

799-601-9710 Adapter for controller (HST)

16

HST16B

q

799-601-9370 Adapter for controller (HST)

26

HST26A

q

“*” Shows not T-adapter but socket.

44

PC2000-8

SEN02012-00

PC2000-8 Hydraulic excavator Form No. SEN02012-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

46

SEN02096-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

40 Troubleshooting

1

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

PC2000-8

1

SEN02096-00

40 Troubleshooting

Failure code [B@BCNS] Eng. Water Overheat.................................................................................. 22 Failure code [B@BCZK] Eng. Water Lvl Low ..................................................................................... 24 Failure code [B@CBNS] PTO Oil Overheat (or change of VHMS-LED display from n5 to 61).......... 26 Failure code [B@HANS] Hydr. Oil Overheat ...................................................................................... 28 Failure code [B@HAZK] Low Hydraulic Oil Level (or change of VHMS-LED display from n5 to 52) . 30 Failure code [CA111] ECM Critical Internal Failure ............................................................................ 32 Failure code [CB111] ECM Critical Internal Failure ............................................................................ 34 Failure code [CA115] Eng. Ne and Bkup Speed Sens Error .............................................................. 36 Failure code [CB115] Eng. Ne and Bkup Speed Sens Error .............................................................. 37 Failure code [CA122] Chg Air Press Sensor High Error..................................................................... 38 Failure code [CA123] Chg Air Press Sensor Low Error ..................................................................... 40 Failure code [CA131] Throttle Sensor High Error............................................................................... 42 Failure code [CA132] Throttle Sensor Low Error ............................................................................... 44 Failure code [CA135] Eng Oil Press Sensor High Error..................................................................... 46 Failure code [CA141] Eng Oil Press Sensor Low Error...................................................................... 48 Failure code [CA144] Coolant Temp Sens High Error........................................................................ 50 Failure code [CA145] Coolant Temp Sens Low Error......................................................................... 52 Failure code [CA153] Chg Air Temp Sensor High Error ..................................................................... 54 Failure code [CA154] Chg Air Temp Sensor Low Error...................................................................... 56 Failure code [CA187] Sens Supply 2 Volt Low Error.......................................................................... 58 Failure code [CB187] Sens Supply 2 Volt Low Error.......................................................................... 58 Failure code [CA212] Eng Oil Temp Sensor High Error ..................................................................... 60 Failure code [CA213] Eng Oil Temp Sensor Low Error ...................................................................... 62

2

PC2000-8

40 Troubleshooting

SEN02096-00

Troubleshooting by failure code, Part 1

1

Failure code [0410KA] Fuel LV. Sensor Failure

1

User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code 0410KA

Trouble

• No sensor current • None in particular. • While fuel is added, fuel level gauge does not rise from red range (E). • While fuel level is low, fuel level gauge does not lower from green range (F).

Cause Defective fuel level sensor (internal dis1 connection or short circuit)

Possible causes and standard value in normal state

Fuel LV. Sensor Failure (Machine monitor system)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P21A (male) Fuel level Resistance Between (1) and chassis ground

+1.0

FULL (Upper limit)

10 –3.0 z

EMPTY (Lower limit)

+10

85 0 z Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. harness (Disconnec2 tion or defective con- Wiring harness between CM01 (female) (9) – Resistance Max. 1 z tact in connector) P21A (female) (1) a Prepare with starting switch OFF, then turn starting switch ON and carry Hot short in wiring harout troubleshooting. 3 ness (Contact with 24 Wiring harness between CM01 (female) (9) – V circuit) Voltage Max. 1 V P21A (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CM01 (female) Fuel level Resistance Defective machine 4 +1.0 monitor FULL (Upper limit) 10 –3.0 z Between (9) and chassis ground +10 EMPTY (Lower limit) 85 0 z

Circuit diagram related to fuel level sensor

PC2000-8

3

SEN02096-00

40 Troubleshooting

Failure code [0410KB] Fuel LV. Sensor Failure User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code 0410KB

Trouble

Fuel LV. Sensor Failure (Machine monitor system)

• Sensor current flows. • None in particular. • Fuel level monitor lights up while engine is running

Cause Low fuel level (when 1 the system is normal) Defective fuel level sensor (internal dis2 connection or short circuit) Possible causes and standard value in normal state

1

Ground fault in wiring 3 harness (Contact with GND circuit)

4

Defective machine monitor

Standard value in normal state/Remarks on troubleshooting a Add fuel. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P21A (male) Fuel level Resistance Between (1) and chassis ground

+1.0

FULL (Upper limit)

10 –3.0 z

EMPTY (Lower limit)

+10

FULL (Upper limit)

10 –3.0 z

EMPTY (Lower limit)

85 0 z

85 0 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between harness CM01 (female) (9) – P21A Resistance Min. 1 Mz (female) (1) and the grounding a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CM01 (female) Fuel level Resistance Between (9) and chassis ground

+1.0 +10

Circuit diagram related to fuel level sensor

4

PC2000-8

40 Troubleshooting

SEN02096-00

Failure code [6014NX] Hydraulic Oil Filter Clogging (or change of VHMS-LED display from n5 to 51) User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

1

Failure code Hydraulic Oil Filter Clogging Trouble (VHMS controller system) 6014NX • While engine was running, signal circuit of hydraulic oil filter clogging sensor was opened (disconnected from GND). • None in particular. • None in particular. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n5 o 51 (codes are displayed by 2 digits) Cause Standard value in normal state/Remarks on troubleshooting Clogging of hydraulic 1 oil filter (when the sys- Check the hydraulic oil filter, and replace it if clogged. tem is normal) a Prepare with starting switch OFF, then carry out troubleshooting without Defective hydraulic oil turning starting switch ON. filter clogging switch P40 (male) Hydraulic oil filter Resistance 2 (Internal disconnecValue in normal state Max. 1 z tion or short circuit) Between (1) and (2) Value when clogged Min. 1 Mz Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. harness (Disconnec3 tion or defective con- Wiring harness between CV02B (female) (1) – Resistance Max. 1 z tact in connector) P40 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 4 harness (Contact with Between wiring harness of CV02B (female) (1) – GND circuit) Resistance Min. 1 Mz P40 (female) (1) and the grounding a Prepare with starting switch OFF, start engine and then carry out troubleshooting. Defective VHMS CV02B Hydraulic oil filter Voltage 5 controller Value in normal state Max. 1V Between (1) and chassis ground Value when clogged 20 – 30 V

Circuit diagram related to hydraulic oil clogging sensor

PC2000-8

5

SEN02096-00

40 Troubleshooting

Failure code [8800ZG] Auto grease abnormally User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

1

Failure code Auto grease abnormally Trouble (Pump controller 2 system) 8800ZG • Abnormality occurred to the grease pump pressure sensor circuit. • When the grease pressure fails to reach set standard level during automatic or forcible greasing. Default value: Max. 19.6 MPa {Max. 200 kg/cm3}/min. • None in particular (Provides the error display alone). • Grease level is low. • The automatic lubrication cannot work. • Input from the automatic greasing pressure sensor can be checked with monitoring function. (Monitoring code: 13900, automatic greasing pressure) Cause Grease level is low 1 (when the system is normal) Defective grease pump pressure sensor (inter2 nal disconnection or short circuit) 3

Defective pump controller 2

Standard value in normal state/Remarks on troubleshooting Check the grease level, and add it if low. If failure code [DHPSKX] is displayed, carry out the troubleshooting first as stated. if failure code [dA25KP] is displayed, carry out the troubleshooting first as stated. a Prepare with starting switch OFF (disconnect P48), then turn the switch ON and carry out troubleshooting. Between CP04 Voltage Max. 0.8 V (3) – (21)

Circuit diagram related to grease pump pressure sensor

6

PC2000-8

40 Troubleshooting

SEN02096-00

Failure code [7@HAZL] VR1/P1F Relief Press Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

1

Failure code VR1/P1F Relief Press Abnormality Trouble (pump controller 1 system) 7@HAZL • Signal circuit of VR1/P1F system pump pressure sensor detected 37.3 MPa or higher {380 kg/cm2} or higher). • None in particular (Provides the error display alone). • If machine is operated as it is, hydraulic components may be damaged. • Pump pressure of VR1/P1F system can be checked with the machine monitor. Monitoring code: 01124, P1F pump pressure PM clinic (7/12), (8/12) and (10/12) Cause Abnormal high-pressure of VR1/P1F sys1 tem pump pressure (when the system is normal) Defective VR1/P1F 2 system pump pressure sensor 3

Defective pump controller 1

Standard value in normal state/Remarks on troubleshooting

Check VR1/P1F system pump relief pressure. Correct, if any.

If failure code [OHPEKX] is displayed, carry out troubleshooting for it first. If failure code [DA25KP] is displayed, carry out the troubleshooting as stated. a Prepare with starting switch OFF, start engine and then carry out troubleshooting. CP01 Voltage Between (9) and (21) Max. 0.8 V

Circuit diagram related to VR1/P1F system pump pressure sensor

PC2000-8

7

SEN02096-00

40 Troubleshooting

Failure code [7@HBZL] VL1/P1R Relief Press Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code 7@HBZL

Trouble

1

VL1/P1R Relief Press Abnormality (Pump controller 1 system)

• Signal circuit of VL1/P1R system pump pressure sensor detected 37.3 MPa or higher {380 kg/cm2} or higher). • None in particular (Provides the error display alone). • If machine is operated as it is, hydraulic components may be damaged. • Pump pressure of VL1/P1R system can be checked with the machine monitor. Monitoring screen: monitoring code: 01125, P1R pump pressure PM clinic (7/12), (8/12) and (10/12) Cause Abnormal high-pressure of VL1/P1R sys1 tem pump pressure (when the system is normal) Defective VL1/P1R 2 system pump pressure sensor system

3

Defective pump controller 1

Standard value in normal state/Remarks on troubleshooting

Check VL1/P1R system pump relief pressure. Correct, if any.

If failure code [DHPFKX] is displayed, carry out the troubleshooting as stated. If failure code [DA25KP] is displayed, carry out the troubleshooting as stated. a Prepare with starting switch OFF, start engine and then carry out troubleshooting. CP01 Voltage Between (3) and (21) Max. 0.8 V

Circuit diagram related to VL1/P1R system pump pressure sensor

8

PC2000-8

40 Troubleshooting

SEN02096-00

Failure code [7@HCZL] VR2/P2F Relief Press Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code 7@HCZL

Trouble

1

VR2/P2F Relief Press Abnormality (Pump controller 1 system)

• Signal circuit of VR2/P2F system pump pressure sensor detected 37.3 MPa or higher ({380 kg/cm2} or higher). • None in particular (Provides the error display alone). • If machine is operated as it is, hydraulic components may be damaged. • Pump pressure of VR2/P2F system can be checked with the machine monitor. Monitoring screen: monitoring code: 01126, P2F pump pressure PM clinic (7/12), (9/12) and (11/12) Cause Standard value in normal state/Remarks on troubleshooting Abnormal high-pressure VR2/P2F system 1 Check VR2/P2F system pump relief pressure. Correct, if any. pump pressure (when the system is normal) If failure code [DHPGKX] is displayed, carry out the troubleshooting as Defective VR2/P2F stated. 2 system pump presIf failure code [DA25KP] is displayed, carry out the troubleshooting as sure sensor system stated. a Prepare with starting switch OFF, start engine and then carry out troubleshooting. Defective pump 3 CP01 Voltage controller 1 Between (20) and (21) Max. 0.8 V

Circuit diagram related to VR2/P2F system pump pressure sensor

PC2000-8

9

SEN02096-00

40 Troubleshooting

Failure code [7@HDZL] VL2/P2R Relief Press Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code 7@HDZL

VL2/P2R Relief Press Abnormality (Pump controller 1 system)

• Signal circuit of VL2/P2R system pump pressure sensor detected 37.3 MPa or higher {380 kg/cm2} or higher). • None in particular (Provides the error display alone). • If machine is operated as it is, hydraulic components may be damaged. • Pump pressure of VL2/P2R system can be checked with the machine monitor. Monitoring screen: monitoring code: 01127, P2R pump pressure PM clinic (7/12), (9/12) and (11/12) Cause Abnormal high-pressure of VL2/P2R sys1 tem pump pressure (when the system is normal) Defective VL2/P2R 2 system pump pressure sensor

3

10

Trouble

1

Defective pump controller 1

Standard value in normal state/Remarks on troubleshooting

Check VL2/P2R system pump relief pressure. Correct, if any.

If failure code [DHPHKX] is displayed, carry out the troubleshooting as stated. If failure code [DA25KP] is displayed, carry out the troubleshooting as stated. a Prepare with starting switch OFF, start engine and then carry out troubleshooting. CP01 Voltage Between (14) and (21) Max. 0.8 V

PC2000-8

40 Troubleshooting

SEN02096-00

Circuit diagram related to VL2/P2R system pump pressure sensor

PC2000-8

11

SEN02096-00

40 Troubleshooting

Failure code [AA10NX] Aircleaner Clogging User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

12

1

Failure code Aircleaner Clogging Trouble (Machine monitor system) AA10NX • While engine was running, signal circuit of air cleaner clogging sensor was opened (disconnected from GND). • None in particular. • If machine is operated as it is, engine may be damaged. • If an air cleaner clogging monitor on the machine monitor lights up in red while the engine is running, this failure code will be recorded. • Input from the air cleaner clogging switch (ON/OFF) can be checked with monitoring function. (Code: 04501, Monitor Input 2) Cause Standard value in normal state/Remarks on troubleshooting Clogging of air cleaner 1 (when the system is Check the air cleaner for clogging and then clean or replace it if clogged. normal) a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective air cleaner P23A (male) and Air cleaner Resistance 2 clogging sensor (interP23B (male) nal disconnection) Value in normal state Max. 1 z Between (1) and (2) Value when clogged Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CM02 (female) (4) – Resistance Max. 1 z Disconnection in wiring P23A (female) (1) harness (DisconnecWiring harness between CM02 (female) (4) – 3 Resistance Max. 1 z tion or defective con- P23B (female) (1) tact in connector) Wiring harness between P23A (female) (2) – JE6 Resistance Max. 1 z and chassis ground Wiring harness between P23B (female) (2) – JE6 Resistance Max. 1 z and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective machine CM02 Air cleaner Voltage 4 monitor Max. 1 V Between (4) and chas- Value in normal state sis ground Value when clogged 20 – 30 V

PC2000-8

40 Troubleshooting

SEN02096-00

Circuit diagram related to aircleaner clogging sensor

PC2000-8

13

SEN02096-00

40 Troubleshooting

Failure code [AB00KE] Charge Voltage Low User code

Failure code

—

AB00KE

Contents of trouble Action of controller Problem that appears on machine Related information

1

Trouble Charge Voltage Low (Mechanical system)

• Signal voltage from alternator is below 20 V while the engine is running. • None in particular. • If machine is operated as it is, battery may not be charged. • If a charge level monitor on the machine monitor lights up in red while the engine is running, this failure code will be recorded. • Input from alternator (voltage, ON or OFF) can be checked with monitoring function. (Code 04300: Charge voltage, 04501: Monitor input 2) Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.

1

Defective alternator (Low power generation)

Alternator

Engine

Voltage

Between R terminal – chassis ground

Above low idle

27.5 – 29.5 V

If the voltage is abnormal, check the belt tension too.

Possible causes and standard value in normal state

Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without harness turning starting switch ON. 2 (Disconnection in wiring or defective contact in Wiring harness between CM01 (female) (11) – Resistance Max. 1 z JB113 – Alternator R terminal connector)

Ground fault in wiring harness 3 (Short circuit with GND circuit)

4

14

Defective machine monitor

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between CM01 (female) (11), JB113, and alternator terminal R, or between P02 (female) (11), or between P02 Resistance Min. 1 Mz (female) (11), battery relay terminal BR and grounding a Prepare with starting switch OFF, then start engine and carry out troubleshooting. CM01

Engine

Voltage

Between (11) – chassis ground

Above low idle

27.5 – 29.5 V

PC2000-8

40 Troubleshooting

SEN02096-00

Circuit diagram related to engine preheating, starting and charging circuits

PC2000-8

15

SEN02096-00

40 Troubleshooting

Failure code [aB00KE] Low Upper ALR Charge Voltage (or change of VHMS-LED display from n9 to 11) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code aB00KE

Trouble

Low Upper ALR Charge Voltage (VHMS controller system)

• While engine is running, power generation signal from the upper alternator is not input. • None in particular. • If machine is operated as it is, battery may not be charged. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n9 o 11 (codes are displayed by 2 digits) Cause

Possible causes and standard value in normal state

16

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, start engine and then carry out troubleshooting. Defective alternator 1 Alternator Engine speed Voltage (low power generation) Between terminal R – Medium or higher 27.5 – 29.5 V chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without 2 Disconnection in wiring turning starting switch ON. harness (Disconnection or defective con- Wiring harness between CV02A (female) (4) and Resistance Max. 1 z tact in connector) Alternator R terminal a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 3 harness (Contact with Between CV02A (female) (4) and Alternator R GND circuit) Resistance Max. 1 Mz terminal a Prepare with starting switch OFF, start engine and then carry out troubleshooting. Defective VHMS CV02A Engine speed Voltage 4 controller Between (4) and chasMedium or higher 27.5 – 29.5 V sis ground

PC2000-8

40 Troubleshooting

SEN02096-00

Circuit diagram related to engine preheating, starting and charging circuits

PC2000-8

17

SEN02096-00

40 Troubleshooting

Failure code [B@BAZG] Eng. Oil Press. Low User code

Failure code

—

B@BAZG

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

Eng. Oil Press. Low (Engine controller system)

• While engine was running, signal circuit of engine oil pressure switch detected low engine oil pressure (opening of sensor contact). • Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation. If machine is operated as it is, engine may be damaged. • Input (Voltage) from oil pressure sensor can be checked with monitoring function (Code: 37200). • Signals of engine oil pressure switch are input to engine controller and then transmitted to machine monitor through communication system. • Method of reproducing failure code: Start engine. Cause 1

Defective sensor power supply system

Standard value in normal state/Remarks on troubleshooting If code [CA187] or [CA227] is indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.

Defective oil pressure 2 sensor (Internal trouble)

POIL Between (1) – (2)

Voltage Power supply

4.75 – 5.25 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Disconnection in wiring harness (Disconnec3 tion in wiring or defective contact in connector)

Ground fault in wiring 4 harness (Short circuit with GND circuit)

5

Defective engine controller

Wiring harness between ENG (L) (female) (37) – POIL (female) (1)

Resistance

Max. 1 z

Wiring harness between ENG (L) (female) (47) – POIL (female) (2)

Resistance

Max. 1 z

Wiring harness between ENG (L) (female) (13) – POIL (female) (3)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (L) (female) (37) – POIL (female) (1) and chassis ground

Resistance Min. 1 Mz

Wiring harness between ENG (L) (female) (13) – POIL (female) (3) and chassis ground

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG (L) Between (37) – (47)

18

Voltage Power supply

4.75 – 5.25 V

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Circuit diagram related to engine oil pressure sensor

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Failure code [B@BAZK] Eng. Oil Level Low User code

Failure code

—

B@BAZK

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

Eng. Oil Level Low (Machine monitor system)

• The signal circuit of the engine oil level sensor is opened (disconnected from grounding) while the engine is stopped. • None in particular. • If machine is operated as it is, engine may be damaged. • If the engine oil level monitor on the machine monitor lights up in red while the engine is running, this failure code is recorded. • Input from the engine oil level sensor (ON or OFF) can be checked in the monitoring function. (Code No. 04501: Monitor input 2) Cause

Standard value in normal state/Remarks on troubleshooting

Lowering of engine oil level a Check the engine oil level and add new oil. 1 (when system is nor(If this phenomenon frequently occurs, investigate the cause.) mal)

Possible causes and standard value in normal state

Defective engine oil level sensor 2 (Internal disconnection)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. OLLV (male) Between (1) – (2)

Engine oil level

Resistance

Normal level

Max. 1 z

Below normal level

Min. 1 Mz

Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without harness turning starting switch ON. 3 (Disconnection in wiring or defective contact in Wiring harness between CM02 (female) (2) – Resistance Max. 1 z OLLV (female) (1) connector) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4

20

Defective machine monitor

CM02

Engine oil level

Voltage

Between (2) – chassis ground

Normal level

Max. 1 V

Below normal level

20 – 30 V

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Circuit diagram related to engine oil level sensor

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Failure code [B@BCNS] Eng. Water Overheat User code

Failure code

—

B@BCNS

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

Eng. Water Overheat (Engine controller system)

• The signal circuit of the engine coolant temperature sensor detected temperature above 105°C • Fixes coolant temperature (90°C) and continues operation. • If machine is operated as it is, engine may be damaged. • Input from the engine coolant temperature sensor (temperature) can be checked with monitoring function (Code: 04107) • Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine monitor. Cause

Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective coolant tem1 perature sensor (InterCoolant TWTR (male) Resistance nal trouble) temperature Between (A) – (B)

Possible causes and standard value in normal state

10 – 100°C

0.6 – 20 kz

a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (DisconnecWiring harness between ENG (L) (female) (15) – 2 tion in wiring or defecResistance Max. 1 z TWTR (female) (A) tive contact in Wiring harness between ENG (L) (female) (38) – connector) Resistance Max. 1 z TWTR (female) (B) Ground fault in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. harness 3 (Short circuit with GND Between wiring harness of ENG (L) (female) (15) Resistance Min. 1 Mz circuit) – TWTR (female) (A) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4

22

Defective engine controller

ENG (L) (female)

Engine coolant temperature

Resistance

Between (15) – (38) chassis ground

10 – 100°C

0.6 – 20 kz

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Circuit diagram related to coolant temperature sensor

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Failure code [B@BCZK] Eng. Water Lvl Low User code

Failure code

—

B@BCZK

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

Eng. Water Lvl Low (Machine monitor system)

• While engine was running, signal circuit of radiator coolant level sensor was opened (disconnected with GND). • None in particular. • If machine is operated as it is, engine may overheat. • If the radiator coolant level monitor on the machine monitor lights up in red while the engine is stopped (the starting switch is at the ON position), this failure code is recorded. • Input from the radiator coolant level sensor (ON/OFF) can be checked with monitoring function. (Code 04500: Monitor Input 1) Cause

Standard value in normal state/Remarks on troubleshooting

Sub-tank coolant level Check the radiator sub-tank coolant level. If it is low, add coolant. 1 low (While system is (If it is reduced frequently, find out the cause.) normal) Defective radiator coolant level sensor 1 2 (Internal disconnection) Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P24A (male) Between (1) – (2)

Sub-tank coolant level

Resistance

Within normal level

Max. 1 z

Below LOW level

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness Wiring harness between CM02 (female) (3) – Resistance Max. 1 z 3 (Disconnection in wiring P24 (female) (1) or defective contact in Wiring harness between P24 (female) (2) – chasconnector) Resistance Max. 1 z sis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4

24

Defective machine monitor

CM02

Sub-tank coolant level

Voltage

Between (3) – chassis ground

Within normal level

Max. 1 V

Below LOW level

20 – 30 V

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Circuit diagram related to radiator coolant level switch

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Failure code [B@CBNS] PTO Oil Overheat (or change of VHMS-LED display from n5 to 61) User code — Contents of trouble Action of controller Problem that appears on machine Related information

1

Failure code PTO Oil Overheat Trouble (VHMS controller system) B@CBNS • Signal circuit of PTO oil temperature sensor detected 125°C or higher. • Action of controller • None in particular. • If machine is operated as it is, PTO may be damaged. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n5 o 61 (codes are displayed by 2 digits) • PTO oil temperature can be checked by downloading data to PC after the snapshot. Cause PTO oil temperature 1 overheat (when the system is normal)

Standard value in normal state/Remarks on troubleshooting Check PTO lubricating system. Correct, if any.

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P19 (male) Oil temperature Resistance 25°C 46 – 59 kz Between (1) and (2) 100°C 3.6 – 4.0 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between CV02A (female) (2) – harness (DisconnecResistance Max. 1 z 3 tion or defective con- P19 (female) (1) tact in connector) Between wiring harness of CV02A (female) (12) Resistance Min. 1 Mz – P19 (female) (2) and the grounding a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 4 harness (Contact with Between wiring harness of CV02A (female) (2) – GND circuit) Resistance Min. 1 Mz P19 (female) (1) and the grounding a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CV02A Oil temperature Resistance Defective VHMS 25°C 46 – 59 kz 5 controller Between (2) and (12) 100°C 3.6 – 4.0 kz Between (2) and chas— Min. 1 Mz sis ground

Defective PTO oil temperature sensor (inter2 nal disconnection or short circuit)

Possible causes and standard value in normal state

26

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Circuit diagram related to PTO oil temperature sensor

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Failure code [B@HANS] Hydr. Oil Overheat User code

Failure code

—

B@HANS

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

Hydr. Oil Overheat (Pump controller 2 system)

• While engine was running, signal of hydraulic oil temperature sensor input 102°C or higher. • None in particular. • If machine is operated as it is, hydraulic components may be seized. • If hydraulic oil temperature monitor on the machine monitor lights up in red while the engine is running, this failure code will be recorded. • Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring function. (Code 04401: Hydraulic oil temperature, 04403: Hydraulic oil temperature sensor voltage) Cause 1

Hydr. Oil Overheat (when system is normal)

Standard value in normal state/Remarks on troubleshooting Check the hydraulic oil for overheating. If it has been overheated, find out the cause and check the hydraulic equipment for damage, then repair. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective hydraulic oil 2 temperature sensor (Internal short circuit)

P22 (male)

Hydraulic oil temperature

Between (1) – (2) Between (2) – chassis ground

Resistance 90 – 3.5 kz

10 – 100°C

Min. 1 Mz

Ground fault in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. harness 3 (Short circuit with GND Wiring harness between CP04 (female) (9) – Resistance Min. 1 Mz circuit) P22 (female) (1) and chassis ground Defective pump 4 controller 2

28

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between CP04 (4) – (9)

Voltage

Min. 4.5 V

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Circuit diagram related to hydraulic oil temperature sensor

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Failure code [B@HAZK] Low Hydraulic Oil Level (or change of VHMSLED display from n5 to 52) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code B@HAZK

Trouble

• Hydraulic oil level sensor detected the low level. • None in particular. • If machine is operated as it is, hydraulic components may be damaged. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n5 o 52 (codes are displayed by 2 digits) Cause Hydraulic oil low level 1 (when the system is normal)

2

Possible causes and standard value in normal state

3

4

5

30

Low Hydraulic Oil Level (VHMS controller system)

Standard value in normal state/Remarks on troubleshooting Check the level of hydraulic oil tank. If low level, add hydraulic oil.

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective hydraulic oil P39 (male) Oil level Resistance level sensor (internal disconnection or short Value in normal state Max. 1 z circuit) Between (1) and (2) Value when oil level is Min. 1 Mz low Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. harness (Disconnection or defective con- Between wiring harness CV02B (female) (2) – Resistance Max. 1 z tact in connector) P39 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. harness (Contact with Between wiring harness CV02B (female) (2) – GND circuit) Resistance Min. 1 Mz P39 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P39 (male) Oil level Resistance Defective VHMS controller Value in normal state Max. 1 z Between (1) and (2) Value when oil level is Min. 1 Mz low

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Circuit diagram related to hydraulic oil level sensor

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Failure code [CA111] ECM Critical Internal Failure User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA111

Trouble

• Blinks warning lamp and sounds alarm buzzer. • Machine continues operation normally but may stop suddenly or may not able to start again once it stops.

Disconnection in wiring harness (Discon2 nection in wiring or defective contact in connector) Ground fault in wiring 3 harness (Contact with GND circuit)

4

32

ECM Critical Internal Failure (Engine controller system)

• Controller has abnormality in it.

Cause Defective circuit 1 breaker

Possible causes and standard value in normal state

1

Defective engine controller

Standard value in normal state/Remarks on troubleshooting Circuit breaker may be defective. Check it directly. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE03 (female) (3) – Resistance Max. 1 z battery (+) Wiring harness between CE03 (female) (1) – Resistance Max. 1 z ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE03 (female) (3) – Resistance Min. 1 Mz battery (+) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CE03 Voltage Between (3) – (1) 20 – 30 V

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Circuit diagram related to engine controller power supply

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Failure code [CB111] ECM Critical Internal Failure User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB111

Trouble

• Blinks warning lamp and sounds alarm buzzer. • Machine continues operation normally but may stop suddenly or may not able to start again once it stops.

Disconnection in wiring harness (Discon2 nection in wiring or defective contact in connector) Ground fault in wiring 3 harness (Contact with GND circuit)

4

34

ECM Critical Internal Failure (Engine controller system)

• Controller has abnormality in it.

Cause Defective circuit 1 breaker

Possible causes and standard value in normal state

1

Defective engine controller

Standard value in normal state/Remarks on troubleshooting Circuit breaker may be defective. Check it directly. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE06 (female) (3) – batResistance Max. 1 z tery (+) Wiring harness between CE06 (female) (1) – Resistance Max. 1 z ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE06 (female) (3) – Resistance Min. 1 Mz battery (+) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CE06 Voltage Between (3) – (1) 20 – 30 V

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Circuit diagram related to engine controller power supply

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Failure code [CA115] Eng. Ne and Bkup Speed Sens Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code Eng. Ne and Bkup Speed Sens Error Trouble (Engine controller system) CA115 • Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor circuit. • Flashes warning lamp and turns on alarm buzzer. • Engine does not start (during engine stop). • Engine stops (during engine running).

Cause Defective Ne speed 1 sensor circuit Defective Bkup speed 2 sensor circuit Defective Ne speed 3 sensor mounting section 4

Bkup speed sensor mounting section

Defective connection 5 of sensor (wrong connection) Defective engine 6 controller

36

1

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting of [CA689]. Carry out troubleshooting of [CA778]. Since a mounting section of Ne speed sensor can be suspected to be defective, directly check the mounting section. (Defective installation of sensor itself, internal defect of flywheel, etc.) Since a mounting section of Bkup speed sensor can be suspected to be defective, directly check the mounting section. (Defective installation of sensor itself, internal defect of supply pump, etc.) The defective (wrong) connections of Ne speed sensor and Bkup speed sensor can be suspected. Directly check them. Engine controller can be suspected to be defective if no problem is found in causes 1 – 5 (since this is an internal defect, it cannot be diagnosed).

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Failure code [CB115] Eng. Ne and Bkup Speed Sens Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code Eng. Ne and Bkup Speed Sens Error Trouble (Engine controller system) CB115 • Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor circuit. • Flashes warning lamp and turns on alarm buzzer. • Engine does not start (during engine stop). • Engine stops (during engine running).

Cause Defective Ne speed 1 sensor circuit Defective Bkup speed 2 sensor circuit Defective Ne speed 3 sensor mounting section 4

Bkup speed sensor mounting section

Defective connection 5 of sensor (wrong connection) Defective engine 6 controller

PC2000-8

1

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting of [CB689]. Carry out troubleshooting of [CB778]. Since a mounting section of Ne speed sensor can be suspected to be defective, directly check the mounting section. (Defective installation of sensor itself, internal defect of flywheel, etc.) Since a mounting section of Bkup speed sensor can be suspected to be defective, directly check the mounting section. (Defective installation of sensor itself, internal defect of supply pump, etc.) The defective (wrong) connections of Ne speed sensor and Bkup speed sensor can be suspected. Directly check them. Engine controller can be suspected to be defective if no problem is found in causes 1 – 5 (since this is an internal defect, it cannot be diagnosed).

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Failure code [CA122] Chg Air Press Sensor High Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA122

Trouble

1

Chg Air Press Sensor High Error (Engine controller system)

• Excessively high voltage is detected at circuit of charge pressure (boost pressure) sensor. • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}). • Flashes warning lamp and turns on alarm buzzer. • Acceleration performance of engine deteriorates. • The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring function. (Code: 36501 Boost pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause Defective sensor 1 power source circuit

Possible causes and standard value in normal state

38

Standard value in normal state/Remarks on troubleshooting If failure code [CA227] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. PIM Voltage Defective charge presBetween (1) – (3) Power source 4.75 – 5.25 V 2 sure (boost pressure) sensor (internal defect) Since the sensor voltage is measured with the harness being connected, if the voltage is abnormal, first check the harness and the controller to make it sure if there is no other cause of the trouble, and then judge the sensor voltage. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wirWiring harness between ENG (L) (female) (37) – Resistance Max. 1 z ing harness PIM (female) (1) 3 (disconnection or Wiring harness between ENG (L) (female) (44) – defective contact of Resistance Max. 1 z PIM (female) (2) connectors) Wiring harness between ENG (L) (female) (47) – Resistance Max. 1 z PIM (female) (3) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between Defective harness Resistance Min. 1 Mz ENG (L) (female) (37) – PIM (female) (1) grounding 4 (contact with ground Between ground and wiring harness between Resistance Min. 1 Mz circuit) ENG (L) (female) (44) – PIM (female) (2) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (47) – PIM (female) (3) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (L) (female) (37) to PIM (female) (1) and wiring harness from Resistance Min. 1 Mz ENG (L) (female) (44) to PIM (female) (2) Harness short 5 (Harness internal Between wiring harness from ENG (L) (female) short) (37) to PIM (female) (1) and wiring harness from Resistance Min. 1 Mz ENG (L) (female) (47) to PIM (female) (3) Between wiring harness from ENG (L) (female) (44) to PIM (female) (3) and wiring harness from Resistance Min. 1 Mz ENG (L) (female) (47) to PIM (female) (3) a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. Defective engine 6 controller ENG (L) Voltage Between (37) – (47) Power source 4.75 – 5.25 V

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Circuit diagram related to charge pressure sensor

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Failure code [CA123] Chg Air Press Sensor Low Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

40

Failure code CA123

Trouble

1

Chg Air Press Sensor Low Error (Engine controller system)

• Excessively low voltage is detected at circuit of charge pressure (boost pressure) sensor. • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}). • Flashes warning lamp and turns on alarm buzzer. • Acceleration performance of engine deteriorates. • The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring function. (Code: 36501 Boost pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause 1

Defective sensor power source circuit

Standard value in normal state/Remarks on troubleshooting If failure code [CA187] is displayed at the same time, carry out troubleshooting for it first.

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Failure code [CA131] Throttle Sensor High Error User code E14 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA131

Trouble

• If abnormality occurs while starting switch is ON, controller fixes sensor to value just before occurrence of abnormality and continues operation. • If starting switch is turned ON while there is abnormality, controller fixes sensor to 100% value and continues operation. • Blinks warning lamp and sounds alarm buzzer. • Engine speed cannot be controlled with fuel dial. • Fuel dial signal voltage can be checked with monitoring function (Code: 03000 Fuel dial voltage) • Method of reproducing failure code: Turn starting switch ON.

2

Defective fuel dial (Internal defect)

Disconnection in wiring harness (Discon3 nection in wiring or defective contact in connector)

Ground fault in wiring 4 harness (Contact with GND circuit)

5

42

Throttle Sensor High Error (Engine controller system)

• High voltage was detected in throttle sensor signal circuit.

Cause Defective decelerator 1 sensor power supply system

Possible causes and standard value in normal state

1

Defective engine controller

Standard value in normal state/Remarks on troubleshooting If failure code [CA2185] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. DEC (male) Resistance Between (1) – (3) 4.0 – 6.0 kz Between (2) – (1) 0.25 – 5.0 kz Between (2) – (3) 0.25 – 5.0 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (22) – Resistance Max. 1z P20 (female) (1) Wiring harness between CE02 (female) (9) – Resistance Max. 1z P20 (female) (2) Wiring harness between CE02 (female) (23) – Resistance Max. 1z P20 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (22) – Resistance Min. 1 Mz P20 (female) (1) Wiring harness between CE02 (female) (9) – Resistance Min. 1 Mz P20 (female) (2) Wiring harness between CE02 (female) (23) – Resistance Min. 1 Mz P20 (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CE02 Voltage Between (22) – (23) Power supply 4.75 – 5.25 V Between (9) – (23) Signal 0.5 – 4.5 V

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Circuit diagram related to decelerator pedal sensor

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Failure code [CA132] Throttle Sensor Low Error User code E14 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

44

Failure code CA132

Trouble

1

Throttle Sensor Low Error (Engine controller system)

• Excessively low voltage is detected at signal circuit of throttle sensor. • Operates with the fixed value that is same as the value just before the abnormality is detected, if abnormality occurs with the starting switch in the ON position. • If the starting switch is turned to the ON position in as-is abnormal condition, the controller operates with 100% value. • Flashes warning lamp and turns on alarm buzzer. • Engine speed cannot be controlled by fuel dial. • The signal voltage of fuel dial can be checked in monitoring mode. (Code: 03000 Fuel dial) • Duplication of failure code: turn ON the starting switch. Cause 1

Defective sensor power supply circuit

Standard value in normal state/Remarks on troubleshooting If failure code [CA2186] is displayed at the same time, carry out troubleshooting for it first.

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Failure code [CA135] Eng Oil Press Sensor High Error User code CALL E02 Contents of trouble Action of controller

Failure code CA135

Trouble

1

Eng Oil Press Sensor High Error (Engine controller system)

• Excessively high voltage is detected at oil pressure sensor circuit. • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2}) • Flashes warning lamp and turns on alarm buzzer.

Problem that appears on machine Related information

• The signal voltage of engine oil pressure sensor can be checked in monitoring function. (Code: 37201 Engine oil pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause Defective sensor 1 power source circuit

Defective oil pressure 2 sensor (internal defect)

Disconnection in wiring harness 3 (disconnection or defective contact of connectors) Possible causes and standard value in normal state

Defective harness grounding 4 (contact with ground circuit)

Harness short 5 (Harness internal short)

6

46

Defective engine controller

Standard value in normal state/Remarks on troubleshooting If failure code [CA187] or [CA227] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. POIL Voltage Between (1) – (2) Power source 4.75 – 5.25 V Since the sensor voltage is measured with the harness being connected, if the voltage is abnormal, first check the harness and the controller to make it sure if there is no other cause of the trouble, and then judge the sensor voltage. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (L) (female) (37) – Resistance Max. 1 z POIL (female) (1) Wiring harness between ENG (L) (female) (47) – Resistance Max. 1 z POIL (female) (3) Wiring harness between ENG (L) (female) (13) – Resistance Max. 1 z POIL (female) (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (37) – POIL (female) (1) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (47) – POIL (female) (3) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (13) – POIL (female) (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (L) (female) (37) to POIL (female) (1) and wiring harness from Resistance Min. 1 Mz ENG (L) (female) (47) to POIL (female) (3) Between wiring harness from ENG (L) (female) (37) to POIL (female) (1) and wiring harness from Resistance Min. 1 Mz ENG (L) (female) (13) to POIL (female) (2) Between wiring harness from ENG (L) (female) (47) to POIL (female) (2) and wiring harness from Resistance Min. 1 Mz ENG (L) (female) (13) to POIL (female) (3) a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. ENG (L) Voltage Between (37) – (47) Power source 4.75 – 5.25 V

PC2000-8

40 Troubleshooting

SEN02096-00

Circuit diagram related to oil pressure sensor

PC2000-8

47

SEN02096-00

40 Troubleshooting

Failure code [CA141] Eng Oil Press Sensor Low Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

48

Failure code CA132

Trouble

1

Eng Oil Press Sensor Low Error (Engine controller system)

• Excessively low voltage is detected at oil pressure sensor circuit. • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2}) • Flashes warning lamp and turns on alarm buzzer.

• The signal voltage of engine oil pressure sensor can be checked in monitoring function. (Code: 37201 Engine oil pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause 1

Defective sensor power source circuit

Standard value in normal state/Remarks on troubleshooting If failure code [CA187] is displayed at the same time, carry out troubleshooting for it first.

PC2000-8

SEN02096-00

40 Troubleshooting

Failure code [CA144] Coolant Temp Sens High Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA144

Trouble

1

Coolant Temp Sens High Error (Engine controller system)

• Excessively high voltage is detected at signal circuit of coolant temperature sensor. • Operates with a fixed coolant temperature (90°C). • Flashes warning lamp and turns on alarm buzzer. • Exhaust gas color becomes white. • The signal voltage of coolant temperature sensor can be checked in monitoring function. (Code: 04105 Coolant temperature sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause

Possible causes and standard value in normal state

50

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still Defective coolant OFF. 1 temperature sensor TWTR (male) Coolant temperature Resistance (Internal defect) Between (A) – (B) 10 – 100°C 0.6 – 20 kz a Prepare with starting switch OFF and diagnose with starting switch still Disconnection in wiring OFF. harness Wiring harness between ENG (L) (female) (15) – 2 (disconnection or Resistance Max. 1 z TWTR (female) (A) defective contact of Wiring harness among ENG (L) (female) (38) – connectors) Resistance Max. 1 z JB – TWTR (female) (B) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 3 (Harness internal Between ENG (L) (female) (15) – all pins of ENG short) (L) (female) (with all connectors in the harness Resistance Min. 1 Mz disconnected) Since the connections among coolant temperature sensor – engine harness – engine controller are suspected to be defective, check for a defective connection. Defective wiring har• Connector is loose, lock is broken, seal is broken 4 ness connector • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still Defect in other locaOFF. 5 tions than engine conENG (L) (female) Coolant temperature Resistance troller Between (15) – (38) 10 – 100°C 0.6 – 20 kz Defective engine Engine controller is possibly defective if no problem is found in causes 1 – 6 controller 5. (Since this is an internal defect, it cannot be diagnosed.)

PC2000-8

40 Troubleshooting

SEN02096-00

Circuit diagram related to coolant temperature sensor

PC2000-8

51

SEN02096-00

40 Troubleshooting

Failure code [CA145] Coolant Temp Sens Low Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA145

Trouble

1

Coolant Temp Sens Low Error (Engine controller system)

• Excessively low voltage is detected at signal circuit of coolant temperature sensor. • Operates with a fixed coolant temperature (90°C). • Flashes warning lamp and turns on alarm buzzer. • Exhaust gas color becomes white. • The signal voltage of coolant temperature sensor can be checked in monitoring function. (Code: 04105 Coolant temperature sensor voltage) Cause

Possible causes and standard value in normal state

52

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still Defective coolant OFF. 1 temperature sensor TWTR (male) Coolant temperature Resistance (Internal defect) Between (A) – (B) 10 – 100°C 0.6 – 20 kz a Prepare with starting switch OFF and diagnose with starting switch still Defective harness OFF. 2 grounding (contact with Between ground and wiring harness between ground circuit) Resistance Min. 1 Mz ENG (L) (female) (15) – TWTR (female) (A) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 3 (Harness internal Between ENG (L) (female) (15) – all pins of ENG short) (L) (female) (with all connectors in the harness Resistance Min. 1 Mz disconnected) Since the connections among coolant temperature sensor – engine harness – engine controller are suspected to be defective, check for a defective connection. Defective wiring har4 • Connector is loose, lock is broken, seal is broken ness connector • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still Defect in other locaOFF. 5 tions than engine conENG (L) (female) Coolant temperature Resistance troller Between (15) – (38) 10 – 100°C 0.6 – 20 kz Defective engine Engine controller is possibly defective if no problem is found in causes 1 – 6 controller 5. (Since this is an internal defect, it cannot be diagnosed.)

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40 Troubleshooting

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Circuit diagram related to coolant temperature sensor

PC2000-8

53

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40 Troubleshooting

Failure code [CA153] Chg Air Temp Sensor High Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code Chg Air Temp Sensor High Error Trouble (Engine controller system) CA153 • Excessively high voltage is detected at signal circuit of charge temperature (boost temperature) sensor. • Operates with a fixed charge temperature (boost temperature) (70°C). • Exhaust gas color becomes white. • The signal voltage of the charge temperature (boost temperature) sensor can be checked with the monitoring function. (Code: 18501 Boost temperature sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause Defective charge temperature (boost tem1 perature) sensor (internal defect)

Disconnection in wiring harness (discon2 nection or defective contact of connectors)

Possible causes and standard value in normal state

Harness short 3 (Harness internal short)

4

Defective wiring harness connector

Defect in other loca5 tions than engine controller 6

54

1

Defective engine controller

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. TIM (male) Air boost temperature Resistance Between (A) – (B) 10 – 100°C 0.5 – 20 kz Between (A) – ground In all range Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (L) (female) (23) – Resistance Max. 1 z TIM (female) (A) Wiring harness between ENG (L) (female) (47) – Resistance Max. 1 z TIM (female) (B) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ENG (L) (female) (23) – all pins of ENG (L) (female) (with all connectors in the harness Resistance Min. 1 Mz disconnected) Since the connections among charge temperature (boost temperature) sensor – engine harness – engine controller are suspected to be defective, check for a defective connection. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (L) (female) Air boost temperature Resistance Between (23) – (47) 10 – 100°C 0.5 – 20 kz Engine controller is possibly defective if no problem is found in causes 1 – 5. (Since this is an internal defect, it cannot be diagnosed.)

PC2000-8

40 Troubleshooting

SEN02096-00

Circuit diagram related to charge temperature sensor

PC2000-8

55

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40 Troubleshooting

Failure code [CA154] Chg Air Temp Sensor Low Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

1

Failure code Chg Air Temp Sensor Low Error Trouble (Engine controller system) CA154 • Excessively low voltage is detected at signal circuit of charge temperature (boost temperature) sensor. • Operates with a fixed charge temperature (boost temperature) (70°C). • Exhaust gas color becomes white. • The signal voltage of the charge temperature (boost temperature) sensor can be checked with the monitoring function. (Code: 18501 Boost temperature sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause

Possible causes and standard value in normal state

56

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still Defective charge temOFF. perature (boost temTIM (male) Air boost temperature Resistance 1 perature) sensor Between (A) – (B) 10 – 100°C 0.5 – 20 kz (internal defect) Between (A) – ground In all range Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still Defective harness OFF. 2 grounding (contact with Between ground and wiring harness between ground circuit) Resistance Min. 1 Mz ENG (L) (female) (23) – TIM (female) (A) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 3 (Harness internal Between ENG (L) (female) (23) – all pins of ENG short) (L) (female) (with all connectors in the harness Resistance Min. 1 Mz disconnected) Since the connections among charge temperature (boost temperature) sensor – engine harness – engine controller are suspected to be defective, check for a defective connection. Defective wiring har4 • Connector is loose, lock is broken, seal is broken ness connector • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locaENG (L) (female) Air boost temperature Resistance 5 tions than engine controller Between (23) – (47) 10 – 100°C 0.5 – 20 kz Between (23) – ground In all range Min. 1 Mz Defective engine Engine controller is possibly defective if no problem is found in causes 1 – 6 controller 5. (Since this is an internal defect, it cannot be diagnosed.)

PC2000-8

40 Troubleshooting

SEN02096-00

Circuit diagram related to charge temperature sensor

PC2000-8

57

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40 Troubleshooting

Failure code [CA187] Sens Supply 2 Volt Low Error User code E15 Contents of trouble

Action of controller

Problem that appears on machine Related information Possible causes and standard value in normal state

Failure code CA187

Trouble

1

Sens Supply 2 Volt Low Error (Engine controller system)

• Low voltage was detected in sensor power supply (2) (5 V) circuit. • Ambient pressure sensor sets ambient temperature to default value (52.44 kPa {0.5 kg/cm2}) and continues operation. • Oil pressure sensor sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation. • Charge pressure sensor fixes charge pressure to (400 kPa {4.1 kg/cm2}) and continues operation. • Bkup sensor operates with Ne speed sensor signal. • Blinks warning lamp and sounds alarm buzzer. • Output lowers.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA227].

Failure code [CB187] Sens Supply 2 Volt Low Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

58

Failure code CA187

Trouble

1

Sens Supply 2 Volt Low Error (Engine controller system)

• Low voltage was detected in sensor power supply (2) (5 V) circuit. • Bkup sensor operates with Ne speed sensor signal. • Blinks warning lamp and sounds alarm buzzer. • Output lowers.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CB227].

PC2000-8

SEN02096-00

40 Troubleshooting

Failure code [CA212] Eng Oil Temp Sensor High Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA212

Trouble

• Sets oil temperature to default value (100°C) and continues operation.

Defective oil tempera1 ture sensor (Internal defect) Disconnection in wiring harness (Discon2 nection in wiring or defective contact in connector) Ground fault in wiring 3 harness (Contact with GND circuit)

4

60

Eng Oil Temp Sensor High Error (Engine controller system)

• High voltage was detected in engine oil temperature sensor circuit.

Cause

Possible causes and standard value in normal state

1

Defective engine controller

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TOIL (male) Oil temperature Resistance Between (A) – (B) 0 – 100°C 0.5 – 36 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (L) (female) (17) – Resistance Max. 1 z TOIL (female) (A) Wiring harness between ENG (L) (female) (47) – Resistance Max. 1 z TOIL (female) (B) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (L) (female) (17) – Resistance Min. 1 Mz TOIL (female) (A) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (L) Oil temperature Resistance (17) – (47) 0 – 100°C 0.5 – 36 kz

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SEN02096-00

Circuit diagram related to engine oil temperature sensor

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61

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40 Troubleshooting

Failure code [CA213] Eng Oil Temp Sensor Low Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

62

Failure code CA213

Trouble

1

Eng Oil Temp Sensor Low Error (Engine controller system)

• Low voltage was detected in engine oil temperature sensor circuit. • Sets oil temperature to default value (100°C) and continues operation.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA212].

PC2000-8

SEN02096-00

PC2000-8 Hydraulic excavator Form No. SEN02096-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

64

SEN02097-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

40 Troubleshooting

1

Troubleshooting by failure code, Part 2 Troubleshooting by failure code, Part 2 .......................................................................................................... 4 Failure code [CA221] Ambient Press Sens High Error ........................................................................ 4 Failure code [CA222] Ambient Press Sens Low Error ......................................................................... 6 Failure code [CA227] Sens Supply 2 Volt High Error........................................................................... 8 Failure code [CB227] Sens Supply 2 Volt High Error......................................................................... 10 Failure code [CA234] Eng Over Speed .............................................................................................. 12 Failure code [CA238] Ne Speed Sens Supply Volt Error ................................................................... 14 Failure code [CB238] Ne Speed Sens Supply Volt Error ................................................................... 16 Failure code [CA263] Fuel Temp Sensor High Error.......................................................................... 18 Failure code [CB263] Fuel Temp Sensor High Error.......................................................................... 20 Failure code [CA265] Fuel Temp Sensor Low Error........................................................................... 21 Failure code [CB265] Fuel Temp Sensor Low Error........................................................................... 21 Failure code [CA271] IMV/PCV1 Short Error ..................................................................................... 22 Failure code [CB271] IMV/PCV1 Short Error ..................................................................................... 24 Failure code [CA272] IMV/PCV1 Open Error..................................................................................... 26 Failure code [CB272] IMV/PCV1 Open Error..................................................................................... 28

PC2000-8

1

SEN02097-00

40 Troubleshooting

Failure code [CA273] PCV2 Short Error............................................................................................. 30 Failure code [CB273] PCV2 Short Error............................................................................................. 32 Failure code [CA274] PCV2 Open Error ............................................................................................ 34 Failure code [CB274] PCV2 Open Error ............................................................................................ 36 Failure code [CA322] Inj #1(L#1) Open/Short Error ........................................................................... 38 Failure code [CA323] Inj #5(L#5) Open/Short Error ........................................................................... 40 Failure code [CA324] Inj #3(L#3) Open/Short Error ........................................................................... 42 Failure code [CA325] Inj #6(L#6) Open/Short Error ........................................................................... 44 Failure code [CA331] Inj #2(L#2) Open/Short Error ........................................................................... 46 Failure code [CA332] Inj #4(L#4) Open/Short Error ........................................................................... 48 Failure code [CA342] Calibration Code Incompatibility ...................................................................... 50 Failure code [CB342] Calibration Code Incompatibility ...................................................................... 50 Failure code [CA351] Injectors Drive Circuit Error ............................................................................. 52 Failure code [CB351] Injectors Drive Circuit Error ............................................................................. 54 Failure code [CA352] Sens Supply 1 Volt Low Error.......................................................................... 56 Failure code [CB352] Sens Supply 1 Volt Low Error.......................................................................... 56 Failure code [CA386] Sens Supply 1 Volt High Error ......................................................................... 58 Failure code [CB386] Sens Supply 1 Volt High Error ......................................................................... 60 Failure code [CA441] Battery Voltage Low Error................................................................................ 62 Failure code [CB441] Battery Voltage Low Error................................................................................ 62 Failure code [CA442] Battery Voltage High Error ............................................................................... 63 Failure code [CB442] Battery Voltage High Error ............................................................................... 63 Failure code [CA449] Rail Press Very High Error............................................................................... 64 Failure code [CB449] Rail Press Very High Error............................................................................... 64

2

PC2000-8

SEN02097-00

40 Troubleshooting

Troubleshooting by failure code, Part 2

1

Failure code [CA221] Ambient Press Sens High Error

1

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA213

Trouble

• Excessively high voltage is detected at signal circuit of atmospheric pressure sensor. • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}). • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode. (Code: 37401 Atmospheric pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause Defective sensor 1 power source circuit

Defective atmospheric 2 pressure sensor (internal defect)

Disconnection in wiring harness (disconnection 3 or defective contact of connectors) Possible causes and standard value in normal state Defective harness 4 grounding (contact with ground circuit)

Harness short 5 (Harness internal short)

4

Ambient Press Sens High Error (Engine controller system)

Standard value in normal state/Remarks on troubleshooting If failure code [CA352] or [CA386] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch ON. PAMB Voltage Between (1) – (3) Power source 4.75 – 5.25 V Between (2) – (3) Signal 0.5 – 4.5 V Since the sensor voltage is measured with the harness being connected, if the voltage is abnormal, first check the harness and the controller to make it sure if there is no other cause of the trouble, and then judge the sensor voltage. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (L) (female) (37) – Resistance Max. 1 z PAMB (female) (1) Wiring harness between ENG (L) (female) (3) – Resistance Max. 1 z PAMB (female) (2) Wiring harness between ENG (L) (female) (38) – Resistance Max. 1 z PAMB (female) (3) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (37) – PAMB (female) (1) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (3) – PAMB (female) (2) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (38) – PAMB (female) (3) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (L) (female) (37) to PAMB (female) (1) and wiring harness Resistance Min. 1 Mz from ENG (L) (female) (3) to PAMB (female) (2) Between wiring harness from ENG (L) (female) (37) to PAMB (female) (1) and wiring harness Resistance Min. 1 Mz from ENG (L) (female) (38) to PAMB (female) (3) Between wiring harness from ENG (L) (female) (3) to PAMB (female) (2) and wiring harness from Resistance Min. 1 Mz ENG (L) (female) (38) to PAMB (female) (3)

PC2000-8

40 Troubleshooting

SEN02097-00

Cause Possible causes and standard value in normal state

6

Defective engine controller

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. ENG (L) Voltage Between (37) – (38) 4.75 – 5.25 V Between (3) – (38) 0.5 – 4.5 V

Circuit diagram related to atmospheric pressure sensor

PC2000-8

5

SEN02097-00

40 Troubleshooting

Failure code [CA222] Ambient Press Sens Low Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

6

Failure code CA222

Trouble

1

Ambient Press Sens Low Error (Engine controller system)

• Excessively low voltage is detected at signal circuit of atmospheric pressure sensor. • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}). • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode. (Code: 37401 Atmospheric pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting of failure code [CA221].

PC2000-8

SEN02097-00

40 Troubleshooting

Failure code [CA227] Sens Supply 2 Volt High Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA227

Trouble

• • • • •

Operates using Ne speed sensor signal instead of Bkup speed sensor signal. Operate oil pressure sensor with oil pressure at default value (250 kPa {2.5 kg/cm2}) Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.5 kg/cm2}) Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}). Flashes warning lamp and turns on alarm buzzer.

• Output decreases.

2

Defective sensor (internal defect)

Disconnection in wiring harness 3 (disconnection or defective contact of connectors)

Defective harness grounding 4 (contact with ground circuit)

Harness short 5 (Harness internal short)

6

8

Sens Supply 2 Volt High Error (Engine controller system)

• Excessively high voltage is detected in sensor power source (2) (5V) circuit.

Cause Defective related 1 circuits

Possible causes and standard value in normal state

1

Defective engine controller

Standard value in normal state/Remarks on troubleshooting Check the codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. a Prepare with starting switch OFF and diagnose with starting switch ON. Bkup speed sensor G connector Disconnect the devices Engine oil pressure POIL connector on the right one at a sensor time. Atmospheric pressure If the code disappears, PAMB connector sensor that device is internally Charge pressure sendefective. PIM connector sor a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (L) (female) (37) – Resistance Max. 1 z each sensor (female) Wiring harness between ENG (L) (female) (47) – Resistance Max. 1 z each sensor (female) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (37) – each sensor (female) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (47) – each sensor (female) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (L) (female) (37) to each sensor (female) and wiring harness Resistance Min. 1 Mz from ENG (L) (female) (47) to each sensor (female) a Prepare with starting switch OFF and diagnose with starting switch ON. ENG (L) Voltage Between (37) – (47) 4.75 – 5.25 V

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to sensor power source (2) (5V)

PC2000-8

9

SEN02097-00

40 Troubleshooting

Failure code [CB227] Sens Supply 2 Volt High Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB227

Trouble

• Bkup speed sensor operates with Ne speed sensor signal. • Output lowers.

2

Defective sensor (Internal defect)

Disconnection in wiring harness (Discon3 nection in wiring or defective contact in connector)

Ground fault in wiring 4 harness (Contact with GND circuit)

Short circuit in wiring 5 harness (with another wiring harness)

6

10

Sens Supply 2 Volt High Error (Engine controller system)

• High voltage was detected in sensor power supply (2) (5 V) circuit.

Cause Related defective 1 system

Possible causes and standard value in normal state

1

Defective engine controller

Standard value in normal state/Remarks on troubleshooting If another code is also displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When device at right is disconnected, if error Bkup speed sensor G connector code disappears, that device has defect in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (R) (female) (37) – Resistance Max. 1 z each sensor (female) Wiring harness between ENG (R) (female) (47) – Resistance Max. 1 z each sensor (female) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (R) (female) (37) – Resistance Min. 1 Mz each sensor (female) Wiring harness between ENG (R) (female) (47) – Resistance Min. 1 Mz each sensor (female) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness from ENG (R) (female) (37) to each sensor (female) and wiring harness Resistance Min. 1 Mz from ENG (R) (female) (47) to each sensor (female) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ENG (R) Voltage Between (37) – (47) 4.75 – 5.25 V

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to sensor power source (2) (At right bank)

PC2000-8

11

SEN02097-00

40 Troubleshooting

Failure code [CA234] Eng Over Speed User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code Eng Over Speed Trouble (Engine controller system) CA234 • The engine speed exceeds upper control limit speed. • Flashes warning lamp and turns on alarm buzzer. • Stops operation of injector until the engine speed drops to the normal speed. • Engine speed fluctuates. • The engine speed can be checked in monitoring function. (Code: 01000 Engine speed) • Duplication of failure code: Start engine and operate at high idle. Cause Defective related 1 circuits 2 Improper usage 3

12

1

Defective engine controller

Standard value in normal state/Remarks on troubleshooting Check the codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. The improper usage of equipped machine can be suspected. Instruct the proper usage. Engine controller can be suspected to be defective if no problem is found in causes 1 – 2 (since this is an internal defect, it cannot be diagnosed).

PC2000-8

SEN02097-00

40 Troubleshooting

Failure code [CA238] Ne Speed Sens Supply Volt Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA238

Trouble

• Controls using Bkup speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Bkup speed sensor is defective at the same time). • Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).

Defective Ne speed 1 sensor (internal defect)

Disconnection in wiring harness 2 (disconnection or defective contact of connectors)

Defective harness grounding 3 (contact with ground circuit)

Harness short 4 (Harness internal short)

5

14

Ne Speed Sens Supply Volt Error (Engine controller system)

• Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.

Cause

Possible causes and standard value in normal state

1

Defective engine controller

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnect a device shown on the right. If the failure code disapNe speed sensor Ne connector pears, that device is internally defective. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (L) (female) (16) – Resistance Max. 1 z Ne (female) (1) Wiring harness between ENG (L) (female) (48) – Resistance Max. 1 z Ne (female) (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (16) – Ne (female) (1) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (48) – Ne (female) (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (L) (female) (16) to Ne (female) (1) and wiring harness from Resistance Min. 1 Mz ENG (L) (female) (48) to Ne (female) (2) a Prepare with starting switch OFF and diagnose with starting switch ON. ENG (L) Voltage Between (16) – (48) 4.75 – 5.25 V

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to Ne speed sensor power source

PC2000-8

15

SEN02097-00

40 Troubleshooting

Failure code [CB238] Ne Speed Sens Supply Volt Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB238

Trouble

• Controls using Bkup speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Bkup speed sensor is defective at the same time). • Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).

Defective Ne speed 1 sensor (internal defect)

Disconnection in wiring harness 2 (disconnection or defective contact of connectors)

Defective harness grounding 3 (contact with ground circuit)

Harness short 4 (Harness internal short)

5

16

Ne Speed Sens Supply Volt Error (Engine controller system)

• Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.

Cause

Possible causes and standard value in normal state

1

Defective engine controller

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnect a device shown on the right. If the failure code disapNe speed sensor Ne connector pears, that device is internally defective. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (L) (female) (16) – Resistance Max. 1 z Ne (female) (1) Wiring harness between ENG (R) (female) (48) – Resistance Max. 1 z Ne (female) (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (16) – Ne (female) (1) Between ground and wiring harness between Resistance Min. 1 Mz ENG (R) (female) (48) – Ne (female) (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (L) (female) (16) to Ne (female) (1) and wiring harness from Resistance Min. 1 Mz ENG (R) (female) (48) to Ne (female) (2) a Prepare with starting switch OFF and diagnose with starting switch ON. Voltage Between ENG (L) (16) – ENG (R) (48) 4.75 – 5.25 V

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to Ne speed sensor power source

PC2000-8

17

SEN02097-00

40 Troubleshooting

Failure code [CA263] Fuel Temp Sensor High Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA263

Trouble

1

Fuel Temp Sensor High Error (Engine controller system)

• Excessively high voltage is detected at fuel temperature sensor circuit. • Operates with a fixed fuel temperature (95°C).

• The signal voltage of engine fuel temperature sensor can be checked in monitoring function. (Code: 14201 Engine fuel temperature sensor voltage) Cause

Possible causes and standard value in normal state

18

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still Defective fuel temperaOFF. 1 ture sensor (internal TFUEL (male) Fuel temperature Resistance defect) Between (A) – (B) 10 – 100°C 0.6 – 20 kz a Prepare with starting switch OFF and diagnose with starting switch still Disconnection in wirOFF. ing harness Wiring harness between ENG (L) (female) (30) – 2 (disconnection or Resistance Max. 1 z TFUEL (female) (A) defective contact of Wiring harness between ENG (L) (female) (47) – connectors) Resistance Max. 1 z TFUEL (female) (B) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding Between ground and wiring harness between 3 Resistance Min. 1 Mz (contact with ground ENG (L) (female) (30) – TFUEL (female) (A) circuit) a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (L) (female) Fuel temperature Resistance Defective engine 4 controller Between (30) – (47) 10 – 100°C 0.6 – 20 kz

PC2000-8

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SEN02097-00

Circuit diagram related to fuel temperature sensor

PC2000-8

19

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40 Troubleshooting

Failure code [CB263] Fuel Temp Sensor High Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB263

Trouble

1

Fuel Temp Sensor High Error (Engine controller system)

• Excessively high voltage is detected at fuel temperature sensor circuit. • Operates with a fixed fuel temperature (95°C).

• The signal voltage of engine fuel temperature sensor can be checked in monitoring function. (Code: 14201 Engine fuel temperature sensor voltage) Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still Defective fuel temperaOFF. 1 ture sensor (internal TFUEL (male) Fuel temperature Resistance defect) Between (A) – (B) 10 – 100°C 0.6 – 20 kz a Prepare with starting switch OFF and diagnose with starting switch still Disconnection in wirOFF. ing harness Wiring harness between ENG (R) (female) (30) – 2 (disconnection or Resistance Max. 1 z TFUEL (female) (A) defective contact of Wiring harness between ENG (R) (female) (47) – connectors) Resistance Max. 1 z TFUEL (female) (B) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding Between ground and wiring harness between 3 Resistance Min. 1 Mz (contact with ground ENG (R) (female) (30) – TFUEL (female) (A) circuit) a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (R) (female) Fuel temperature Resistance Defective engine 4 controller Between (30) – (47) 10 – 100°C 0.6 – 20 kz

Circuit diagram related to fuel temperature sensor

20

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40 Troubleshooting

SEN02097-00

Failure code [CA265] Fuel Temp Sensor Low Error User code E15 Contents of trouble Action of controller

Failure code CA265

Trouble

1

Fuel Temp Sensor Low Error (Engine controller system)

• Low voltage was detected in fuel temperature sensor circuit. • Substitutes coolant temperature sensor. • If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95°C) and continues operation.

Problem that appears on machine Related information Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA263].

Failure code [CB265] Fuel Temp Sensor Low Error User code E15 Contents of trouble Action of controller

Failure code CB265

Trouble

1

Fuel Temp Sensor Low Error (Engine controller system)

• Low voltage was detected in fuel temperature sensor circuit. • Substitutes coolant temperature sensor. • If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95°C) and continues operation.

Problem that appears on machine Related information Possible causes and standard value in normal state

PC2000-8

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CB263].

21

SEN02097-00

40 Troubleshooting

Failure code [CA271] IMV/PCV1 Short Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA271

Trouble

1

IMV/PCV1 Short Error (Engine controller system)

• Short circuit occurred in supply pump PCV1 circuit. • Blinks warning lamp and sounds alarm buzzer.

Cause

1

2 Possible causes and standard value in normal state 3

4

22

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective supply pump PCV1 (male) Resistance PCV1 (Internal short circuit) Between (1) – (2) 2.3 – 5.3 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (L) (female) (4) – harness (Contact with Resistance Min. 1 Mz PCV1 (female) (1) GND circuit) Wiring harness between ENG (L) (female) (5) – Resistance Min. 1 Mz PCV1 (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with Wiring harness between ENG (L) (female) (4) – Voltage Max. 1 V 24V circuit) in wiring PCV1 (female) (1) harness Wiring harness between ENG (L) (female) (5) – Voltage Max. 1 V PCV1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (L) (female) Resistance controller Between (4) – (5) 2.3 – 5.3 z Between (4), (5) – ground Min. 1 Mz

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to supply pump PCV1

PC2000-8

23

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40 Troubleshooting

Failure code [CB271] IMV/PCV1 Short Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB271

Trouble

1

IMV/PCV1 Short Error (Engine controller system)

• Short circuit occurred in supply pump PCV1 circuit. • Blinks warning lamp and sounds alarm buzzer.

Cause

1

2 Possible causes and standard value in normal state 3

4

24

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective supply pump PCV1 (male) Resistance PCV1 (Internal short circuit) Between (1) – (2) 2.3 – 5.3 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (R) (female) (4) – harness (Contact with Resistance Min. 1 Mz PCV1 (female) (1) GND circuit) Wiring harness between ENG (R) (female) (5) – Resistance Min. 1 Mz PCV1 (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with Wiring harness between ENG (R) (female) (4) – Voltage Max. 1 V 24V circuit) in wiring PCV1 (female) (1) harness Wiring harness between ENG (R) (female) (5) – Voltage Max. 1 V PCV1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (R) (female) Resistance controller Between (4) – (5) 2.3 – 5.3 z Between (4), (5) – ground Min. 1 Mz

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to supply pump PCV1

PC2000-8

25

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40 Troubleshooting

Failure code [CA272] IMV/PCV1 Open Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA272

Trouble

1

IMV/PCV1 Open Error (Engine controller system)

• Disconnection occurred in supply pump PCV1 circuit. • Blinks warning lamp and sounds alarm buzzer.

Cause

1

2 Possible causes and standard value in normal state 3

4

26

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Defective supply pump turning starting switch ON. PCV1 PCV1 (male) Resistance (Internal disconnecBetween (1) – (2) 2.3 – 5.3 z tion) Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wirturning starting switch ON. ing harness (DisconWiring harness between ENG (L) (female) (4) – nection in wiring or Resistance Max. 1 z PCV1 (female) (1) defective Wiring harness between ENG (L) (female) (5) – contact in connector) Resistance Max. 1 z PCV1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (L) (female) (4) – Resistance Min. 1 Mz harness (Contact with PCV1 (female) (1) GND circuit) Wiring harness between ENG (L) (female) (5) – Resistance Min. 1 Mz PCV1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (L) (female) Resistance controller Between (4) – (5) 2.3 – 5.3 z Between (4), (5) – ground Min. 1 Mz

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to supply pump PCV1

PC2000-8

27

SEN02097-00

40 Troubleshooting

Failure code [CB272] IMV/PCV1 Open Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB272

Trouble

1

IMV/PCV1 Open Error (Engine controller system)

• Disconnection occurred in supply pump PCV1 circuit. • Blinks warning lamp and sounds alarm buzzer.

Cause

1

2 Possible causes and standard value in normal state 3

4

28

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Defective supply pump turning starting switch ON. PCV1 PCV1 (male) Resistance (Internal disconnecBetween (1) – (2) 2.3 – 5.3 z tion) Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wirturning starting switch ON. ing harness (DisconWiring harness between ENG (R) (female) (4) – nection in wiring or Resistance Max. 1 z PCV1 (female) (1) defective Wiring harness between ENG (R) (female) (5) – contact in connector) Resistance Max. 1 z PCV1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (R) (female) (4) – Resistance Min. 1 Mz harness (Contact with PCV1 (female) (1) GND circuit) Wiring harness between ENG (R) (female) (5) – Resistance Min. 1 Mz PCV1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (R) (female) Resistance controller Between (4) – (5) 2.3 – 5.3 z Between (4), (5) – ground Min. 1 Mz

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to supply pump PCV1

PC2000-8

29

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40 Troubleshooting

Failure code [CA273] PCV2 Short Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA273

Trouble

1

PCV2 Short Error (Engine controller system)

• Short circuit occurred in supply pump PCV2 circuit. • Blinks warning lamp and sounds alarm buzzer.

Cause

1

2 Possible causes and standard value in normal state 3

4

30

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective supply pump PCV2 (male) Resistance PCV2 (Internal short circuit) Between (1) – (2) 2.3 – 5.3 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (L) (female) (9) – harness (Contact with Resistance Min. 1 Mz PCV2 (female) (1) GND circuit) Wiring harness between ENG (L) (female) (10) – Resistance Min. 1 Mz PCV2 (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with Wiring harness between ENG (L) (female) (9) – Voltage Max. 1 V 24V circuit) in wiring PCV2 (female) (1) harness Wiring harness between ENG (L) (female) (10) – Voltage Max. 1 V PCV2 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (L) (female) Resistance controller Between (9) – (10) 2.3 – 5.3 z Between (9), (10) – ground Min. 1 Mz

PC2000-8

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SEN02097-00

Circuit diagram related to supply pump PCV2

PC2000-8

31

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Failure code [CB273] PCV2 Short Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB273

Trouble

1

PCV2 Short Error (Engine controller system)

• Short circuit occurred in supply pump PCV2 circuit. • Blinks warning lamp and sounds alarm buzzer.

Cause

1

2 Possible causes and standard value in normal state 3

4

32

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective supply pump PCV2 (male) Resistance PCV2 (Internal short circuit) Between (1) – (2) 2.3 – 5.3 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (R) (female) (9) – harness (Contact with Resistance Min. 1 Mz PCV2 (female) (1) GND circuit) Wiring harness between ENG (R) (female) (10) – Resistance Min. 1 Mz PCV2 (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with Wiring harness between ENG (R) (female) (9) – Voltage Max. 1 V 24V circuit) in wiring PCV2 (female) (1) harness Wiring harness between ENG (R) (female) (10) – Voltage Max. 1 V PCV2 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (R) (female) Resistance controller Between (9) – (10) 2.3 – 5.3 z Between (9), (10) – ground Min. 1 Mz

PC2000-8

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SEN02097-00

Circuit diagram related to supply pump PCV2

PC2000-8

33

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40 Troubleshooting

Failure code [CA274] PCV2 Open Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA274

Trouble

1

PCV2 Open Error (Engine controller system)

• Disconnection occurred in supply pump PCV2 circuit. • Blinks warning lamp and sounds alarm buzzer.

Cause

Possible causes and standard value in normal state

34

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Defective supply pump turning starting switch ON. 1 PCV2 (Internal disconPCV2 (male) Resistance nection) Between (1) – (2) 2.3 – 5.3 z a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wirturning starting switch ON. ing harness (DisconWiring harness between ENG (L) (female) (9) – 2 nection in wiring or Resistance Max. 1 z PCV2 (female) (1) defective contact in Wiring harness between ENG (L) (female) (10) – connector) Resistance Max. 1 z PCV2 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (L) (female) (9) – 3 harness (Contact with Resistance Min. 1 Mz PCV2 (female) (1) GND circuit) Wiring harness between ENG (L) (female) (10) – Resistance Min. 1 Mz PCV2 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (L) (female) Resistance 4 controller Between (9) – (10) 2.3 – 5.3 z Between (9), (10) – ground Min. 1 Mz

PC2000-8

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SEN02097-00

Circuit diagram related to supply pump PCV2

PC2000-8

35

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Failure code [CB274] PCV2 Open Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB274

Trouble

1

PCV2 Open Error (Engine controller system)

• Disconnection occurred in supply pump PCV2 circuit. • Blinks warning lamp and sounds alarm buzzer.

Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Defective supply pump turning starting switch ON. 1 PCV2 (Internal disconPCV2 (male) Resistance nection) Between (1) – (2) 2.3 – 5.3 z a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wirturning starting switch ON. ing harness (DisconWiring harness between ENG (R) (female) (9) – 2 nection in wiring or Resistance Max. 1 z PCV2 (female) (1) defective contact in Wiring harness between ENG (R) (female) (10) – connector) Resistance Max. 1 z PCV2 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (R) (female) (9) – 3 harness (Contact with Resistance Min. 1 Mz PCV2 (female) (1) GND circuit) Wiring harness between ENG (R) (female) (10) – Resistance Min. 1 Mz PCV2 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (R) (female) Resistance 4 controller Between (9) – (10) 2.3 – 5.3 z Between (9), (10) – ground Min. 1 Mz

Circuit diagram related to supply pump PCV2

36

PC2000-8

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40 Troubleshooting

Failure code [CA322] Inj #1(L#1) Open/Short Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA322

Trouble

1

Inj #1(L#1) Open/Short Error (Engine controller system)

• A disconnection or short circuit has occurred in injector No. 1 circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Speed is not stable.

Cause

1

2 Possible causes and standard value in normal state

3

4

5

38

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective injector No. 1 CN1 (male) Resistance (internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still Disconnection in wiring OFF. harness Wiring harness between ENG (L) (female) (45) – (disconnection or Resistance Max. 1 z CN1 (female) (1) defective contact of Wiring harness between ENG (L) (female) (53) – connectors) Resistance Max. 1 z CN1 (female) (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between Resistance Min. 1 Mz grounding (contact with ENG (L) (female) (45) – CN1 (female) (1) ground circuit) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (53) – CN1 (female) (2) Defective another cylinIf multiple failure codes are displayed for injector malfunction, carry out der injector or wiring troubleshooting for them, too. harness a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective engine ENG (L) (female) Resistance controller Between (45) – (53) 0.4 – 1.1 z Between (45), (53) and ground Min. 1 Mz

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to injector No. 1

PC2000-8

39

SEN02097-00

40 Troubleshooting

Failure code [CA323] Inj #5(L#5) Open/Short Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA323

Trouble

1

Inj #5(L#5) Open/Short Error (Engine controller system)

• A disconnection or short circuit has occurred in injector No. 5 circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Speed is not stable.

Cause

1

2 Possible causes and standard value in normal state

3

4

5

40

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective injector No. 5 CN5 (male) Resistance (internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still Disconnection in wiring OFF. harness Wiring harness between ENG (L) (female) (46) – (disconnection or Resistance Max. 1 z CN5 (female) (1) defective contact of Wiring harness between ENG (L) (female) (60) – connectors) Resistance Max. 1 z CN5 (female) (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between Resistance Min. 1 Mz grounding (contact ENG (L) (female) (46) – CN5 (female) (1) with ground circuit) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (60) – CN5 (female) (2) Defective another cylIf multiple failure codes are displayed for injector malfunction, carry out inder injector or wiring troubleshooting for them, too. harness a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective engine ENG (L) (female) Resistance controller Between (46) – (60) 0.4 – 1.1 z Between (46), (60) and ground Min. 1 Mz

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to injector No. 5

PC2000-8

41

SEN02097-00

40 Troubleshooting

Failure code [CA324] Inj #3(L#3) Open/Short Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA324

Trouble

1

Inj #3(L#3) Open/Short Error (Engine controller system)

• A disconnection or short circuit has occurred in injector No. 3 circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Speed is not stable.

Cause

1

2 Possible causes and standard value in normal state

3

4

5

42

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective injector No. 3 CN3 (male) Resistance (internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still Disconnection in wiring OFF. harness Wiring harness between ENG (L) (female) (55) – (disconnection or Resistance Max. 1 z CN3 (female) (1) defective contact of Wiring harness between ENG (L) (female) (52) – connectors) Resistance Max. 1 z CN3 (female) (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between Resistance Min. 1 Mz grounding (contact ENG (L) (female) (55) – CN3 (female) (1) with ground circuit) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (52) – CN3 (female) (2) Defective another cylIf multiple failure codes are displayed for injector malfunction, carry out inder injector or wiring troubleshooting for them, too. harness a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective engine ENG (L) (female) Resistance controller Between (55) – (52) 0.4 – 1.1 z Between (55), (52) and ground Min. 1 Mz

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to injector No. 3

PC2000-8

43

SEN02097-00

40 Troubleshooting

Failure code [CA325] Inj #6(L#6) Open/Short Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA325

Trouble

1

Inj #6(L#6) Open/Short Error (Engine controller system)

• A disconnection or short circuit has occurred in injector No. 6 circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Speed is not stable.

Cause

1

2 Possible causes and standard value in normal state

3

4

5

44

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective injector No. 6 CN6 (male) Resistance (internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still Disconnection in wiring OFF. harness Wiring harness between ENG (L) (female) (57) – (disconnection or Resistance Max. 1 z CN6 (female) (1) defective contact of Wiring harness between ENG (L) (female) (59) – connectors) Resistance Max. 1 z CN6 (female) (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between Resistance Min. 1 Mz grounding (contact ENG (L) (female) (57) – CN6 (female) (1) with ground circuit) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (59) – CN6 (female) (2) Defective another cylIf multiple failure codes are displayed for injector malfunction, carry out inder injector or wiring troubleshooting for them, too. harness a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective engine ENG (L) (female) Resistance controller Between (57) – (59) 0.4 – 1.1 z Between (57), (59) and ground Min. 1 Mz

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to injector No. 6

PC2000-8

45

SEN02097-00

40 Troubleshooting

Failure code [CA331] Inj #2(L#2) Open/Short Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA331

Trouble

1

Inj #2(L#2) Open/Short Error (Engine controller system)

• A disconnection or short circuit has occurred in injector No. 2 circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Speed is not stable.

Cause

1

2 Possible causes and standard value in normal state

3

4

5

46

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective injector No. 2 CN2 (male) Resistance (internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still Disconnection in wiring OFF. harness Wiring harness between ENG (L) (female) (54) – (disconnection or Resistance Max. 1 z CN2 (female) (1) defective contact of Wiring harness between ENG (L) (female) (51) – connectors) Resistance Max. 1 z CN2 (female) (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between Resistance Min. 1 Mz grounding (contact ENG (L) (female) (54) – CN2 (female) (1) with ground circuit) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (51) – CN2 (female) (2) Defective another cylIf multiple failure codes are displayed for injector malfunction, carry out inder injector or wiring troubleshooting for them, too. harness a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective engine ENG (L) (female) Resistance controller Between (54) – (51) 0.4 – 1.1 z Between (54), (51) and ground Min. 1 Mz

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to injector No. 2

PC2000-8

47

SEN02097-00

40 Troubleshooting

Failure code [CA332] Inj #4(L#4) Open/Short Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA332

Trouble

1

Inj #4(L#4) Open/Short Error (Engine controller system)

• A disconnection or short circuit has occurred in injector No. 4 circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Speed is not stable.

Cause

1

2 Possible causes and standard value in normal state

3

4

5

48

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective injector No. 4 CN4 (male) Resistance (internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still Disconnection in wiring OFF. harness Wiring harness between ENG (L) (female) (56) – (disconnection or Resistance Max. 1 z CN4 (female) (1) defective contact of Wiring harness between ENG (L) (female) (58) – connectors) Resistance Max. 1 z CN4 (female) (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between Resistance Min. 1 Mz grounding (contact ENG (L) (female) (56) – CN4 (female) (1) with ground circuit) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (58) – CN4 (female) (2) Defective another cylIf multiple failure codes are displayed for injector malfunction, carry out inder injector or wiring troubleshooting for them, too. harness a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective engine ENG (L) (female) Resistance controller Between (56) – (58) 0.4 – 1.1 z Between (56), (58) and ground Min. 1 Mz

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to injector No. 4

PC2000-8

49

SEN02097-00

40 Troubleshooting

Failure code [CA342] Calibration Code Incompatibility User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Failure code CA342

Trouble

1

Calibration Code Incompatibility (Engine controller system)

• Data mismatch occurred in engine controller. • Blinks warning lamp and sounds alarm buzzer. • Engine cannot be started or operated.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA111].

Failure code [CB342] Calibration Code Incompatibility User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

50

Failure code CB342

Trouble

1

Calibration Code Incompatibility (Engine controller system)

• Data mismatch occurred in engine controller. • Blinks warning lamp and sounds alarm buzzer. • Engine cannot be started or operated.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CB111].

PC2000-8

SEN02097-00

40 Troubleshooting

Failure code [CA351] Injectors Drive Circuit Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA351

Trouble

1

Injectors Drive Circuit Error (Engine controller system)

• Abnormality has occurred in injector drive circuit. • Operates with limited output. (Limits common rail pressure.) • Flashes warning lamp and turns on alarm buzzer. • Output decreases.

Cause

1

2

Possible causes and standard value in normal state

3

4

5

52

Standard value in normal state/Remarks on troubleshooting Check the failure codes (codes for injector system trouble) that are disDefective related played at the same time. If any other codes are displayed, carry out troucircuits bleshooting for those codes. Since a fuse or breaker of equipped machine side can be suspected to be defective, directly check them. Defective breaker (If fuse is blown, or breaker is shut off, it is highly possible that a defective grounding, etc. has occurred in the circuit.) a Prepare with starting switch OFF and diagnose with starting switch still Disconnection in wiring OFF. harness Wiring harness between CE03 (female) (3) (4) – (disconnection or Resistance Max. 1 z battery (+) defective contact of Wiring harness between CE03 (female) (1) (2) connectors) Resistance Max. 1 z and ground a Prepare with starting switch OFF and diagnose with starting switch still Defective harness OFF. grounding (contact Between ground and wiring harness between with ground circuit) Resistance Min. 1 Mz CE03 (female) (3) (4) – battery (+) a Prepare with starting switch OFF and diagnose with starting switch ON. Defective engine CE03 Voltage controller Between (3), (4) – (1), (2) 20 – 30 V

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to controller power source

PC2000-8

53

SEN02097-00

40 Troubleshooting

Failure code [CB351] Injectors Drive Circuit Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB351

Trouble

1

Injectors Drive Circuit Error (Engine controller system)

• Abnormality occurred in injector drive circuit. • Limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.

Cause Related defective 1 system 2

Possible causes and standard value in normal state

3

4

5

54

Standard value in normal state/Remarks on troubleshooting If another code (code of injector system abnormality) is also displayed, carry out troubleshooting for it. Fuse or circuit breaker on applicable machine side may be defective. Defective circuit Check them directly. (If fuse is broken or circuit breaker is turned OFF, cirbreaker cuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (DisconnecWiring harness between CE06 (female) (3), (4) – tion in wiring or defecResistance Max. 1 z battery (+) tive contact in Wiring harness between CE06 (female) (1), (2) – connector) Resistance Max. 1 z ground a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. harness (Contact with Wiring harness between CE06 (female) (3), (4) – GND circuit) Resistance Min. 1 Mz battery (+) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine controller CE06 Voltage Between (3), (4) – (1), (2) 20 – 30 V

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to engine controller power supply

PC2000-8

55

SEN02097-00

40 Troubleshooting

Failure code [CA352] Sens Supply 1 Volt Low Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Failure code CA352

Trouble

1

Sens Supply 1 Volt Low Error (Engine controller system)

• Low voltage was detected in sensor power supply (1) (5 V) circuit. • Common rail pressure sensor limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA386].

Failure code [CB352] Sens Supply 1 Volt Low Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

56

Failure code CB352

Trouble

1

Sens Supply 1 Volt Low Error (Engine controller system)

• Low voltage was detected in sensor power supply (1) (5 V) circuit. • Common rail pressure sensor limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CB386].

PC2000-8

SEN02097-00

40 Troubleshooting

Failure code [CA386] Sens Supply 1 Volt High Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA386

Trouble

• Common rail pressure sensor limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.

2

3

4

5

6

58

Sens Supply 1 Volt High Error (Engine controller system)

• High voltage was detected in sensor power supply (1) (5 V) circuit.

Cause Related defective 1 system

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting If another code is also displayed, carry out troubleshooting for it.

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective sensor When device at right is (Internal defect) disconnected, if error Left common rail PFUEL connector code disappears, that pressure sensor device has defect in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between ENG (L) (female) (33) – Resistance Max. 1 z harness (DisconnecPFUEL (female) (1) tion in wiring or defecWiring harness between ENG (L) (female) (25) – tive contact in Resistance Max. 1 z PFUEL (female) (2) connector) Wiring harness between ENG (L) (female) (47) – Resistance Max. 1 z PFUEL (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (L) (female) (33) – Resistance Min. 1 Mz Ground fault in wiring PFUEL (female) (1) harness (Contact with Wiring harness between ENG (L) (female) (25) – GND circuit) Resistance Min. 1 Mz PFUEL (female) (2) Wiring harness between ENG (L) (female) (47) – Resistance Min. 1 Mz PFUEL (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between ENG (L) (female) (33) – PFUEL (female) (1) and wiring Resistance Min. 1 Mz harness between ENG (L) (female) (25) – PFUEL (female) (2) Short circuit in wiring Between wiring harness between ENG (L) harness (with another (female) (33) – PFUEL (female) (1) and wiring wiring harness) Resistance Min. 1 Mz harness between ENG (L) (female) (47) – PFUEL (female) (3) Between wiring harness between ENG (L) (female) (25) – PFUEL (female) (2) and wiring Resistance Min. 1 Mz harness between ENG (L) (female) (47) – PFUEL (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine ENG (L) Voltage controller Between (33) – (47) 4.75 – 5.25 V

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to sensor power supply 1 (5V)

PC2000-8

59

SEN02097-00

40 Troubleshooting

Failure code [CB386] Sens Supply 1 Volt High Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB386

Trouble

• Common rail pressure sensor limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.

2

3

4

5

6

60

Sens Supply 1 Volt High Error (Engine controller system)

• High voltage was detected in sensor power supply (1) (5 V) circuit.

Cause Related defective 1 system

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting If another code is also displayed, carry out troubleshooting for it.

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective sensor When device at right is (Internal defect) disconnected, if error Right common rail PFUEL connector code disappears, that pressure sensor device has defect in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between ENG (R) (female) (33) – Resistance Max. 1 z harness (DisconnecPFUEL (female) (1) tion in wiring or defecWiring harness between ENG (R) (female) (25) – tive contact in Resistance Max. 1 z PFUEL (female) (2) connector) Wiring harness between ENG (R) (female) (47) – Resistance Max. 1 z PFUEL (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (R) (female) (33) – Resistance Min. 1 Mz Ground fault in wiring PFUEL (female) (1) harness (Contact with Wiring harness between ENG (R) (female) (25) – GND circuit) Resistance Min. 1 Mz PFUEL (female) (2) Wiring harness between ENG (R) (female) (47) – Resistance Min. 1 Mz PFUEL (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between ENG (R) (female) (33) – PFUEL (female) (1) and wiring Resistance Min. 1 Mz harness between ENG (R) (female) (25) – PFUEL (female) (2) Short circuit in wiring Between wiring harness between ENG (R) harness (with another (female) (33) – PFUEL (female) (1) and wiring wiring harness) Resistance Min. 1 Mz harness between ENG (R) (female) (47) – PFUEL (female) (3) Between wiring harness between ENG (R) (female) (25) – PFUEL (female) (2) and wiring Resistance Min. 1 Mz harness between ENG (R) (female) (47) – PFUEL (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine ENG (R) Voltage controller Between (33) – (47) 4.75 – 5.25 V

PC2000-8

40 Troubleshooting

SEN02097-00

Circuit diagram related to sensor power supply (1) (5V)

PC2000-8

61

SEN02097-00

40 Troubleshooting

Failure code [CA441] Battery Voltage Low Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Failure code CA441

Trouble

1

Battery Voltage Low Error (Engine controller system)

• Low voltage was detected in power supply voltage circuit. • Blinks warning lamp and sounds alarm buzzer. • Machine continues operation normally but may stop suddenly or may not able to start again once it stops.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA111].

Failure code [CB441] Battery Voltage Low Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

62

Failure code CB441

Trouble

1

Battery Voltage Low Error (Engine controller system)

• Low voltage was detected in power supply voltage circuit. • Blinks warning lamp and sounds alarm buzzer. • Machine continues operation normally but may stop suddenly or may not able to start again once it stops.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CB111].

PC2000-8

40 Troubleshooting

SEN02097-00

Failure code [CA442] Battery Voltage High Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Failure code CA442

Trouble

Battery Voltage High Error (Engine controller system)

• High voltage was detected in power supply voltage circuit. • Blinks warning lamp and sounds alarm buzzer. • Machine continues operation normally but may stop suddenly or may not able to start again once it stops.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA111].

Failure code [CB442] Battery Voltage High Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

PC2000-8

1

Failure code CB442

Trouble

1

Battery Voltage High Error (Engine controller system)

• High voltage was detected in power supply voltage circuit. • Blinks warning lamp and sounds alarm buzzer. • Machine continues operation normally but may stop suddenly or may not able to start again once it stops.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CB111].

63

SEN02097-00

40 Troubleshooting

Failure code [CA449] Rail Press Very High Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Failure code CA449

Trouble

1

Rail Press Very High Error (Engine controller system)

• Common rail pressure sensor circuit detected abnormally high pressure (Level 2). • Limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA553].

Failure code [CB449] Rail Press Very High Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

64

Failure code CB449

Trouble

1

Rail Press Very High Error (Engine controller system)

• Common rail pressure sensor circuit detected abnormally high pressure (Level 2). • Limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CB553].

PC2000-8

SEN02097-00

PC2000-8 Hydraulic excavator Form No. SEN02097-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

66

SEN02098-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

40 Troubleshooting

1

Troubleshooting by failure code, Part 3 Troubleshooting by failure code, Part 3 .......................................................................................................... 4 Failure code [CA451] Rail Press Sensor High Error ............................................................................ 4 Failure code [CB451] Rail Press Sensor High Error ............................................................................ 6 Failure code [CA452] Rail Press Sensor Low Error ............................................................................. 8 Failure code [CB452] Rail Press Sensor Low Error ............................................................................. 8 Failure code [CA553] Rail Press High Error......................................................................................... 9 Failure code [CB553] Rail Press High Error....................................................................................... 10 Failure code [CA554] Rail Press Sensor In Range Error ....................................................................11 Failure code [CB554] Rail Press Sensor In Range Error ....................................................................11 Failure code [CA559] Rail Press Low Error ....................................................................................... 12 Failure code [CB559] Rail Press Low Error ....................................................................................... 16 Failure code [CA689] Eng Ne Speed Sensor Error............................................................................ 20 Failure code [CB689] Eng Ne Speed Sensor Error............................................................................ 22 Failure code [CA691] Intake Air Temp Sens High Error ..................................................................... 24 Failure code [CA692] Intake Air Temp Sens Low Error...................................................................... 26 Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................................ 27

PC2000-8

1

SEN02098-00

40 Troubleshooting

Failure code [CB731] Eng Bkup Speed Sens Phase Error ................................................................ 27 Failure code [CA757] All Persistent Data Lost Error .......................................................................... 28 Failure code [CB757] All Persistent Data Lost Error .......................................................................... 28 Failure code [CA778] Eng Bkup Speed Sensor Error ........................................................................ 30 Failure code [CB778] Eng Bkup Speed Sensor Error ........................................................................ 32 Failure code [CA781] CEN Communication Error .............................................................................. 34 Failure code [CB781] CEN Communication Error .............................................................................. 36 Failure code [CA1117] Persistent Data Lost Error.............................................................................. 37 Failure code [CB1117] Persistent Data Lost Error.............................................................................. 37 Failure code [CA1257] Harness Key Error ......................................................................................... 38 Failure code [CB1257] Harness Key Error ......................................................................................... 39 Failure code [CB1548] Inj #7(R#1) Open/Short Error ........................................................................ 40 Failure code [CB1549] Inj #8(R#2) Open/Short Error ........................................................................ 42 Failure code [CB1551] Inj #10(R#4) Open/Short Error ...................................................................... 44 Failure code [CB1552] Inj #11(R#5) Open/Short Error....................................................................... 46 Failure code [CB1553] Inj #12(R#6) Open/Short Error ...................................................................... 48 Failure code [CB1622] Inj #9(R#3) Open/Short Error ........................................................................ 50 Failure code [CA1633] KOMNET Data link Time out Error ................................................................ 52 Failure code [CA2185] Throt Sens Sup Volt High Error ..................................................................... 54 Failure code [CA2186] Throt Sens Sup Volt Low Error ...................................................................... 56 Failure code [CA2249] Rail Press Very Low Error ............................................................................. 57 Failure code [CB2249] Rail Press Very Low Error ............................................................................. 57 Failure code [CA2555] Grid Heater Relay Volt Low Error .................................................................. 58 Failure code [CA2556] Grid Heater Relay Volt High Error ................................................................. 60

2

PC2000-8

SEN02098-00

40 Troubleshooting

Troubleshooting by failure code, Part 3

1

Failure code [CA451] Rail Press Sensor High Error

1

User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA451

Trouble

• Excessively high voltage has occurred in the common rail pressure sensor circuit. • Operates with limited output.(Limits common rail pressure.) • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • The signal voltage of the common rail pressure sensor can be checked with the monitoring function. (Code: 36401 Common rail pressure sensor voltage) Cause Defective sensor 1 power source circuit

Defective common rail 2 pressure sensor (internal defect)

Disconnection in wiring harness (disconnection 3 or defective contact of connectors) Possible causes and standard value in normal state Defective harness 4 grounding (contact with ground circuit)

Harness short 5 (Harness internal short)

4

Rail Press Sensor High Error (Engine controller system)

Standard value in normal state/Remarks on troubleshooting If failure code [CA352] or [CA386] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. PFUEL Voltage Between (1) – (3) Power source 4.75 – 5.25 V Between (2) – (3) Signal 0.25 – 4.6 V Since the sensor voltage is measured with the harness being connected, if the voltage is abnormal, first check the harness and the controller to make it sure if there is no other cause of the trouble, and then judge the sensor voltage. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (L) (female) (33) – Resistance Max. 1 z PFUEL (female) (1) Wiring harness between ENG (L) (female) (25) – Resistance Max. 1 z PFUEL (female) (2) Wiring harness between ENG (L) (female) (47) – Resistance Max. 1 z PFUEL (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (33) – PFUEL (female) (1) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (25) – PFUEL (female) (2) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (47) – PFUEL (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness from ENG (L) (female) (33) to PFUEL (female) (1) and wiring harness Resistance Min. 1 Mz from ENG (L) (female) (25) to PFUEL (female) (2) Between wiring harness from ENG (L) (female) (33) to PFUEL (female) (1) and wiring harness Resistance Min. 1 Mz from ENG (L) (female) (47) to PFUEL (female) (3) Between wiring harness from ENG (L) (female) (25) to PFUEL (female) (2) and wiring harness Resistance Min. 1 Mz from ENG (L) (female) (47) to PFUEL (female) (3)

PC2000-8

40 Troubleshooting

SEN02098-00

Cause Possible causes and standard value in normal state

6

Defective engine controller

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. ENG (L) Voltage Between (33) – (47) 4.75 – 5.25 V Between (25) – (47) 0.25 – 4.6 V

Circuit diagram related to common rail pressure sensor

PC2000-8

5

SEN02098-00

40 Troubleshooting

Failure code [CB451] Rail Press Sensor High Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB451

Trouble

1

Rail Press Sensor High Error (Engine controller system)

• High voltage was detected in common rail pressure sensor circuit. • Limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Signal voltage of common rail pressure sensor can be checked with monitoring function (Code: 36404: Common rail pressure sensor voltage). Cause Defective sensor 1 power supply system

2

3

Possible causes and standard value in normal state 4

5

6

Standard value in normal state/Remarks on troubleshooting If code [CB352] or [CB386] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. PFUEL Voltage Defective common rail Between (1) – (3) Power supply 4.75 – 5.25 V pressure sensor Between (2) – (3) Signal 0.25 – 4.6 V (Internal defect) Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between ENG (R) (female) (33) – Resistance Max. 1 z harness (DisconnecPFUEL (female) (1) tion in wiring or defecWiring harness between ENG (R) (female) (25) – tive contact in Resistance Max. 1 z PFUEL (female) (2) connector) Wiring harness between ENG (R) (female) (47) – Resistance Max. 1 z PFUEL (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (R) (female) (33) – Resistance Min. 1 Mz Ground fault in wiring PFUEL (female) (1) harness (Contact with Wiring harness between ENG (R) (female) (25) – GND circuit) Resistance Min. 1 Mz PFUEL (female) (2) Wiring harness between ENG (R) (female) (47) – Resistance Min. 1 Mz PFUEL (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between ENG (R) (female) (33) – PFUEL (female) (1) and wiring Resistance Min. 1 Mz harness between ENG (R) (female) (25) – PFUEL (female) (2) Short circuit in wiring harness (with another Between wiring harness between ENG (R) (female) (33) – PFUEL (female) (1) and wiring wiring harness) Resistance Min. 1 Mz harness between ENG (R) (female) (47) – PFUEL (female) (3) Between wiring harness between ENG (R) (female) (25) – PFUEL (female) (2) and wiring Resistance Min. 1 Mz harness between ENG (R) (female) (47) – PFUEL (female) (3)

PC2000-8

40 Troubleshooting

SEN02098-00

Cause Possible causes and standard value in normal state

6

Defective engine controller

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ENG (R) Voltage Between (33) – (47) 4.75 – 5.25 V Between (25) – (47) 0.25 – 4.6 V

Circuit diagram related to common rail pressure sensor

PC2000-8

7

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40 Troubleshooting

Failure code [CA452] Rail Press Sensor Low Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Failure code CA452

Trouble

1

Rail Press Sensor Low Error (Engine controller system)

• Low voltage was detected in common rail pressure sensor circuit. • Limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Signal voltage of common rail pressure sensor can be checked with monitoring function (Code: 36401: Common rail pressure sensor voltage). Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA451].

Failure code [CB452] Rail Press Sensor Low Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

8

Failure code CB452

Trouble

1

Rail Press Sensor Low Error (Engine controller system)

• Low voltage was detected in common rail pressure sensor circuit. • Limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Signal voltage of common rail pressure sensor can be checked with monitoring function (Code: 36401: Common rail pressure sensor voltage). Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CB451].

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40 Troubleshooting

SEN02098-00

Failure code [CA553] Rail Press High Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA553

• Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Common rail pressure can be checked with the monitoring function. (Code: 36400 Common rail pressure)

2 3

4 5 6 7

PC2000-8

Rail Press High Error (Engine controller system)

• Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.

1

Possible causes and standard value in normal state

Trouble

1

Cause Defective related circuits Improper fuel has been used. Defective electrical system of common rail pressure sensor Defective mechanical system of common rail pressure sensor Defective overflow valve Clogged overflow piping Defective pressure limiter

Standard value in normal state/Remarks on troubleshooting Check the codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. Since the use of improper fuel can be suspected, check the fuel. (Viscosity is too high) Since an electrical defect of common rail pressure sensor is suspected, carry out troubleshooting for the following code. [CA451] Since a mechanical defect of common rail pressure sensor is suspected, directly check the sensor. Since a damage of spring, wear of seat or sticking of ball is suspected, directly check them. Since an overflow piping is suspected to be clogged, directly check it. Since a mechanical defect of pressure limiter is suspected, directly check the limiter.

9

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40 Troubleshooting

Failure code [CB553] Rail Press High Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB553

• Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Common rail pressure can be checked with the monitoring function. (Code: 36400 Common rail pressure)

2 3

4 5 6 7

10

Rail Press High Error (Engine controller system)

• Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.

1

Possible causes and standard value in normal state

Trouble

1

Cause Defective related circuits Improper fuel has been used. Defective electrical system of common rail pressure sensor Defective mechanical system of common rail pressure sensor Defective overflow valve Clogged overflow piping Defective pressure limiter

Standard value in normal state/Remarks on troubleshooting Check the codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. Since the use of improper fuel can be suspected, check the fuel. (Viscosity is too high) Since an electrical defect of common rail pressure sensor is suspected, carry out troubleshooting for the following code. [CB451] Since a mechanical defect of common rail pressure sensor is suspected, directly check the sensor. Since a damage of spring, wear of seat or sticking of ball is suspected, directly check them. Since an overflow piping is suspected to be clogged, directly check it. Since a mechanical defect of pressure limiter is suspected, directly check the limiter.

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40 Troubleshooting

SEN02098-00

Failure code [CA554] Rail Press Sensor In Range Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Failure code CA554

Trouble

Rail Press Sensor In Range Error (Engine controller system)

• In-range error has occurred in common rail pressure sensor circuit. • Operates with limited output.(Limits common rail pressure.) • Flashes warning lamp and turns on alarm buzzer. • Output decreases.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting of [CA451].

Failure code [CB554] Rail Press Sensor In Range Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

PC2000-8

1

Failure code CB554

Trouble

1

Rail Press Sensor In Range Error (Engine controller system)

• In-range error has occurred in common rail pressure sensor circuit. • Operates with limited output.(Limits common rail pressure.) • Flashes warning lamp and turns on alarm buzzer. • Output decreases.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting of [CB451].

11

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40 Troubleshooting

Failure code [CA559] Rail Press Low Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code CA559

Trouble

1

Rail Press Low Error (Engine controller system)

• Loss of pressure feed (level 1) from supply pump has occurred. • Limits common rail pressure. • Output decreases. • Flashes warning lamp and turns on alarm buzzer.

Cause Standard value in normal state/Remarks on troubleshooting Defective related cirCheck the codes that are displayed at the same time. If any other codes 1 cuits are displayed, carry out troubleshooting for those codes. Improper fuel has been 2 Since the use of improper fuel is suspected, directly check the fuel. used. a See “Note 1” for the contents of diagnosis. See Testing and adjusting “Testing fuel pressure” for the pressure inspection of the fuel low pressure circuit. Defective low pressure 3 Pressure in fuel low pressure circuit device Min. 0.15 MPa circuit (At high idle or under the load equiv{Min. 1.5 kg/cm2} alent to rating (stalling)) Clogged filter or 4 a See “Note 2” for the contents of diagnosis. strainer Defective electrical Since an electrical defect of supply pump PCV is suspected, carry out 5 system of supply pump troubleshooting for the following codes. PCV [CA271], [CA272], [CA273], and [CA274] Defective common rail Since a defect of common rail pressure sensor is suspected, check for a 6 pressure sensor damage in harnesses. a As for testing an amount of pressure limiter leak, see testing and adjusting “Testing fuel return and leak amount”. Defective pressure 7 Max. 10 cc/min. limiter Pressure limiter leak amount [Equivalent to rated operation (stalling)] a As for the test relating to return (spill) limit amount of injector, see Testing and adjusting “Testing fuel return and leak amount”. Speed under the conditions which are equivalent to rated operation Injector return (spill) limit amount (stalling) 8 Defective injector 1,600 rpm 960 cc/min 1,700 rpm 1,020 cc/min 1,800 rpm 1,080 cc/min 1,900 rpm 1,140 cc/min 2,000 rpm 1,200 cc/min Supply pump can be suspected to be defective if no problem is found in 9 Defective supply pump causes 1 – 8.

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for nopressure feed”.

12

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Note 1: When low-pressure circuit equipment is defective, check the following: 1) Fuel level 2) Clogged fuel tank breather 3) Stuck or worn feed pump, clogged filter 4) Leaked or clogged low-pressure fuel pipe 5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.) 6) Clogged fuel filter 7) Fuel in oil pan (fuel leakage in head cover) Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) q Overflow valve (1): Spring is seen through both holes. q Bypass valve (2): Spring is seen through hole on nut side. q Fuel inlet joint (3): Gauze filter is seen through both holes.

Note 2: Check, clean, and replace the filters and strainers according to the following procedure. 1) Gauze filter: Disassemble and check. If clogged, clean. 2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too. 3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.

PC2000-8

13

SEN02098-00

40 Troubleshooting

Check sheet for no-pressure feed Model Model and serial No.

Operation No. #

Date inspected

Engine Engine serial No.

/

/

Service meter #

h

Worker's name

A. Visual inspections 1

Fuel leakage to outside

2

Clogged fuel tank breather

Pass Fail

Pass Fail

B. Inspections with machine monitor (failure history, monitoring, and reduced cylinder mode operation) 3

Checking failure codes

/

/

/

/

Checking monitoring information Code

*1

4

Display item

Engine speed

Condition for inspection

Unit

Standard value (reference value)

Low idle

rpm

800 – 850

High idle

rpm

1,955 – 2,005

Equivalent to rating

rpm

2,000

Measured value

Pass Fail

Low idle

%

0

High idle

%

100

Equivalent to rating

mm3

—

—

—

Command for common rail pressure

Equivalent to rating

MPa

*5

Fuel pressure in common rail

Equivalent to rating

MPa

*6

Command for fuel injection timing

*2

Throttle speed

*3

Command for fuel injection rate

*4

Low idle

CA

—

—

—

High idle

CA

—

—

—

Equivalent to rating

CA

—

—

—

kPa

—

—

—

*7

Boost pressure

Equivalent to rating

*8

Coolant temperature (high temperature)

Low idle

°C

—

—

—

*9

Coolant temperature (low temperature)

Low idle

°C

—

—

—

*10

Fuel temperature

Low idle

°C

—

—

—

Unit

Standard value (reference value)

Checking reduced cylinder mode operation (engine speed) Function

5 *11

Cut-out cylinder

14

Measured value

Pass Fail

Cylinder No. 1

Low idle

rpm

—

—

—

Cylinder No. 2

Low idle

rpm

—

—

—

Cylinder No. 3

Low idle

rpm

—

—

—

Cylinder No. 4

Low idle

rpm

—

—

—

Cylinder No. 5

Low idle

rpm

—

—

—

Cylinder No. 6

Low idle

rpm

—

—

—

Condition for inspection

Unit

Standard value (reference value)

At high idle or under the load equivalent to rating (stalling)

MPa {kg/cm2}

Min. 0.15 {Min. 1.5}

C. Inspection of pressure in fuel circuit 6

Condition for inspection

Pressure in fuel low pressure circuit

Measured value

Pass Fail

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40 Troubleshooting

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D. Inspection of strainer and filter 7

Visual inspection of strainer

8

Visual inspection of gauze filter

9

Visual inspection of fuel filter

Pass Fail

10 Visual inspection of bypass valve

E. Inspection of fuel leak and return amount 11

Pressure limiter leak amount

12 Injector return amount

Unit

Standard value (reference value)

Under the load equivalent to rating (stalling)

cc/min

Max 10

Equivalent to rating: 1,600 rpm

cc/min

960

Equivalent to rating: 1,700 rpm

cc/min

1,020

Equivalent to rating: 1,800 rpm

cc/min

1,080

Equivalent to rating: 1,900 rpm

cc/min

1,140

Equivalent to rating: 2,000 rpm

cc/min

1,200

Condition for inspection

Measured value

Pass Fail

Rotation speed:

Return amount:

Inspection items *1 – *10 of B-4: When inspecting with the monitoring function, see “Monitoring code table”. Inspection items *11 of B-5: When inspecting with the monitoring function, see “Adjustment mode table”. Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder

PC2000-8

15

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40 Troubleshooting

Failure code [CB559] Rail Press Low Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code CB559

Trouble

1

Rail Press Low Error (Engine controller system)

• Loss of pressure feed (level 1) from supply pump has occurred. • Limits common rail pressure. • Output decreases. • Flashes warning lamp and turns on alarm buzzer.

Cause Standard value in normal state/Remarks on troubleshooting Defective related cirCheck the codes that are displayed at the same time. If any other codes 1 cuits are displayed, carry out troubleshooting for those codes. Improper fuel has been 2 Since the use of improper fuel is suspected, directly check the fuel. used. a See “Note 1” for the contents of diagnosis. See Testing and adjusting “Testing fuel pressure” for the pressure inspection of the fuel low pressure circuit. Defective low pressure 3 Pressure in fuel low pressure circuit device Min. 0.15 MPa circuit (At high idle or under the load equiv{Min. 1.5 kg/cm2} alent to rating (stalling)) Clogged filter or 4 a See “Note 2” for the contents of diagnosis. strainer Defective electrical Since an electrical defect of supply pump PCV is suspected, carry out 5 system of supply pump troubleshooting for the following codes. PCV [CB271], [CB272], [CB273], and [CB274] Defective common rail Since a defect of common rail pressure sensor is suspected, check for a 6 pressure sensor damage in harnesses. a As for testing an amount of pressure limiter leak, see testing and adjusting “Testing fuel return and leak amount”. Defective pressure 7 Max. 10 cc/min. limiter Pressure limiter leak amount [Equivalent to rated operation (stalling)] a As for the test relating to return (spill) limit amount of injector, see Testing and adjusting “Testing fuel return and leak amount”. Speed under the conditions which are equivalent to rated operation Injector return (spill) limit amount (stalling) 8 Defective injector 1,600 rpm 960 cc/min 1,700 rpm 1,020 cc/min 1,800 rpm 1,080 cc/min 1,900 rpm 1,140 cc/min 2,000 rpm 1,200 cc/min Supply pump can be suspected to be defective if no problem is found in 9 Defective supply pump causes 1 – 8.

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for nopressure feed”.

16

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Note 1: When low-pressure circuit equipment is defective, check the following: 1) Fuel level 2) Clogged fuel tank breather 3) Stuck or worn feed pump, clogged filter 4) Leaked or clogged low-pressure fuel pipe 5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.) 6) Clogged fuel filter 7) Fuel in oil pan (fuel leakage in head cover) Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) q Overflow valve (1): Spring is seen through both holes. q Bypass valve (2): Spring is seen through hole on nut side. q Fuel inlet joint (3): Gauze filter is seen through both holes.

Note 2: Check, clean, and replace the filters and strainers according to the following procedure. 1) Gauze filter: Disassemble and check. If clogged, clean. 2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too. 3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.

PC2000-8

17

SEN02098-00

40 Troubleshooting

Check sheet for no-pressure feed Model Model and serial No.

Operation No. #

Date inspected

Engine Engine serial No.

/

/

Service meter #

h

Worker's name

A. Visual inspections 1

Fuel leakage to outside

2

Clogged fuel tank breather

Pass Fail

Pass Fail

B. Inspections with machine monitor (failure history, monitoring, and reduced cylinder mode operation) 3

Checking failure codes

/

/

/

/

Checking monitoring information Code

*1

4

Display item

Engine speed

Condition for inspection

Unit

Standard value (reference value)

Low idle

rpm

800 – 850

High idle

rpm

1,955 – 2,005

Equivalent to rating

rpm

1,800

Measured value

Pass Fail

Low idle

%

0

High idle

%

100

Equivalent to rating

mm3

—

—

—

Command for common rail pressure

Equivalent to rating

MPa

*5

Fuel pressure in common rail

Equivalent to rating

MPa

*6

Command for fuel injection timing

*2

Throttle speed

*3

Command for fuel injection rate

*4

Low idle

CA

—

—

—

High idle

CA

—

—

—

Equivalent to rating

CA

—

—

—

kPa

—

—

—

*7

Boost pressure

Equivalent to rating

*8

Coolant temperature (high temperature)

Low idle

°C

—

—

—

*9

Coolant temperature (low temperature)

Low idle

°C

—

—

—

*10

Fuel temperature

Low idle

°C

—

—

—

Unit

Standard value (reference value)

Checking reduced cylinder mode operation (engine speed) Function

5 *11

Cut-out cylinder

18

Measured value

Pass Fail

Cylinder No. 1

Low idle

rpm

—

—

—

Cylinder No. 2

Low idle

rpm

—

—

—

Cylinder No. 3

Low idle

rpm

—

—

—

Cylinder No. 4

Low idle

rpm

—

—

—

Cylinder No. 5

Low idle

rpm

—

—

—

Cylinder No. 6

Low idle

rpm

—

—

—

Condition for inspection

Unit

Standard value (reference value)

At high idle or under the load equivalent to rating (stalling)

MPa {kg/cm2}

Min. 0.15 {Min. 1.5}

C. Inspection of pressure in fuel circuit 6

Condition for inspection

Pressure in fuel low pressure circuit

Measured value

Pass Fail

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40 Troubleshooting

SEN02098-00

D. Inspection of strainer and filter 7

Visual inspection of strainer

8

Visual inspection of gauze filter

9

Visual inspection of fuel filter

Pass Fail

10 Visual inspection of bypass valve

E. Inspection of fuel leak and return amount 11

Pressure limiter leak amount

12 Injector return amount

Unit

Standard value (reference value)

Under the load equivalent to rating (stalling)

cc/min

Max 10

Equivalent to rating: 1,600 rpm

cc/min

960

Equivalent to rating: 1,700 rpm

cc/min

1,020

Equivalent to rating: 1,800 rpm

cc/min

1,080

Equivalent to rating: 1,900 rpm

cc/min

1,140

Equivalent to rating: 2,000 rpm

cc/min

1,200

Condition for inspection

Measured value

Pass Fail

Rotation speed:

Return amount:

Inspection items *1 – *10 of B-4: When inspecting with the monitoring function, see “Monitoring code table”. Inspection items *11 of B-5: When inspecting with the monitoring function, see “Adjustment mode table”. Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder

PC2000-8

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40 Troubleshooting

Failure code [CA689] Eng Ne Speed Sensor Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA689

Trouble

1

Eng Ne Speed Sensor Error (Engine controller system)

• Abnormal signal of the engine Ne speed sensor has been detected. • Operates using Bkup speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Bkup speed sensor is defective at the same time). • Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).

Cause Defective sensor 1 power source circuit

2

3

Possible causes and standard value in normal state

4

5

6 7

20

Standard value in normal state/Remarks on troubleshooting If failure code [CA238] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between ENG (L) (female) (16) – Resistance Max. 1 z harness NE (female) (1) (disconnection or Wiring harness between ENG (L) (female) (48) – defective contact of Resistance Max. 1 z NE (female) (2) connectors) Wiring harness between ENG (L) (female) (27) – Resistance Max. 1 z NE (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between Defective harness Resistance Min. 1 Mz ENG (L) (female) (16) – NE (female) (1) grounding (contact with ground Between ground and wiring harness between Resistance Min. 1 Mz circuit) ENG (L) (female) (48) – NE (female) (2) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (27) – NE (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness from ENG (L) (female) (16) to NE (female) (1) and wiring harness from Resistance Min. 1 Mz ENG (L) (female) (48) to NE (female) (2) Harness short (Harness internal Between wiring harness from ENG (L) (female) short) (16) to NE (female) (1) and wiring harness from Resistance Min. 1 Mz ENG (L) (female) (27) to NE (female) (3) Between wiring harness from ENG (L) (female) (48) to NE (female) (2) and wiring harness from Resistance Min. 1 Mz ENG (L) (female) (27) to NE (female) (3) Defective mounting of sensor or defective Since defective mounting of Ne speed sensor (improper gap) or defective parts for speed detec- parts for speed detection (flywheel) can be suspected, directly check it. tion Engine Ne speed sensor can be suspected to be defective if no problem is Defective engine Ne found in causes 1 – 5 (since this is an internal defect, it cannot be diagspeed sensor nosed). Defective engine Engine controller can be suspected to be defective if no problem is found controller in causes 1 – 6 (since this is an internal defect, it cannot be diagnosed).

PC2000-8

40 Troubleshooting

SEN02098-00

Circuit diagram related to engine Ne speed sensor

PC2000-8

21

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40 Troubleshooting

Failure code [CB689] Eng Ne Speed Sensor Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB689

Trouble

1

Eng Ne Speed Sensor Error (Engine controller system)

• Abnormal signal of the engine Ne speed sensor has been detected. • Operates using Bkup speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Bkup speed sensor is defective at the same time). • Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).

Cause Defective sensor 1 power source circuit

2

3

Possible causes and standard value in normal state

4

5

6 7

22

Standard value in normal state/Remarks on troubleshooting If failure code [CB238] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between ENG (L) (female) (16) – Resistance Max. 1 z harness NE (female) (1) (disconnection or Wiring harness between ENG (R) (female) (48) – defective contact of Resistance Max. 1 z NE (female) (2) connectors) Wiring harness between ENG (R) (female) (27) – Resistance Max. 1 z NE (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between Defective harness Resistance Min. 1 Mz ENG (L) (female) (16) – NE (female) (1) grounding (contact with ground Between ground and wiring harness between Resistance Min. 1 Mz circuit) ENG (R) (female) (48) – NE (female) (2) Between ground and wiring harness between Resistance Min. 1 Mz ENG (R) (female) (27) – NE (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness from ENG (L) (female) (16) to NE (female) (1) and wiring harness from Resistance Min. 1 Mz ENG (R) (female) (48) to NE (female) (2) Harness short (Harness internal Between wiring harness from ENG (L) (female) short) (16) to NE (female) (1) and wiring harness from Resistance Min. 1 Mz ENG (R) (female) (27) to NE (female) (3) Between wiring harness from ENG (R) (female) (48) to NE (female) (2) and wiring harness from Resistance Min. 1 Mz ENG (R) (female) (27) to NE (female) (3) Defective mounting of sensor or defective Since defective mounting of Ne speed sensor (improper gap) or defective parts for speed detec- parts for speed detection (flywheel) can be suspected, directly check it. tion Engine Ne speed sensor can be suspected to be defective if no problem is Defective engine Ne found in causes 1 – 5 (since this is an internal defect, it cannot be diagspeed sensor nosed). Defective engine Engine controller can be suspected to be defective if no problem is found controller in causes 1 – 6 (since this is an internal defect, it cannot be diagnosed).

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40 Troubleshooting

SEN02098-00

Circuit diagram related to engine Ne speed sensor

PC2000-8

23

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40 Troubleshooting

Failure code [CA691] Intake Air Temp Sens High Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA691

Trouble

• Fixes intake air temperature (25°C) and continues operation.

• Input state from the intake air temperature sensor can be checked with monitoring function (Code: 18400 Intake air temperature, Code: 18401 Intake air temperature sensor voltage)

Defective charge tem1 perature sensor (Internal defect)

Disconnection in wiring harness (Disconnec2 tion in wiring or defective contact in connector) Ground fault in wiring 3 harness (Contact with GND circuit)

4

24

Intake Air Temp Sens High Error (Engine controller system)

• Intake air temperature sensor circuit detected high voltage.

Cause

Possible causes and standard value in normal state

1

Defective engine controller

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TAMB Intake air temperature Resistance Between (A) – (B) 10 – 100°C 0.5 – 20 kz Between (A) – ground All range Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (L) (female) (43) – Resistance Max. 1z TAMB (female) (A) Wiring harness between ENG (L) (female) (47) – Resistance Max. 1z TAMB (female) (B) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (L) (female) (43) – Resistance Min. 1 Mz TAMB (female) (A) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (L) (female) Intake air temperature Resistance Between (43) – (47) 10 – 100°C 0.5 – 20 kz

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40 Troubleshooting

SEN02098-00

Circuit diagram related to intake air temperature sensor

PC2000-8

25

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40 Troubleshooting

Failure code [CA692] Intake Air Temp Sens Low Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

26

Failure code CA692

Trouble

1

Intake air temperature sensor abnormally low level (Only left bank): Low voltage detection (Engine controller system)

• Intake air temperature sensor circuit detected low voltage. • Fixes intake air temperature (25°C) and continues operation.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA691].

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40 Troubleshooting

SEN02098-00

Failure code [CA731] Eng Bkup Speed Sens Phase Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA731

Trouble

1

Eng Bkup Speed Sens Phase Error (Engine controller system)

• Abnormal phase has been detected in the engine Bkup sensor circuit. • Operates using engine Ne speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Ne speed sensor is defective at the same time). • Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).

Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting Since a defect of engine Ne speed sensor can be suspected, carry out Defective engine Ne 1 troubleshooting for the following code. speed sensor circuit [CA689] Since a defect of engine Bkup speed sensor can be suspected, carry out Defective engine Bkup 2 troubleshooting for the following code. speed sensor system [CA778]

Failure code [CB731] Eng Bkup Speed Sens Phase Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB731

Trouble

1

Eng Bkup Speed Sens Phase Error (Engine controller system)

• Abnormal phase has been detected in the engine Bkup sensor circuit. • Operates using engine Ne speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Ne speed sensor is defective at the same time). • Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).

Cause

Possible causes and standard value in normal state

PC2000-8

Standard value in normal state/Remarks on troubleshooting Since a defect of engine Ne speed sensor can be suspected, carry out Defective engine Ne 1 troubleshooting for the following code. speed sensor circuit [CB689] Since a defect of engine Bkup speed sensor can be suspected, carry out Defective engine Bkup 2 troubleshooting for the following code. speed sensor system [CB778]

27

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Failure code [CA757] All Persistent Data Lost Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Failure code CA757

Trouble

1

All Persistent Data Lost Error (Engine controller system)

• Loss of all data in engine controller has been detected. • Flashes warning lamp and turns on alarm buzzer. • The engine cannot be started, or cannot be operated.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting of [CA111].

Failure code [CB757] All Persistent Data Lost Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

28

Failure code CB757

Trouble

1

All Persistent Data Lost Error (Engine controller system)

• Loss of all data in engine controller has been detected. • Flashes warning lamp and turns on alarm buzzer. • The engine cannot be started, or cannot be operated.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting of [CB111].

PC2000-8

SEN02098-00

40 Troubleshooting

Failure code [CA778] Eng Bkup Speed Sensor Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA778

Trouble

1

Eng Bkup Speed Sensor Error (Engine controller system)

• Abnormal engine Bkup speed sensor signal has been detected. • Operates using Ne speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Ne speed sensor is defective at the same time). • Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).

Cause Defective sensor 1 power source circuit

2

3

Possible causes and standard value in normal state

4

5

6 7

30

Standard value in normal state/Remarks on troubleshooting If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between ENG (L) (female) (37) – Resistance Max. 1 z harness left G (female) (1) (disconnection or Wiring harness between ENG (L) (female) (47) – defective contact of Resistance Max. 1 z left G (female) (2) connectors) Wiring harness between ENG (L) (female) (26) – Resistance Max. 1 z left G (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between Resistance Min. 1 Mz Defective harness ENG (L) (female) (37) – left G (female) (1) grounding (contact Between ground and wiring harness between with ground circuit) Resistance Min. 1 Mz ENG (L) (female) (47) – left G (female) (2) Between ground and wiring harness between Resistance Min. 1 Mz ENG (L) (female) (26) – left G (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness from ENG (L) (female) (37) to left G (female) (1) and wiring harness Resistance Min. 1 Mz from ENG (L) (female) (47) to left G (female) (2) Harness short (Harness internal Between wiring harness from ENG (L) (female) short) (37) to left G (female) (1) and wiring harness Resistance Min. 1 Mz from ENG (L) (female) (26) to left G (female) (3) Between wiring harness from ENG (L) (female) (47) to left G (female) (2) and wiring harness Resistance Min. 1 Mz from ENG (L) (female) (26) to left G (female) (3) Defective mounting of Since defective mounting of Bkup speed sensor (improper gap) or defecsensor or defective tive parts for speed detection (in supply pump) can be suspected, directly parts for speed deteccheck it. tion Engine Bkup speed sensor can be suspected to be defective if no problem Defective engine Bkup is found in causes 1 – 5 (since this is an internal defect, it cannot be diagspeed sensor nosed). Defective engine Engine controller can be suspected to be defective if no problem is found controller in causes 1 – 6 (since this is an internal defect, it cannot be diagnosed).

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Circuit diagram related to engine Bkup speed sensor

PC2000-8

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Failure code [CB778] Eng Bkup Speed Sensor Error User code E15 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB778

Trouble

Eng Bkup Speed Sensor Error (Engine controller system)

• Engine Bkup speed sensor signal detected abnormality. • Operates with Ne speed sensor signal • Blinks warning lamp and sounds alarm buzzer. • If engine has been running, it stops (when Ne speed sensor is also defective). • If engine has been stopped, it cannot start (when Ne speed sensor is also defective).

Cause Defective sensor 1 power supply system Disconnection in wiring harness (Disconnec2 tion in wiring or defective contact in connector)

Ground fault in wiring 3 harness (Contact with GND circuit) Possible causes and standard value in normal state

Short circuit in wiring 4 harness (with another wiring harness)

Defective sensor 5 installation or defective speed sensing part Defective engine Bkup 6 speed sensor Defective engine 7 controller

32

1

Standard value in normal state/Remarks on troubleshooting If failure code [CB187] or [CB227] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (R) (female) (37) – Resistance Max. 1 z right G (female) (1) Wiring harness between ENG (R) (female) (47) – Resistance Max. 1 z right G (female) (2) Wiring harness between ENG (R) (female) (26) – Resistance Max. 1 z right G (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (R) (female) (37) – Resistance Min. 1 Mz right G (female) (1) Wiring harness between ENG (R) (female) (47) – Resistance Min. 1 Mz right G (female) (2) Wiring harness between ENG (R) (female) (26) – Resistance Min. 1 Mz right G (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between ENG (R) (female) (37) – right G (female) (1) and wiring Resistance Min. 1 Mz harness between ENG (R) (female) (47) – right G (female) (2) Between wiring harness between ENG (R) (female) (37) – right G (female) (1) and wiring Resistance Min. 1 Mz harness between ENG (R) (female) (26) – right G (female) (3) Between wiring harness between ENG (R) (female) (47) – right G (female) (2) and wiring Resistance Min. 1 Mz harness between ENG (R) (female) (26) – right G (female) (3) Bkup speed sensor may be installed defectively (improper clearance) or speed sensing part (in supply pump) may be defective. Check them directly. If causes 1 – 5 are not detected, engine Bkup speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

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Circuit diagram related to engine Bkup speed sensor

PC2000-8

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Failure code [CA781] CEN Communication Error User code E0E Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA781

Trouble

1

CEN Communication Error (Engine controller system)

• Communication error occurred between engine controllers (Left bank). • Blinks warning lamp and sounds alarm buzzer. • During operation: Engine continues operation with 1 bank. • When key is ON: Engine cannot be started.

Cause

Possible causes and standard value in normal state

34

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (DisconnecWiring harness between ENG (L) (female) (8) – 1 tion in wiring or defecResistance Max. 1 z ENG (R) (female) (8) tive contact in Wiring harness between ENG (L) (female) (6) – connector) Resistance Max. 1 z ENG (R) (female) (6) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (L) (female) (8) – 2 harness (Contact with Resistance Min. 1 Mz ENG (R) (female) (8) GND circuit) Wiring harness between ENG (L) (female) (6) – Resistance Min. 1 Mz ENG (R) (female) (6) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (L) (female) Resistance 3 controller Between (8) – (6) 108 – 132 z Between (8), (6) – ground Min. 1 Mz

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Circuit diagram related to communication between multiple controller

PC2000-8

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Failure code [CB781] CEN Communication Error User code E0E Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

36

Failure code CB781

Trouble

1

CEN Communication Error (Engine controller system)

• Communication error occurred between engine controllers (Right bank). • Blinks warning lamp and sounds alarm buzzer. • During operation: Engine continues operation with 1 bank. • When key is ON: Engine cannot be started.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA781].

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SEN02098-00

Failure code [CA1117] Persistent Data Lost Error Error code E10 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Failure code CA1117

Trouble Persistent Data Lost Error (LH bank) (Engine controller system)

• All data in engine controller are lost. • None in particular.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting [CA111].

Failure code [CB1117] Persistent Data Lost Error Error code E10 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

PC2000-8

1

Failure code CB1117

1

Trouble Persistent Data Lost Error (RH bank) (Engine controller system)

• All data in engine controller are lost. • None in particular.

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting [CB111].

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Failure code [CA1257] Harness Key Error User code E0E Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code CA1257

Trouble

1

Harness Key Error (Engine controller system)

• Controller of each bank disagrees with distinction wiring harness (Left bank). • Stops operation. • Blinks warning lamp and sounds alarm buzzer. • When key is ON: Engine cannot be started.

Cause Standard value in normal state/Remarks on troubleshooting Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without harness (Disconnecturning starting switch ON. 1 tion in wiring or defecWiring harness between CE02 (female) (7) – tive contact in Resistance Max. 1 z CE02 (female) (34) connector) Ground fault in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2 harness (Contact with GND circuit) Between CE02 (female) (8) – ground Resistance Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine 3 controller Between CE02 (female) (7) – ground Resistance Min. 1 Mz Between CE02 (female) (8) – ground Resistance Max. 1 z

Circuit diagram related to multicontroller distinction wiring harness key

38

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Failure code [CB1257] Harness Key Error User code E0E Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code CB1257

Trouble

1

Harness Key Error (Engine controller system)

• Controller of each bank disagrees with distinction wiring harness (Right bank). • Stops operation. • Blinks warning lamp and sounds alarm buzzer. • When key is ON: Engine cannot be started.

Cause Standard value in normal state/Remarks on troubleshooting Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without harness (Disconnecturning starting switch ON. 1 tion in wiring or defecWiring harness between CE05 (female) (7) – tive contact in Resistance Min. 1 Mz CE05 (female) (34) connector) Ground fault in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2 harness (Contact with GND circuit) Between CE05 (female) (8) – ground Resistance Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine 3 controller Between CE05 (female) (7) – ground Resistance Min. 1 Mz Between CE05 (female) (8) – ground Resistance Min. 1 Mz

Circuit diagram related to multicontroller distinction wiring harness key

PC2000-8

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Failure code [CB1548] Inj #7(R#1) Open/Short Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB1548

Trouble

1

Inj #7(R#1) Open/Short Error (Engine controller system)

• Disconnection or short circuit occurred in injector #7 circuit. • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Engine speed is unstable.

Cause

1

2

Possible causes and standard value in normal state

3

4

5

40

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #7 CN1 (male) Resistance (Internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (DisconnecWiring harness between ENG (R) (female) (45) – tion in wiring or defecResistance Max. 1 z CN1 (female) (1) tive contact in Wiring harness between ENG (R) (female) (53) – connector) Resistance Max. 1 z CN1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (R) (female) (45) – Resistance Min. 1 Mz harness (Contact with CN1 (female) (1) GND circuit) Wiring harness between ENG (R) (female) (53) – Resistance Min. 1 Mz CN1 (female) (2) Defective injector of another cylinder or If failure codes of 1 or more injectors are displayed, carry out troubleshootdefective wiring haring for them. ness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (R) (female) Resistance controller Between (45) – (53) 0.4 – 1.1 z Between (45), (53) – ground Min. 1 Mz

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SEN02098-00

Circuit diagram related to injector #7 (R/B #1)

PC2000-8

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Failure code [CB1549] Inj #8(R#2) Open/Short Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB1549

Trouble

1

Inj #8(R#2) Open/Short Error (Engine controller system)

• Disconnection or short circuit occurred in injector #8 circuit. • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Engine speed is unstable.

Cause

1

2

Possible causes and standard value in normal state

3

4

5

42

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #8 CN2 (male) Resistance (Internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (DisconnecWiring harness between ENG (R) (female) (54) – tion in wiring or defecResistance Max. 1 z CN2 (female) (1) tive contact in Wiring harness between ENG (R) (female) (51) – connector) Resistance Max. 1 z CN2 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (R) (female) (54) – Resistance Min. 1 Mz harness (Contact with CN2 (female) (1) GND circuit) Wiring harness between ENG (R) (female) (51) – Resistance Min. 1 Mz CN2 (female) (2) Defective injector of another cylinder or If failure codes of 1 or more injectors are displayed, carry out troubleshootdefective wiring haring for them. ness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (R) (female) Resistance controller Between (54) – (51) 0.4 – 1.1 z Between (54), (51) – ground Min. 1 Mz

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Circuit diagram related to injector #8 (R/B #2)

PC2000-8

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Failure code [CB1551] Inj #10(R#4) Open/Short Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB1551

Trouble

1

Inj #10(R#4) Open/Short Error (Engine controller system)

• Disconnection or short circuit occurred in injector #10 circuit. • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Engine speed is unstable.

Cause

1

2

Possible causes and standard value in normal state

3

4

5

44

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #10 CN4 (male) Resistance (Internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (DisconnecWiring harness between ENG (R) (female) (56) – tion in wiring or defecResistance Max. 1 z CN4 (female) (1) tive contact in Wiring harness between ENG (R) (female) (58) – connector) Resistance Max. 1 z CN4 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (R) (female) (56) – Resistance Min. 1 Mz harness (Contact with CN4 (female) (1) GND circuit) Wiring harness between ENG (R) (female) (58) – Resistance Min. 1 Mz CN4 (female) (2) Defective injector of another cylinder or If failure codes of 1 or more injectors are displayed, carry out troubleshootdefective wiring haring for them. ness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (R) (female) Resistance controller Between (56) – (58) 0.4 – 1.1 z Between (56), (58) – ground Min. 1 Mz

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Circuit diagram related to injector #10 (R/B #4)

PC2000-8

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Failure code [CB1552] Inj #11(R#5) Open/Short Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB1552

Trouble

1

Inj #11(R#5) Open/Short Error (Engine controller system)

• Disconnection or short circuit occurred in injector #11 circuit. • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Engine speed is unstable.

Cause

1

2

Possible causes and standard value in normal state

3

4

5

46

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #11 CN5 (male) Resistance (Internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (DisconnecWiring harness between ENG (R) (female) (46) – tion in wiring or defecResistance Max. 1 z CN5 (female) (1) tive contact in Wiring harness between ENG (R) (female) (60) – connector) Resistance Max. 1 z CN5 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (R) (female) (46) – Resistance Min. 1 Mz harness (Contact with CN5 (female) (1) GND circuit) Wiring harness between ENG (R) (female) (60) – Resistance Min. 1 Mz CN5 (female) (2) Defective injector of another cylinder or If failure codes of 1 or more injectors are displayed, carry out troubleshootdefective wiring haring for them. ness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (R) (female) Resistance controller Between (46) – (60) 0.4 – 1.1 z Between (46), (60) – ground Min. 1 Mz

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Circuit diagram related to injector #11 (R/B #5)

PC2000-8

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Failure code [CB1553] Inj #12(R#6) Open/Short Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB1553

Trouble

1

Inj #12(R#6) Open/Short Error (Engine controller system)

• Disconnection or short circuit occurred in injector #12 circuit. • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Engine speed is unstable.

Cause

1

2

Possible causes and standard value in normal state

3

4

5

48

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #12 CN6 (male) Resistance (Internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (DisconnecWiring harness between ENG (R) (female) (57) – tion in wiring or defecResistance Max. 1 z CN6 (female) (1) tive contact in Wiring harness between ENG (R) (female) (59) – connector) Resistance Max. 1 z CN6 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (R) (female) (57) – Resistance Min. 1 Mz harness (Contact with CN6 (female) (1) GND circuit) Wiring harness between ENG (R) (female) (59) – Resistance Min. 1 Mz CN6 (female) (2) Defective injector of another cylinder or If failure codes of 1 or more injectors are displayed, carry out troubleshootdefective wiring haring for them. ness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (R) (female) Resistance controller Between (57) – (59) 0.4 – 1.1 z Between (57), (59) – ground Min. 1 Mz

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Circuit diagram related to injector #12 (R/B #6)

PC2000-8

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Failure code [CB1622] Inj #9(R#3) Open/Short Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CB1622

Trouble

1

Inj #9(R#3) Open/Short Error (Engine controller system)

• Disconnection or short circuit occurred in injector #9 circuit. • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Engine speed is unstable.

Cause

1

2

Possible causes and standard value in normal state

3

4

5

50

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #9 CN3 (male) Resistance (Internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (DisconnecWiring harness between ENG (R) (female) (55) – tion in wiring or defecResistance Max. 1 z CN3 (female) (1) tive contact in Wiring harness between ENG (R) (female) (52) – connector) Resistance Max. 1 z CN3 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between ENG (R) (female) (55) – Resistance Min. 1 Mz harness (Contact with CN3 (female) (1) GND circuit) Wiring harness between ENG (R) (female) (52) – Resistance Min. 1 Mz CN3 (female) (2) Defective injector of another cylinder or If failure codes of 1 or more injectors are displayed, carry out troubleshootdefective wiring haring for them. ness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine ENG (R) (female) Resistance controller Between (55) – (52) 0.4 – 1.1 z Between (55), (52) – ground Min. 1 Mz

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Circuit diagram related to injector #9 (R/B #3)

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Failure code [CA1633] KOMNET Data link Time out Error User code E0E Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA1633

Trouble

1

KOMNET Data link Time out Error (Engine controller system)

• Abnormality occurred in KOMNET communication circuit to engine controller (Left bank). • Operates in default mode or holds the state set when error occurred. • Blinks warning lamp and sounds alarm buzzer. • Information may not be transmitted or received normally through KOMNET communication system and machine may not operate normally.

Cause

Possible causes and standard value in normal state

52

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between CE02 (female) (46) – Resistance Max. 1 z harness (DisconnecCE05 (female) (46) 1 tion in wiring or defecWiring harness between CE02 (female) (47) – tive contact in Resistance Max. 1 z CE05 (female) (47) connector) Wiring harness between CE02 (female) (46) – Resistance 54 – 66 z CE02 (female) (47) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between CE02 (female) (46) – 2 harness (Contact with Resistance Min. 1 Mz CE05 (female) (46) GND circuit) Wiring harness between CE02 (female) (47) – Resistance Min. 1 Mz CE05 (female) (47) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (46) – Defective engine Resistance 54 – 66 z 3 CE02 (female) (47) controller Wiring harness between CE05 (female) (46) – Resistance 54 – 66 z CE05 (female) (47)

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Circuit diagram related to KOMNET

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Failure code [CA2185] Throt Sens Sup Volt High Error User code E14 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA2185

Trouble

1

Throt Sens Sup Volt High Error (Engine controller system)

• High voltage (above 5.25 V) was detected in decelerator pedal sensor power supply circuit. • If trouble occurs while starting switch is ON, controller fixes sensor to value just before occurrence of abnormality and continues operation. • If starting switch is turned ON while there is trouble, controller operates at 100% value. • Blinks warning lamp and sounds alarm buzzer. • Engine speed cannot be controlled with decelerator pedal.

Cause

Possible causes and standard value in normal state

54

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective decelerator When device at right is 1 sensor (Internal defect) disconnected, if code Decelerator sensor DEC connector disappears, that device has trouble in it. a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (DisconnecWiring harness between CE02 (female) (22) – 2 tion in wiring or defecResistance Max. 1 z P20 (female) (1) tive contact in Wiring harness between CE02 (female) (23) – connector) Resistance Max. 1 z P20 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between CE02 (female) (22) – 3 harness (Contact with Resistance Min. 1 Mz P20 (female) (1) GND circuit) Wiring harness between CE02 (female) (23) – Resistance Min. 1 Mz P20 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring 4 harness (with another Between wiring harness between CE02 (female) 108 – wiring harness) (22) – P20 (female) (1) and wiring harness Resistance 132 z between CE02 (female) (23) – P20 (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine 5 controller CE02 Voltage Between (22) – (23) 4.75 – 5.25 V

PC2000-8

40 Troubleshooting

SEN02098-00

Circuit diagram related to decelerator pedal sensor power supply

PC2000-8

55

SEN02098-00

40 Troubleshooting

Failure code [CA2186] Throt Sens Sup Volt Low Error User code E14 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

56

Failure code CA2186

Trouble

1

Throt Sens Sup Volt Low Error (Engine controller system)

• Excessively low voltage is detected in the decelerator pedal sensor (5V) power source circuit. • Operates with the fixed value that is same as the value just before the abnormality is detected, if abnormality occurs with the starting switch in the ON position. • If the starting switch is turned to the ON position in as-is abnormal condition, the controller operates with 100% value. • Flashes warning lamp and turns on alarm buzzer. • Engine speed cannot be controlled by fuel dial.

Cause 1

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA2185].

PC2000-8

40 Troubleshooting

SEN02098-00

Failure code [CA2249] Rail Press Very Low Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Failure code CA2249

Trouble Rail Press Very Low Error (At left bank) (Engine controller system)

• Loss of pressure feed (level 2) occurred in the common rail circuit. • • • • • •

Operates with limited output. Flashes warning lamp and turns on alarm buzzer. Engine is hard to start. Exhaust gas color becomes black. Output decreases. Common rail pressure can be checked with the monitoring function. (Code: 36400 Common rail pressure) Cause

1

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting of [CA559].

Failure code [CB2249] Rail Press Very Low Error User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

PC2000-8

1

Failure code CB2249

1

Trouble Rail Press Very Low Error (At right bank) (Engine controller system)

• Loss of pressure feed (level 2) occurred in the common rail circuit. • • • • • •

Operates with limited output. Flashes warning lamp and turns on alarm buzzer. Engine is hard to start. Exhaust gas color becomes black. Output decreases. Common rail pressure can be checked with the monitoring function. (Code: 36400 Common rail pressure) Cause

1

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting of [CB559].

57

SEN02098-00

40 Troubleshooting

Failure code [CA2555] Grid Heater Relay Volt Low Error User code

Failure code

E15

CA2555

Contents of trouble Action of controller Problem that appears on machine

Trouble

1

Grid Heater Relay Volt Low Error (Engine controller system)

• Voltage low error was detected in grid heater relay circuit. • None in particular. • Engine does not start easily at low temperature.

Related information Possible causes and standard value in normal state

58

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA2556].

PC2000-8

SEN02098-00

40 Troubleshooting

Failure code [CA2556] Grid Heater Relay Volt High Error User code

Failure code

E15

CA2556

Contents of trouble Action of controller Problem that appears on machine

Trouble

1

Grid Heater Relay Volt High Error (Engine controller system)

• Open error was detected in intake air heater relay circuit • Stops driving auto-preheater relay R17. • Auto-preheater does not work (Manual preheater works). • Engine does not start easily at low temperature.

Related information Cause Defective grid heater 1 relay (Internal defect)

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R17 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness Wiring harness between CE02 (female) (40) – 2 (Disconnection in wirResistance Max. 1 z R17 (female) (1) ing or defective contact Wiring harness between CE02 (female) (42) – in connector) Resistance Max. 1 z R17 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between CE02 (female) (40) – harness 3 Resistance Min. 1 Mz (Short circuit with GND R17 (female) (1) and chassis ground circuit) Wiring harness between CE02 (female) (42) – Resistance Min. 1 Mz R17 (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4

Defective engine controller

CE02 Between (40) – (42)

60

Heater relay

Voltage

Operating condition

Max. 1 V

Stop condition

20 – 30 V

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40 Troubleshooting

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Circuit diagram related to engine preheater

PC2000-8

61

SEN02098-00

PC2000-8 Hydraulic excavator Form No. SEN02098-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

62

SEN02099-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

40 Troubleshooting

1

Troubleshooting by failure code, Part 4 Troubleshooting by failure code, Part 4 .......................................................................................................... 4 Failure code [D110KB] Battery Relay Drive S/C .................................................................................. 4 Failure code [D163KB] Flash Light Relay S/C ..................................................................................... 6 Failure code [D195KA] Step Light Relay Disc...................................................................................... 8 Failure code [D195KY] Step Light Relay S/C..................................................................................... 10 Failure code [D1E9KB] Wiper Drive Relay 1 S/C............................................................................... 12 Failure code [D1EAKB] Wiper Drive Relay 2 S/C .............................................................................. 14 Failure code [D1EBKB] Lower Wiper Brake Relay Short Circuit........................................................ 16 Failure code [D1ECKB] Upper Wiper Brake Relay Short Circuit ....................................................... 18 Failure code [DA22KK] Pump 1 Solenoid Power Low Error .............................................................. 20 Failure code [dA22KK] Pump 2 Solenoid Power Low Error ............................................................... 22 Failure code [DA25KP] Pump 1 Sens Supply Vol Low Error ............................................................. 24 Failure code [dA25KP] Pump 2 Sens Supply Vol Low Error .............................................................. 26 Failure code [DA26KP] 5V Sensor 2 Power Abnormality................................................................... 28 Failure code [DA29KQ] Pump 1 Model Select Abnormality ............................................................... 30 Failure code [dA29KQ] Pump 2 Model Select Abnormality................................................................ 32

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1

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40 Troubleshooting

Failure code [DA2RMC] CAN Discon (Pump 1 Con Detected) .......................................................... 34 Failure code [dA2RMC] CAN Discon (Pump 2 Con Detected)........................................................... 36 Failure code [DA2TMC] Pump Comm. ECM Child Abnormality......................................................... 38 Failure code [DBB0KK] VHMS Source Voltage Error (or change of VHMS-LED display from n9 to 01)..................................................................... 40 Failure code [DBB0KQ] VHMS Connector Mismatch (or change of VHMS-LED display from nf to 11) ...................................................................... 42 Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMS-LED display from n9 to 04)..................................................................... 44 Failure code [DBB6KP] VHMS 24V source sys Error (or change of VHMS-LED display from n9 to 02)..................................................................... 46 Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02) ........... 48 Failure code [DGE5KX] Ambient Air Temp Sensor Failure (or change of VHMS-LED display from n4 to 01)..................................................................... 50 Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C......................................................................... 52 Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMS-LED display from n5 to 01)..................................................................... 54

2

PC2000-8

SEN02099-00

40 Troubleshooting

Troubleshooting by failure code, Part 4

1

Failure code [D110KB] Battery Relay Drive S/C

1

User code

Failure code

— Contents of trouble

D110KB

Action of controller Problem that appears on machine Related information

Trouble

• Abnormal current flowed at output to battery relay drive circuit. • Turns output to battery relay drive circuit OFF. • If cause of failure disappears, system resets itself. • There may be a trouble in writing data into the ROM (non-volatile memory) of each controller. • Operating condition of battery relay (ON/OFF) can be checked with monitoring function. (Code 03703: Controller Output 4) Cause

1

Possible causes and standard value in normal state

Battery Relay Drive S/C (Pump controller 1 system)

Defective battery relay (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Battery relay (Unit) Between BR – E

Resistance Approx. 100z

Between BR – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between CP03 (female) (4) – harness 2 D05 – JB112 – battery relay terminal BR or (Short circuit with GND between CP03 (female) (4) – starting switch ter- Resistance Min. 1 Mz circuit) minal BR or between CP03 (female) (4) – D05 (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3

4

Defective pump controller 1

CP03

Turn starting switch OFF.

Voltage

Between (4) – chassis ground

ON o OFF

20 – 30 V (2 – 7 sec.)

PC2000-8

40 Troubleshooting

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Circuit diagram related to battery relay drive

PC2000-8

5

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40 Troubleshooting

Failure code [D163KB] Flash Light Relay S/C User code —

Failure code D163KB

Trouble

1

Flash Light Relay S/C (Pump controller 2 system)

Contents of trouble

• Abnormal current flowed in the flash light relay circuit (the primary circuit of the relay), when power is supplied to the circuit.

Action of controller

• The controller turns OFF the output to the coil circuit of the flash light relay. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.

Problem that appears on machine Related information

• The flash light does not flash. • Operation of the flash light relay circuit (the primary side of the relay) (ON or OFF) can be checked in the monitoring function. (Code No. 03701: Controller output 2) • This error code detects abnormality on the primary (coil) side of the flash light relay and cannot detect abnormality on the secondary (contact) side. Cause

Standard value in normal state/Remarks on troubleshooting

Flash light relay defec- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. tive 1 (Internal short-circuitR13 (male) Resistance ing) Between (1) – (2) 250 – 350 z Possible causes and standard value in normal state

Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ing harness 2 (Contact with ground- Between wiring harness between CP06 (female) Resistance Min. 1 Mz ing circuit) (8) and R13 (female) (1) and grounding a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3

Pump controller 2 defective

CP06

Horn switch

Between (8) – chassis ground

ON OFF

6

Voltage 20 – 30 V Max. 1 V (at constant cycle, 5 seconds) Max. 1 V

PC2000-8

40 Troubleshooting

SEN02099-00

Circuit diagram related to horn and flash light relay

PC2000-8

7

SEN02099-00

40 Troubleshooting

Failure code [D195KA] Step Light Relay Disc User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code D195KA

Trouble

• None in particular (Provides the error display alone). • Step light is not lighting up. • Operating condition of step light relay (ON/OFF) can be checked with monitoring function. (Monitoring code: 03701, controller output 2)

Defective step light 1 relay (Internal disconnection).

Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R07 (male)

Resistance value

Between (1) – (2) 250 – 350 z Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. harness (Disconnec2 tion or defective con- Wiring harness between CP05 (female) (8) – Resistance Max. 1 z tact in connector) R07 (female) (2) value a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. 3

8

Step Light Relay Disc (Pump controller system)

• Step light relay circuit power supply is low. • Error due to FB voltage remaining under 5.7 V for 3 sec continually when commanded for OFF.

Cause

Possible causes and standard value in normal state

1

Defective pump controller 2

CP05 Between (8) and chassis ground

Step light switch OFF

Voltage 20 – 30 V

ON

Max. 1 V (Kept for 60 sec)

PC2000-8

40 Troubleshooting

SEN02099-00

Circuit diagram related to step light relay

PC2000-8

9

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40 Troubleshooting

Failure code [D195KY] Step Light Relay S/C User code —

Failure code D195KY

Trouble

1

Step Light Relay S/C (Pump controller system)

Contents of trouble

• Abnormal current flowed in the step light relay circuit (the primary circuit of the relay), when power is supplied to the circuit.

Action of controller

• Power to the step light relay circuit is switched OFF. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.

Problem that appears on machine Related information

• Step light does not light up. • Operation of the step light relay circuit (the primary side of the relay) (ON or OFF) can be checked in the monitoring function. (Code No. 03701: Controller output 2) • This error code detects abnormality on the primary (coil) side of the step light relay and cannot detect abnormality on the secondary (contact) side. Cause Step light relay defec1 tive (Internal short-circuiting)

Possible causes and standard value in normal state

Between (1) – (2) 250 – 350 z a Prepare with starting switch OFF, then carry out troubleshooting without Grounding fault of wirturning starting switch ON. ing harness 2 (Contact with ground- Between wiring harness between CP05 (female) Resistance Above 1 ing circuit) (8) and R07 (female) (2) and grounding value Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3

10

Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R07 (male) Resistance value

Pump controller 2 defective

CP05 Between (8) – chassis ground

Horn switch OFF

Voltage 20 – 30 V

ON

Below 1 V (Kept for 60 sec)

PC2000-8

40 Troubleshooting

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Circuit diagram related to step light

PC2000-8

11

SEN02099-00

40 Troubleshooting

Failure code [D1E9KB] Wiper Drive Relay 1 S/C User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code D1E9KB

Trouble

1

Wiper Drive Relay 1 S/C (Pump controller system)

• Abnormal current flowed to the lower wiper drive relay output system. • Stops output. • Lower, upper wiper cannot work. • Lower wiper drive relay output (ON-OFF) can be checked with monitoring function. (Monitoring code: 03700, controller output 1) Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace with the relay. Lower wiper drive relay 1 Defective lower wiper (Internal defect) "E" disappears relay Turn the starting switch ON Defective lower wiper "E" does not disappear relay drive circuit a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 2 harness (Contact with Between wiring harness of CP06 (female) (26) – GND circuit) Resistance Min. 1 Mz lower wiper drive relay (SR3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective pump con3 troller 2 Wiper Between CP06 (female) (26) and chassis ground 20 – 30 V switch ON

Note: 1) If "E" disappeared from the error screen when above 1 and 2 are checked and if the wiper operation is not normal, adjust the lower wiper limit position. q Monitoring code: 02208 SWITCH INPUT 5 (LOWER WIPER LIMIT SWITCH: ON) 2) Lower wiper limit switch: Adjust the position to turn it ON. 3) If the switch does not turn ON at the storage position, replace the lower wiper.

12

PC2000-8

40 Troubleshooting

SEN02099-00

Circuit diagram related to lower wiper drive relay

PC2000-8

13

SEN02099-00

40 Troubleshooting

Failure code [D1EAKB] Wiper Drive Relay 2 S/C User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code D1EAKB

Trouble

1

Wiper Drive Relay 2 S/C (Pump controller 2 system)

• Abnormal current flowed to the upper wiper drive relay output system. • Stops output. • Both the upper and lower wiper cannot work. • Upper wiper drive relay output (ON-OFF) can be checked with monitoring function. (Monitoring code: 03700, controller output 1) Cause

Possible causes and standard value in normal state

14

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Upper wiper drive relay Replace with the relay. 1 (Internal defect) Normal state is recovered Defective upper wiper relay Defective upper wiper relay drive cirNormal state is not recovered cuit a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 2 harness (Contact with Between wiring harness of CP06 (female) (26) – GND circuit) upper wiper drive relay (SR3) and chassis Resistance Min. 1 Mz ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective pump con3 troller 2 Wiper Between CP06 (female) (6) and chassis ground 20 – 30 V switch ON

PC2000-8

40 Troubleshooting

SEN02099-00

Circuit diagram related to upper wiper drive relay

PC2000-8

15

SEN02099-00

40 Troubleshooting

Failure code [D1EBKB] Lower Wiper Brake Relay Short Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code D1EBKB

Trouble

Lower Wiper Brake Relay Short Circuit (Pump controller system)

• Abnormal current flowed to the lower wiper brake relay output system. • Stops output. • Lower wiper cannot work. • Lower wiper brake relay output (ON-OFF) can be checked with monitoring function. (Monitoring code: 03700, controller output 1) Cause

1

Possible causes and standard value in normal state

1

Lower wiper brake relay (internal defect)

Ground fault in wiring 2 harness (Contact with GND circuit)

3

Defective pump controller 2

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace with the relay. Defective lower wiper "E" disappears brake relay Turn the starting switch ON Defective lower wiper "E" does not disappear brake relay drive circuit a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness of CP06 (female) (36) – lower wiper drive brake (SR3) and chassis Resistance Min. 1 Mz ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. 2 sec. after Between CP06 (female) (36) and chassis ground wiper switch 20 – 30 V ON o OFF

Note: 1) If "E" disappeared from the error screen when above 1 and 2 are checked and if the wiper operation is not normal, adjust the lower wiper limit position. q Monitoring code: 02208 SWITCH INPUT 5 (LOWER WIPER LIMIT SWITCH: ON) 2) Lower wiper limit switch: Adjust the position to turn it ON. 3) If the switch does not turn ON at the storage position, replace the lower wiper.

16

PC2000-8

40 Troubleshooting

SEN02099-00

Circuit diagram related to lower wiper brake relay

PC2000-8

17

SEN02099-00

40 Troubleshooting

Failure code [D1ECKB] Upper Wiper Brake Relay Short Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code D1ECKB

Trouble

• Stops output. • Both the upper and lower wipers cannot work. • Upper wiper brake relay output (ON-OFF) can be checked with monitoring function. (Monitoring code: 03700, controller output 1)

1

Upper wiper brake relay (internal defect)

Ground fault in wiring 2 harness (Contact with GND circuit)

3

18

Upper Wiper Brake Relay Short Circuit (Pump controller system)

• Abnormal current flowed to the upper wiper brake relay output system.

Cause

Possible causes and standard value in normal state

1

Defective pump controller 2

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace with the relay. Normal state is recovered Defective upper wiper brake relay Defective upper wiper brake relay Normal state is not recovered drive circuit a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness of CP06 (female) (16) – upper wiper brake relay (SR3) and chassis Resistance Min. 1 Mz ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. 2 sec. after Between CP06 (female) (16) and chassis ground wiper switch 20 – 30 V ON o OFF

PC2000-8

40 Troubleshooting

SEN02099-00

Circuit diagram related to upper wiper brake relay

PC2000-8

19

SEN02099-00

40 Troubleshooting

Failure code [DA22KK] Pump 1 Solenoid Power Low Error User code

Failure code

E0E

DA22KK

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

Pump 1 Solenoid Power Low Error (Pump controller 1 system)

• Pump controller solenoid valve is below 20 V. • Limits engine speed to upper limit of 1,400 rpm. • If the solenoid supply voltage drops radically, the swing speed of work equipment and machine travel speed are substantially reduced. • Engine speed does not rise above 1,400 rpm. • If [D110KB] is displayed, carry out troubleshooting for it first. Cause 1

Standard value in normal state/Remarks on troubleshooting

Defective circuit a If circuit breaker B24 is turned OFF, circuit probably has ground fault breaker No. 2 or No. 6 etc. (See Cause 3.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state

Wiring harness between C03 (female) (1), (2), (12), (22) – A03 (male) (2)

Resistance

Max. 1 z

Wiring harness between A03 (female) (2), (4) – B28B

Resistance

Max. 1 z

Wiring harness between battery relay terminal M Resistance – B11

Max. 1 z

Wiring harness between starting switch terminal Resistance BR – battery relay terminal BR

Max. 1 z

Wiring harness between C03 (female) (21), (31), Resistance Min. 1 Mz (32), (33) – JB54 – ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 3 harness (Contact with GND circuit)

Wiring harness between C03 (female) (1), (2), (12), (22) – A03 (male) (2), (4)

Resistance Min. 1 Mz

Wiring harness between A03 (female) (2), (4) – B28B

Resistance Min. 1 Mz

Wiring harness between battery relay terminal M Resistance Min. 1 Mz – B28B Defective pump con4 troller 1

20

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C03 (1), (2), (12), (22) – (21), (31), (32), (33)

Voltage

20 – 30 V

PC2000-8

40 Troubleshooting

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Circuit diagram related to pump controller 1 power supply

PC2000-8

21

SEN02099-00

40 Troubleshooting

Failure code [dA22KK] Pump 2 Solenoid Power Low Error User code

Failure code

E0E

dA22KK

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

Pump 2 Solenoid Power Low Error (Pump controller 2 system)

• Pump controller solenoid valve is below 20 V. • Limits engine speed to upper limit of 1,400 rpm. • If the solenoid supply voltage drops radically, the swing speed of work equipment and machine travel speed is substantially reduced. • Engine speed does not rise above 1,400 rpm. • Swing brake cannot be released. • The machine deviates during travel. • If [D110KB] is displayed, carry out troubleshooting for it first.

1

Cause

Standard value in normal state/Remarks on troubleshooting

Defective circuit breaker B25 or B28

a If circuit breaker B25 or B28 is turned OFF, circuit probably has ground fault etc. (See Cause 3.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state

Wiring harness between CP06 (female) (2), (12), Resistance (22) – JC17 and JB52

Max. 1 z

Wiring harness between CP06 (female) (1), (11) Resistance – JB49 – B28

Max. 1 z

Wiring harness between battery relay terminal M Resistance – B11

Max. 1 z

Wiring harness between starting switch terminal Resistance BR – battery relay terminal BR

Max. 1 z

Wiring harness between CP06 (female) (21), (31), (32), (33) – ground

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 3 harness (Contact with GND circuit)

Wiring harness between CP06 (female) (2), (12), Resistance Min. 1 Mz (22) – JB17 and JB52 Wiring harness between CP06 (female) (1), (11) Resistance Min. 1 Mz – B28B Wiring harness between battery relay terminal M Resistance Min. 1 Mz – B11

4

22

Defective pump controller 2

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between CP06 (2), (12), (22) – (31), (32), (33)

Voltage

20 – 30 V

PC2000-8

40 Troubleshooting

SEN02099-00

Electric diagram related to pump controller power supply

PC2000-8

23

SEN02099-00

40 Troubleshooting

Failure code [DA25KP] Pump 1 Sens Supply Vol Low Error User code

Failure code

E07

DA25KP

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

Pump 1 Sens Supply Vol Low Error (Pump controller 1 system)

• Abnormal current flowed in pressure sensor power supply (5V) circuit. • Turns output to power supply (5V) circuit OFF. • If the trouble disappears over time, the output is restored but the failure code is held as is until the starting switch is turned on again. • • • •

Signal of pressure sensor is not input normally. Pressure sensor failure code is displayed at the same time. Travel and work equipment speeds are insufficient. Fine controllability turns bad.

• State of the input voltage from the pressure sensor can be checked with monitoring function. (Code: 01128 PIF, 01129 PIR, 01130 P2F, 01131 P2R, 01133 RAD, 01135 O/C, pressure sensor input voltage) Cause

Standard value in normal state/Remarks on troubleshooting a Disconnect connector with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective pressure 1 sensor (Internal short circuit)

P25 connector

VL2 – P2R pump pressure sensor

P26 connector

VR1 – P1F pressure sensor

P32 connector

VR2 – P2F pressure sensor

P33 connector

Fan pump (O/C) pressure sensor

P34 connector

Fan pump (RAD) pressure sensor

P35 connector

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Ground fault in wiring harness 2 (Short circuit with GND circuit)

24

Disconnect sensors at right in order. If no error code is displayed, that sensor is defective.

VL1 – P1R pressure sensor

Wiring harness between CP01 (female) (22) – JB116 – P25 (female) (3) and chassis ground [VL1 – P1R pump pressure sensor system]

Resistance Min. 1 Mz

Wiring harness between CP01 (female) (22) – JB116 – P26 (female) (3) and chassis ground [VL2 – P2R pump pressure sensor system]

Resistance Min. 1 Mz

Wiring harness between CP01 (female) (22) – JA116 – P32 (female) (3) and chassis ground [VR1 – P1F pressure sensor system]

Resistance Min. 1 Mz

Wiring harness between CP01 (female) (22) – JB116 – P33 (female) (3) and chassis ground [VR2 – P2F pressure sensor system]

Resistance Min. 1 Mz

Wiring harness between CP01 (female) (22) – JB116 – P34 (female) (3) and chassis ground [Fan pump (O/C) pressure sensor]

Resistance Min. 1 Mz

Wiring harness between CP01 (female) (22) – JB116 – P35 (female) (3) and chassis ground [Fan pump (RAD) pressure sensor system]

Resistance Min. 1 Mz

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Cause Possible causes and standard value in normal state

Defective pump con3 troller 1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CP01

Voltage

Between (22) – (21)

4.5 – 5.5 V

Circuit diagram related to pressure sensor power supply of pump controller 1

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Failure code [dA25KP] Pump 2 Sens Supply Vol Low Error User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code dA25KP

Trouble

Pump 2 Sens Supply Vol Low Error (Pump controller 2 system)

• Abnormal current flowed in pressure sensor power supply circuit. • Stops output to the power supply circuit. • If the trouble disappears over time, the output is restored but the failure code is held as is until the starting switch is turned on again. • Failure code of the pressure sensor abnormality is displayed at the same time. • Work equipment and travel speed is low. • Fine control performance is poor. • State of the input voltage from the pressure sensor can be checked with monitoring function. (Code: 07401 BOOM RAISE, 07501 BOOM LOWER, 07302 BUCKET CURL, 07303 BUCKET DUMP, 07601 ARM OUT, 07201 ARM IN, 09003 SWING LEFT, 09004 SWING RIGHT, 13901 AUTOMATIC LUBRICATION) Cause

Defective pressure 1 sensor (internal short circuit)

Possible causes and standard value in normal state

Ground fault in wiring 2 harness (Contact with GND circuit)

26

1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Boom raise pressure P01 connector sensor Boom lower pressure P02 connector sensor Bucket curling presP03 connector sure sensor Disconnect device sug- Bucket dumping pres- P04 connector gested on the right. At sure sensor this time, if failure code Arm OUT pressure senP05 connector is not indicated, the sor device is defective. Arm IN pressure sensor P06 connector Swing left pressure P07 connector sensor Swing right pressure P08 connector sensor Automatic lubrication P48 connector pressure sensor a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness of CP04 (female) (22) – Resistance Min. 1 Mz P01 (female) (3) and chassis ground Between wiring harness of CP04 (female) (22) – Resistance Min. 1 Mz P02 (female) (3) and chassis ground Between wiring harness of CP04 (female) (22) – Resistance Min. 1 Mz P03 (female) (3) and chassis ground Between wiring harness of CP04 (female) (22) – Resistance Min. 1 Mz P04 (female) (3) and chassis ground Between wiring harness of CP04 (female) (22) – Resistance Min. 1 Mz P05 (female) (3) and chassis ground Between wiring harness of CP04 (female) (22) – Resistance Min. 1 Mz P06 (female) (3) and chassis ground Between wiring harness of CP04 (female) (22) – Resistance Min. 1 Mz P07 (female) (3) and chassis ground Between wiring harness of CP04 (female) (22) – Resistance Min. 1 Mz P08 (female) (3) and chassis ground Between wiring harness of CP04 (female) (22) – Resistance Min. 1 Mz P48 (female) (3) and chassis ground

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Possible causes and standard value in normal state

SEN02099-00

Cause 3

Defective pump controller 2

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CP04 Voltage Between (22) and (21) 4.5 – 5.5 V

Circuit diagram related to pressure sensor power supply of pump controller 2

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Failure code [DA26KP] 5V Sensor 2 Power Abnormality User code E07 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DA26KP

Trouble

1

5V Sensor 2 Power Abnormality (Engine controller 1 system)

• Abnormal current flowed in pressure sensor power supply circuit. • Stops output to the power supply circuit. • If the trouble disappears over time, the output is restored but the failure code is held as is until the starting switch is turned on again. • Differential sensor is not working, disabling pump control. • Input state of pressure sensor can be checked with monitoring function. (Codes: 13808 VR1, 13809 VL1, 13810 VR2, 13811 VL2 and J/S differential pressure) Cause

Possible causes and standard value in normal state

28

Standard value in normal state/Remarks on troubleshooting a Disconnect connector with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (VR1 and P1F) J/S differential pressure sen- P36 connector sor (VL1 and P1R) J/S difDefective J/S differen- Disconnect device sugferential pressure sen- P27 connector 1 tial pressure sensor gested on the right. At sor (internal short circuit) this time, if failure code (VR2 and P2F) J/S difis not indicated, the ferential pressure sen- P37 connector device is defective. sor (VL2 and P2R) J/S differential pressure sen- P28 connector sor a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness of CP03 (female) (34) – Resistance Min. 1 Mz P36 (female) (1) and chassis ground Ground fault in wiring Between wiring harness of CP03 (female) (34) – 2 harness (Contact with Resistance Min. 1 Mz P27 (female) (1) and chassis ground GND circuit) Between wiring harness of CP03 (female) (34) – Resistance Min. 1 Mz P37 (female) (1) and chassis ground Between wiring harness of CP03 (female) (34) – Resistance Min. 1 Mz P28 (female) (1) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective pump con3 troller 1 CP03 Voltage Between (34) and CP01 (21) 4.5 – 5.5 V

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Circuit diagram related to pressure sensor power supply of pump controller 2

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Failure code [DA29KQ] Pump 1 Model Select Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

• • • •

1

Failure code Pump 1 Model Select Abnormality Trouble (Pump controller 1 system) DA29KQ Model code signal for other model than registered in the controller is input. When key is ON, a state continued for over 5 sec where model selection input was for other model than registered or the model selection input state changed while operating. If it is abnormal upon key ON, the controller performs as pump controller 1. When abnormality occurs after key is turned OFF, model information at key-ON time will be retained.

• It does not work when optional model is selected. • If the pump controller is misidentified as 2nd controller, it cannot be controlled. • Input state of model selection code can be checked with monitoring function. (Monitoring code: 00200 name of selected model, 02209 switch input 6, model selection 1: ON) Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (Disconnec1 tion or defective con- Wiring harness between CP02 (female) (37) – Min. 1 Mz JC8 – A03 (19) – JB54 – A24 and chassis Resistance tact in connector) Max. 1 z ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. CP02 Voltage Defective pump con2 troller 1 Between (7) or (17) and chassis 20 – 30 V ground Between (37) and chassis ground Max. 1 V

Note: Machine select 1: CP02 (37), Machine select 2: The input voltage depends the specification except CP02 (27). (CP02 (37) when normal: Input ON "Voltage 1 V maximum", CP02 (27): Input OFF "Voltage 5 V minimum")

30

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Circuit diagram related to model select (pump controller 1)

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Failure code [dA29KQ] Pump 2 Model Select Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

• • • •

1

Failure code Pump 2 Model Select Abnormality Trouble (Pump controller 2 system) dA29KQ Model code signal for other model than registered in the controller is input. When key is ON, a state continued for over 5 sec where model selection input was for other model than registered or the model selection input state changed while operating. If it is abnormal upon key ON, the controller performs as pump controller 1. When abnormality occurs after key is turned OFF, model information at key-ON time will be retained.

• It does not work when optional model is selected. • If the pump controller is misidentified as 1st controller, the ON/OFF valve cannot be controlled. • Input state of model selection can be checked with monitoring function. (Monitoring code: 02205 switch input 2, model selection 2: ON) Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (Disconnec1 tion or defective con- Wiring harness between CP05 (female) (27) – JC13 – A03 (26) – JB56 – A24 (1) and chassis Resistance Max. 1 z tact in connector) ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. CP05 Voltage Defective pump con2 troller 2 Between (7) or (17) and chassis 20 – 30 V ground Between (37) and chassis ground Max. 1 V

Note: Machine select 1: CP05 (37), Machine select 2: The input voltage depends the specification except CP05 (27). (CP05 (37) when normal: Input OFF "Voltage 5 V minimum", CP05 (27): Input ON "Voltage 1 V maximum")

32

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Circuit diagram related to model select (pump controller 2)

PC2000-8

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Failure code [DA2RMC] CAN Discon (Pump 1 Con Detected) User code E0E Contents of trouble Action of controller Problem that appears on machine

1

Failure code CAN Discon (Pump 1 Con Detected) Trouble (Pump controller 1, 2 system) DA2RMC • Pump controller 1 detected communication error in CAN communication circuit between machine monitor, pump controller 2 and engine controller. • The fan speed is set to the maximum. • Engine speed cannot be controlled. • Overheated water temperature judgment is failed. • The fan speed is set to the maximum, while work equipment, swing and machine travel speed are decreased.

Related information Cause

Possible causes and standard value in normal state

34

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between CM02 (female) (10) – harness (DisconnecCE02, CE05 (female) (47) – CP02, CP05 Resistance Max. 1 z 1 tion or defective con- (female) (22) – VH04 (female) (12) tact in connector) Wiring harness between CM02 (female) (8), (9) – CE02 – CE05 (female) (46) – CP02, CP05 Resistance Max. 1 z (female) (32) – VH04 (female) (4), (6), (14) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CM02 (female) (10) – CE02, CE05 (female) (47) – CP02, CP05 Resistance Min. 1 Mz Ground fault in wiring (female) (22) – VH04 (female) (12), and chassis 2 harness (Contact with ground GND circuit) Wiring harness between CM02 (female) (8), (9) – CE02, CE05 (female) (46) – CP02, CP05 Resistance Min. 1 Mz (female) (32) – VH04 (female) (4), (6), (14), and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (10) – CE02, CE05 (female) (47) – CP02, CP05 Hot short in wiring harVoltage Max. 1 V (female) (22) – VH04 (female) (12), and chassis 3 ness (Contact with 24 ground V circuit) Wiring harness between CM02 (female) (8), (9) – CE02, CE05 (female) (46) – CP02, CP05 Voltage Max. 1 V (female) (32) – VH04 (female) (4), (6), (14), and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN termi4 nal resistance K01 (male), K03 (male) Resistance Between (A) and (B) 120 z ± 10 % Defective machine If causes 1 to 4 are not detected, machine monitor, engine controller, or monitor, engine con5 pump controller may be defective. (Troubleshooting cannot be carried out troller, or pump controlsince trouble is in the system.) ler 1 and 2

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Circuit diagram related to CAN communication (pump controller 1)

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Failure code [dA2RMC] CAN Discon (Pump 2 Con Detected) User code E0E Contents of trouble Action of controller Problem that appears on machine Related information

1

Failure code CAN Discon (Pump 2 Con Detected) Trouble (Pump controller 1, 2 system) dA2RMC • Pump controller 2 detected communication error in CAN communication circuit between machine monitor, pump controller 1 and engine controller. • None in particular (Provides the error display alone) • Control data cannot be sent.

Cause

Possible causes and standard value in normal state

36

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CM02 (female) (10) – Disconnection in wiring CE02, CE05 (female) (47) – CP02, CP05 Resistance Max. 1 z harness (Disconnec1 (female) (22) – VH04 (female) (12) tion or defective conWiring harness between CM02 (female) (8), (9) – tact in connector) CE02, CE05 (female) (46) – CP02, CP05 Resistance Max. 1 z (female) (32) – VH04 (female) (4), (6), (14), and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CM02 (female) (10) – CE02, CE05 (female) (47) – CP02, CP05 Resistance Min. 1 Mz Ground fault in wiring (female) (22) – VH04 (female) (12) and chassis 2 harness (Contact with ground GND circuit) Wiring harness between CM02 (female) (8), (9) – CE02, CE05 (female) (46) – CP02, CP05 Resistance Min. 1 Mz (female) (32) – VH04 (female) (4), (6), (14), and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (10) – CE02, CE05 (female) (47) – CP02, CP05 Hot short in wiring harVoltage Max. 1 V (female) (22) – VH04 (female) (12), and chassis 3 ness (Contact with 24 ground V circuit) Wiring harness between CM02 (female) (8), (9) – CE02, CE05 (female) (46) – CP02, CP05 Voltage Max. 1 V (female) (32) – VH04 (female) (4), (6), (14), and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN termi4 nal resistance K03, K01 (male) Resistance Between (A) and (B) 120 z ± 10 % Defective pump conIf causes 1 – 4 are not detected, engine controller may be defective. 5 troller 1 and 2 (Troubleshooting cannot be carried out since trouble is in system.)

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Circuit diagram related to CAN communication (pump controller 2)

PC2000-8

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Failure code [DA2TMC] Pump Comm. ECM Child Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

1

Failure code Pump Comm. ECM Child Abnormality Trouble (Engine controller system) DA2TMC • There is error in KOMNET communication circuits with pump controller 1 and engine controller child. • None in particular (Provides the error display alone). • Error from the engine Child system cannot be detected.

Cause

Possible causes and standard value in normal state

38

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between CM02 (female) (10) – harness (DisconnecCE02, CE05 (female) (47) – CP02, CP05 Resistance Max. 1 z 1 tion or defective con- (female) (22) – VH04 (female) (12) tact in connector) Wiring harness between CM02 (female) (8), (9) – CE02, CE05 (female) (46) – CP02, CP05 Resistance Max. 1 z (female) (32) – VH04 female) (4), (6), (14) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CM02 (female) (10) – CE02, CE05 (female) (47) – CP02, CP05 Ground fault in wiring Resistance Min. 1 Mz (female) (22) – VH04 (female) (12), and chassis 2 harness (Contact with ground GND circuit) Wiring harness between CM02 (female) (8), (9) – CE02, CE05 (female) (46) – CP02, CP05 Resistance Min. 1 Mz (female) (32) – VH04 (female) (4), (6), (14), and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (10) – CE02, CE05 (female) (47) – CP02, CP05 Hot short in wiring harVoltage Max. 1 V (female) (22) – VH04 (female) (12), and chassis 3 ness (Contact with 24 ground V circuit) Wiring harness between CM02 (female) (8), (9) – CE02, CE05 (female) (46) – CP02, CP05 Voltage Max. 1 V (female) (32) – VH04 (female) (4), (6), (14), and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN termi4 nal resistance K01, K03 K03 Resistance Between (A) and (B) Between (A) and (B) 120 z ± 10 % Defective machine monitor, engine conIf causes 1 – 4 are not detected, engine controller may be defective. 5 troller or pump control- (Troubleshooting cannot be carried out since trouble is in system.) ler 1

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Circuit diagram related to KOMNET communication

PC2000-8

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Failure code [DBB0KK] VHMS Source Voltage Error (or change of VHMS-LED display from n9 to 01) User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DBB0KK

Trouble

1

VHMS Source Voltage Error (VHMS controller system)

• While engine is running, VHMS controller switch supply voltage is below 19.5 V. • None in particular. • The system may not work normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n9 o 01 (codes are displayed by 2 digits) Cause Defective circuit 1 breaker

Possible causes and standard value in normal state

40

Standard value in normal state/Remarks on troubleshooting If circuit breaker is shut down, the circuit probably has a ground fault. (See Cause 3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (DisconnecWiring harness between CV01 (female) (8), (9) 2 Resistance Max. 1 z tion or defective con- and battery relay (M) terminal tact in connector) Between CV01 (female) (19), (20) and chassis Resistance Max. 1 z ground a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 3 harness (Contact with Between wiring harness of CV01 (female) (8), (9) GND circuit) Resistance Min. 1 Mz – battery relay (M) terminal and chassis ground a Prepare with starting switch OFF, then turn starting switch START and carry out troubleshooting. Defective VHMS 4 controller CV01 Voltage Between (8), (9) and (19), (20) 20 – 30 V

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Circuit diagram related to VHMS controller

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Failure code [DBB0KQ] VHMS Connector Mismatch (or change of VHMS-LED display from nF to 11) User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DBB0KQ

Trouble

1

Defective VHMS controller connection (VHMS controller system)

• Improper connection of VHMS controller connectors CV02A, CV02B, CV03A and CV03B • None in particular. • Data being downloaded to PC is not displayed normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: nF o 11 (codes are displayed by 2 digits) Cause

Possible causes and standard value in normal state

42

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Check the VHMS controller connectors CV02A and CV03A or CV02B and Improper connector 1 CV03B for improper connection. connection a For the connecting positions of the connectors to the VHMS controller, refer to Testing and adjusting, Part 4, "Preparation work for troubleshooting of electrical system." a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between CV02A (female) (9) – harness (DisconnecJB67 – JB18 – A24 – Battery (–) terminal and Resistance Max. 1 z 2 tion or defective chassis ground (power container) contact in connector) Wiring harness between CV02B (female) (12) – JB67 – JB18 – A24 – Battery (–) terminal and Resistance Max. 1 z chassis ground (power container) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between CV02A (9) – (13) Voltage Max. 1 V Between CV02B (12) – (9) Voltage Max. 1 V Defective VHMS 3 controller Between CV03A (9) – (13) Voltage 20 – 30 V Between CV03B (12) – (9) Voltage 20 – 30 V If the above 1 and 2 are normal, VHMS controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

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Circuit diagram related to VHMS controller

PC2000-8

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Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMSLED display from n9 to 04) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DBB5KP

Trouble

VHMS 5V source sys Error (VHMS controller system)

• The sensor supply voltage is out of the normal range (4.5 – 5.5 V). • None in particular. • The sensor value may not be displayed normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n9 o 04 (codes are displayed by 2 digits) Cause

Possible causes and standard value in normal state

44

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between CV01 (female) (5) – Resistance Max. 1 z ENBP (female) (B) harness (Disconnec1 tion or defective con- Wiring harness between CV02A (female) (13) – Resistance Max. 1 z tact in connector) ENBP (female) (A) Wiring harness between CV02A (female) (18) – Resistance Max. 1 z ENBP (female) (C) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness of CV01 (female) (5) – Resistance Min. 1 Mz Ground fault in wiring ENBP (female) (B) and chassis ground 2 harness (Contact with Between wiring harness of CV01 (female) (13) – GND circuit) Resistance Min. 1 Mz ENBP (female) (A) and chassis ground Between wiring harness of CV01 (female) (18) – Resistance Min. 1 Mz ENBP (female) (C) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective VHMS 3 controller CV01, CV02A Voltage Between CV01 (5) and CV02A (13) 4.5 – 5.5 V

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Circuit diagram related to VHMS controller sensor 5V power source

PC2000-8

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Failure code [DBB6KP] VHMS 24V source sys Error (or change of VHMS-LED display from n9 to 02) User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DBB6KP

Trouble

1

VHMS 24V source sys Error (VHMS controller system)

• The sensor supply voltage is out of the normal range (20 – 30 V). • None in particular. • The sensor value may not be displayed normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n9 o 02 (codes are displayed by 2 digits) Cause

Possible causes and standard value in normal state

46

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CV01 (female) (2) – Resistance Max. 1 z Disconnection in wiring P41A (female) (A) harness (DisconnecWiring harness between CV01 (female) (2) – 1 Resistance Max. 1 z tion or defective con- P41B (female) (A) tact in connector) Wiring harness between CV01 (female) (2) – Resistance Max. 1 z P41C (female) (A) Wiring harness between CV01 (female) (2) – Resistance Max. 1 z P41D (female) (A) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness of CV01 (female) (2) – Resistance Min. 1 Mz P41A (female) (A) and chassis ground Ground fault in wiring Between wiring harness of CV01 (female) (2) – 2 harness (Contact with Resistance Min. 1 Mz P41B (female) (A) and chassis ground GND circuit) Between wiring harness of CV01 (female) (2) – Resistance Min. 1 Mz P41C (female) (A) and chassis ground Between wiring harness of CV01 (female) (2) – Resistance Min. 1 Mz P41D (female) (A) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective VHMS 3 controller CV01, CV02A Voltage Between CV01 (2) and CV02 (13) 20 – 30 V

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Circuit diagram related to VHMS controller sensor 24V power source

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Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02) User code — Contents of trouble Action of controller Problem that appears on machine Related information

1

Failure code KOM-NET/c error Trouble (VHMS controller system) DBBQKR • Communication (CANNET) information from engine controller, pump controller and machine monitor cannot be received. • The state of error occurred is held. • VHMS function fails to collect information from respective controllers. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n8 o 02 (codes are displayed by 2 digits) • If failure codes [CA1633], [DA2RMC] and [DAFRMC] are indicated, carry out troubleshooting for those codes first. Cause

Possible causes and standard value in normal state

48

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between CM02 (female) (10) – harness (DisconnecCE02, CE05 (female) (47) – CP02, CP05 Resistance Max. 1 z 1 tion or defective con- (female) (22) – VH04 (female) (12) tact in connector) Wiring harness between CM02 (female) (8), (9) – CE02, CE05 (female) (46) – CP02, CP05 Resistance Max. 1 z (female) (32) – VH04 (female) (4), (6), (14) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CM02 (female) (10) – CE02, CE05 (female) (47) – CP02, CP05 Ground fault in wiring Resistance Min. 1 Mz (female) (22) – VH04 (female) (12), and chassis 2 harness (Contact with ground GND circuit) Wiring harness between CM02 (female) (8), (9) – CE02, CE05 (female) (46) – CP02, CP05 Resistance Min. 1 Mz (female) (32) – VH04 (female) (4), (6), (14), and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (10) – CE02, CE05 (female) (47) – CP02, CP05 Hot short in wiring harVoltage Max. 1 V (female) (22) – VH04 (female) (12), and chassis 3 ness (Contact with 24 ground V circuit) Between wiring harness between CM02 (female) (8), (9) – CE02, CE05 (female) (46) – CP02, Voltage Max. 1 V CP05 (female) (32) – VH04 (female) (4), (6), (14), and chassis ground 1) Turn the starting switch OFF. 2) Replace VHMS controller 3) Turn starting switch ON. Defective VHMS 4 Defective VHMS controller Normal controller Communication normal? VHMS controller is Abnormal normal

PC2000-8

40 Troubleshooting

SEN02099-00

Circuit diagram related to CAN communication

PC2000-8

49

SEN02099-00

40 Troubleshooting

Failure code [DGE5KX] Ambient Air Temp Sensor Failure (or change of VHMS-LED display from n4 to 01) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DGE5KX

Trouble

Ambient Air Temp Sensor Failure (VHMS controller system)

• Input signal from the sensor is below 0.3 V. • None in particular. • • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n4 o 01 (codes are displayed by 2 digits) Cause

Possible causes and standard value in normal state

50

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Defective atmospheric turning starting switch ON. temperature sensor 1 Atmospheric (Internal disconnecP29 (male) Resistance temperature tion or short circuit) Between (1) and (2) 20°C 4 – 6 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between CV02A (female) (10) – harness (DisconnecResistance Max. 1 z 2 tion or defective con- P29 (female) (1) tact in connector) Wiring harness between CV02A (female) (12) – Resistance Max. 1 z P29 (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Ground fault in wiring Between wiring harness of CV02A (female) (10) Resistance Min. 1 Mz 3 harness (Contact with – P29 (female) (1) and chassis ground GND circuit) Between wiring harness of CV02A (female) (12) Resistance Min. 1 Mz – P29 (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness of CV02A (female) (10) 4 ness (Contact with 24 Voltage Max. 1 V – P29 (female) (1) and chassis ground V circuit) Between wiring harness of CV02A (female) (12) Voltage Max. 1 V – P29 (female) (2) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective VHMS Atmospheric 5 CV02A Resistance controller temperature Between (10) and (12) 20°C 4 – 6 kz

PC2000-8

40 Troubleshooting

SEN02099-00

Circuit diagram related to ambient air temperature sensor

PC2000-8

51

SEN02099-00

40 Troubleshooting

Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DGH2KB

Trouble

• The fan speed is set to the maximum. • If the machine is used as it is, the hydraulic equipment may be damaged. • Input from the hydraulic oil temperature sensor can be checked in the monitoring function. (Code No. 04401: Hydraulic oil temperature, 04403: Hydraulic oil temperature sensor voltage

Hydraulic oil temperature sensor defective 1 (Internal short-circuiting)

52

Hydr. Oil Temp. Sensor S/C (Pump controller 2 system)

• The input voltage from the temperature sensor remained at 0.3 V or below for 5 seconds or more.

Cause

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P22 (male)

Hydraulic oil temperature

Between (1) – (2) Between (1) – chassis ground

Resistance 90 – 3.5 kz

10 – 100°C

Min. 1 Mz

Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ing harness 2 (Contact with ground- Between wiring harness between CP04 (female) Resistance Min. 1 Mz ing circuit) (4) – P22 (female) (2) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Hydraulic oil temperaCP04 (female) Resistance Pump controller 2 ture 3 defective Between (4) – (9) 90 – 3.5 kz 10 – 100°C Between (4) – Min. 1 Mz chassis ground

PC2000-8

40 Troubleshooting

SEN02099-00

Circuit diagram related to hydraulic oil temperature sensor

PC2000-8

53

SEN02099-00

40 Troubleshooting

Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMSLED display from n5 to 01) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DGT3KZ

Trouble

• Signal voltage from PTO oil temperature sensor is below 0.3V. • None in particular. • The snapshot data downloaded to the PC is not displayed normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n5 o 01 (codes are displayed by 2 digits) • PTO oil temperature can be checked by downloading data to PC after the snapshot. Cause Defective PTO oil temperature sensor (inter1 nal disconnection or short circuit)

Disconnection in wiring harness (Disconnec2 tion or defective contact in connector) Possible causes and standard value in normal state

Ground fault in wiring 3 harness (Contact with GND circuit) Hot short in wiring har4 ness (Contact with 24 V circuit)

5

54

PTO Temp Sensor Failure (VHMS controller system)

Defective VHMS controller

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P19 (male) Oil temperature Resistance 25°C 46 – 59 kz Between (1) and (2) 100°C 3.6 – 4.0 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CV02A (female) (2) – Resistance Max. 1 z P19 (female) (1) Wiring harness between CV02A (female) (12) – Resistance Max. 1 z P19 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness of CV02A (female) (2) – Resistance Min. 1 Mz P19 (female) (1) and chassis ground a Prepare with starting switch OFF, then turn it ON and carry out troubleshooting. Between wiring harness of CV02A (female) (2) – Voltage Max. 5 V P19 (female) (1) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CV02A (female) Oil temperature Resistance 25°C 46 – 59 kz Between (2) and (12) 100°C 3.6 – 4.0 kz Between (2) and chas— Min. 1 Mz sis ground

PC2000-8

40 Troubleshooting

SEN02099-00

Circuit diagram related to PTO oil temperature sensor

PC2000-8

55

SEN02099-00

PC2000-8 Hydraulic excavator Form No. SEN02099-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

56

SEN02100-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

40 Troubleshooting

1

Troubleshooting by failure code, Part 5 Troubleshooting by failure code, Part 5 .......................................................................................................... 4 Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 12)....................................................................... 4 Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 22)....................................................................... 6 Failure code [DGT5KB] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 11) ....................................................................... 8 Failure code [dGT5KB] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 21)..................................................................... 10 Failure code [DGT6KA] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 24).................................................................... 12 Failure code [dGT6KA] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26)..................................................................... 14 Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 23)..................................................................... 16

PC2000-8

1

SEN02100-00

40 Troubleshooting

Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26)..................................................................... 18 Failure code [DH25KX] VR1/P1F J/S Dif Press Sensor Abnormality................................................. 20 Failure code [DH26KX] VL1/P1R J/S Dif Press Sensor Abnormality ................................................. 22 Failure code [DH27KX] VR2/P2F J/S Dif Press Sensor Abnormality................................................. 24 Failure code [DH28KX] VL2/P2R J/S Dif Press Sensor Abnormality ................................................. 26 Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 32)..................................................................... 28 Failure code [DHE5KY] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 31)..................................................................... 30 Failure code [DHH2KA] Hydraulic oil filter Sensor Failure (or change of VHMS-LED display from n5 to 53)..................................................................... 32 Failure code [DHPEKX] VR1/P1F Pump P. Sensor Abnormality ....................................................... 34 Failure code [DHPFKX] VL1/P1R Pump P. Sensor Abnormality ........................................................ 36 Failure code [DHPGKX] VR2/P2F Pump P. Sensor Abnormality ....................................................... 38 Failure code [DHPHKX] VL2/P2R Pump P. Sensor Abnormality ....................................................... 40 Failure code [DHPSKX] Auto Grease Press Sensor Abnormality ...................................................... 42 Failure code [DHPTKX] Fan(RAD) Pump P. Sensor Open Circuit ..................................................... 44 Failure code [DHPUKX] Fan(O/C) Pump P. Sensor Open Circuit ...................................................... 46 Failure code [DHS3KX] Arm Dig PPC Press Sensor Abnormality ..................................................... 48 Failure code [DHS4KX] Bucket Curl PPC Press Sensor Abnormality................................................ 50 Failure code [DHS8KX] Boom Raise PPC Press Sensor Abnormality............................................... 52 Failure code [DHS9KX] Boom Lower PPC Press Sensor Abnormality .............................................. 54 Failure code [DHSAKX] Swing Right PPC Press Sensor Abnormality............................................... 56 Failure code [DHSBKX] Swing Left PPC Press Sensor Abnormality ................................................. 58 Failure code [DHSCKX] Arm Dump PPC Press Sensor Abnormality ................................................ 60 Failure code [DHSDKX] Bucket Dump PPC Press Sensor Abnormality ............................................ 62

2

PC2000-8

SEN02100-00

40 Troubleshooting

Troubleshooting by failure code, Part 5

1

Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 12) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

4

Failure code DGT5KA

Trouble

Exhaust Temp. Sensor LBF Failure (VHMS controller system)

• Exhaust gas temperature sensor (LB/F) signal voltage is below 0.5 V. • None in particular. • The snapshot data downloaded to the PC is not displayed normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n3 o 12 (codes are displayed by 2 digits) • Exhaust gas temperature can be checked by downloading data to PC after the snapshot. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor 24 V If failure code [DBB6KP] is displayed, carry out the troubleshooting first as 1 power supply system stated. a Prepare with starting switch OFF, then start engine and carry out trouDefective exhaust gas bleshooting. temperature sensor 2 Switch between the rear and front exhaust gas (LB/F) (Internal disconVH16 connector temperature sensor connectors. If no error code nection) VH17 connector is displayed, that sensor is normal. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas P41A Voltage temperature Defective amplifier for (A) – (C) All temperature range 20 – 30 V exhaust gas tempera3 ture sensor (LB/F) 20°C Approx. 0.9 – 1.2 V (B) – (C) (Internal defect) 500°C Approx. 2.6 – 3.5 V Amplifier voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness or controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between P42A (male) (1) – VH16 Resistance Max. 1 z Disconnection in wiring (female) (1) harness (DisconnecWiring harness between P42A (male) (2) – VH16 4 Resistance Max. 1 z tion or defective con- (female) (2) tact in connector) Wiring harness between CV01 (female) (2) – Resistance Max. 1 z P41A (female) (A) Wiring harness between CV02A (female) (5) – Resistance Max. 1 z P41A (female) (B) a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 5 harness (Contact with Between wiring harness CV02A (female) (5) – GND circuit) Resistance Min. 1 Mz P41A (female) (B) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas Defective VHMS CV02A Voltage 6 temperature controller 20°C Approx. 0.9 – 1.2 V Between (5) and (13) 500°C Approx. 2.6 – 3.5 V

PC2000-8

40 Troubleshooting

SEN02100-00

Circuit diagram related to exhaust temperature sensor

PC2000-8

5

SEN02100-00

40 Troubleshooting

Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 22) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

6

Failure code dGT5KA

Trouble

Exhaust Temp. Sensor LBR Failure (VHMS controller system)

• Exhaust gas temperature sensor (LB/R) signal voltage is below 0.5 V. • None in particular. • The snapshot data downloaded to the PC is not displayed normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n3 o 22 (codes are displayed by 2 digits) • Exhaust gas temperature can be checked by downloading data to PC after the snapshot. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor 24 V If failure code [DBB6KP] is displayed, carry out the troubleshooting first as 1 power supply system stated. a Prepare with starting switch OFF, then start engine and carry out trouDefective exhaust gas bleshooting. temperature sensor 2 Switch between the rear and front exhaust gas (LB/R) (Internal disVH16 connector temperature sensor connectors. If no error code connection) VH17 connector is displayed, that sensor is normal. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas P41B Voltage temperature Defective amplifier for (A) – (C) All temperature range 20 – 30 V exhaust gas tempera3 ture sensor (LB/R) 20°C Approx. 0.9 – 1.2 V (B) – (C) (Internal defect) 500°C Approx. 2.6 – 3.5 V Amplifier voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness or controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between P42B (male) (1) – VH17 Resistance Max. 1 z Disconnection in wiring (female) (1) harness (DisconnecWiring harness between P42B (male) (2) – VH17 4 Resistance Max. 1 z tion or defective con- (female) (2) tact in connector) Wiring harness between CV01 (female) (2) – Resistance Max. 1 z P41B (female) (A) Wiring harness between CV02A (female) (6) – Resistance Max. 1 z P41B (female) (B) a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 5 harness (Contact with Between wiring harness CV02A (female) (6) – GND circuit) Resistance Min. 1 Mz P41B (female) (B) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas Defective VHMS CV02A Voltage 6 temperature controller 20°C Approx. 0.9 – 1.2 V Between (6) and (13) 500°C Approx. 2.6 – 3.5 V

PC2000-8

40 Troubleshooting

SEN02100-00

Circuit diagram related to exhaust temperature sensor

PC2000-8

7

SEN02100-00

40 Troubleshooting

Failure code [DGT5KB] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 11) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

8

Failure code DGT5KB

Trouble

Exhaust Temp. Sensor LBF Failure (VHMS controller system)

• Exhaust gas temperature sensor (LB/F) signal voltage is above 4.9 V. • None in particular. • The snapshot data downloaded to the PC is not displayed normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n3 o 11 (codes are displayed by 2 digits) • Exhaust gas temperature can be checked by downloading data to PC after the snapshot. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor 24 V If failure code [DBB6KP] is displayed, carry out the troubleshooting first as 1 power supply system stated. a Prepare with starting switch OFF, then start engine and carry out trouDefective exhaust gas bleshooting. temperature sensor 2 Switch between the rear and front exhaust gas (LB/F) (Internal disconVH16 connector temperature sensor connectors. If no error code nection) VH17 connector is displayed, that sensor is normal. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas P41A Voltage temperature Defective amplifier for (A) – (C) All temperature range 20 – 30 V exhaust gas tempera3 ture sensor (LB/F) 20°C Approx. 0.9 – 1.2 V (B) – (C) (Internal defect) 500°C Approx. 2.6 – 3.5 V Amplifier voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness or controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 4 harness (Contact with Between wiring harness P42A (male) (1) – VH16 GND circuit) Resistance Min. 1 Mz (female) (1) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry Hot short in wiring harout troubleshooting. 5 ness (Contact with 24 Between wiring harness CV02A (female) (5) – V circuit) Voltage Max. 1 V P41A (female) (B) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas Defective VHMS CV02A Voltage 6 temperature controller 20°C Approx. 0.9 – 1.2 V Between (5) and (13) 500°C Approx. 2.6 – 3.5 V

PC2000-8

40 Troubleshooting

SEN02100-00

Circuit diagram related to exhaust temperature sensor

PC2000-8

9

SEN02100-00

40 Troubleshooting

Failure code [dGT5KB] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 21) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

10

Failure code dGT5KB

Trouble

Exhaust Temp. Sensor LBR Failure (VHMS controller system)

• Exhaust gas temperature sensor (LB/R) signal voltage is above 4.9 V. • None in particular. • The snapshot data downloaded to the PC is not displayed normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n3 o 21 (codes are displayed by 2 digits) • Exhaust gas temperature can be checked by downloading data to PC after the snapshot. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor 24 V If failure code [DBB6KP] is displayed, carry out the troubleshooting first as 1 power supply system stated. a Prepare with starting switch OFF, then start engine and carry out trouDefective exhaust gas bleshooting. temperature sensor 2 Switch between the rear and front exhaust gas (LB/R) (Internal disVH16 connector temperature sensor connectors. If no error code connection) VH17 connector is displayed, that sensor is normal. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas P41B Voltage temperature Defective amplifier for (A) – (C) All temperature range 20 – 30 V exhaust gas tempera3 ture sensor (LB/R) 20°C Approx. 0.9 – 1.2 V (B) – (C) (Internal defect) 500°C Approx. 2.6 – 3.5 V Amplifier voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness or controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 4 harness (Contact with Between wiring harness P42B (male) (1) – VH17 GND circuit) Resistance Min. 1 Mz (female) (1) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry Hot short in wiring harout troubleshooting. 5 ness (Contact with 24 Between wiring harness CV02A (female) (6) – V circuit) Voltage Max. 1 V P41B (female) (B) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas Defective VHMS CV02A Voltage 6 temperature controller 20°C Approx. 0.9 – 1.2 V Between (6) and (13) 500°C Approx. 2.6 – 3.5 V

PC2000-8

40 Troubleshooting

SEN02100-00

Circuit diagram related to exhaust temperature sensor

PC2000-8

11

SEN02100-00

40 Troubleshooting

Failure code [DGT6KA] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 24) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

12

Failure code DGT6KA

Trouble

Exhaust Temp. Sensor RBF Failure (VHMS controller system)

• Exhaust gas temperature sensor (RB/F) signal voltage is below 0.5 V. • None in particular. • The snapshot data downloaded to the PC is not displayed normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n3 o 24 (codes are displayed by 2 digits) • Exhaust gas temperature can be checked by downloading data to PC after the snapshot. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor 24 V If failure code [DBB6KP] is displayed, carry out the troubleshooting first as 1 power supply system stated. a Prepare with starting switch OFF, then start engine and carry out trouDefective exhaust gas bleshooting. temperature sensor 2 Switch between the rear and front exhaust gas (RB/F) (Internal disVH18 connector temperature sensor connectors. If no error code connection) VH19 connector is displayed, that sensor is normal. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas P41C Voltage temperature Defective amplifier for (A) – (C) All temperature range 20 – 30 V exhaust gas tempera3 ture sensor (RB/F) 20°C Approx. 0.9 – 1.2 V (B) – (C) (Internal defect) 500°C Approx. 2.6 – 3.5 V Amplifier voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness or controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between P42C (male) (1) – VH18 Resistance Max. 1 z Disconnection in wiring (female) (1) harness (DisconnecWiring harness between P42C (male) (2) – VH18 4 Resistance Max. 1 z tion or defective con- (female) (2) tact in connector) Wiring harness between CV01 (female) (2) – Resistance Max. 1 z P41C (female) (A) Wiring harness between CV02A (female) (7) – Resistance Max. 1 z P41C (female) (B) a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 5 harness (Contact with Between wiring harness CV02A (female) (7) – GND circuit) Resistance Min. 1 Mz P41C (female) (B)and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas Defective VHMS CV02A Voltage 6 temperature controller 20°C Approx. 0.9 – 1.2 V Between (7) and (13) 500°C Approx. 2.6 – 3.5 V

PC2000-8

40 Troubleshooting

SEN02100-00

Circuit diagram related to exhaust temperature sensor

PC2000-8

13

SEN02100-00

40 Troubleshooting

Failure code [dGT6KA] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

14

Failure code dGT6KA

Trouble

Exhaust Temp. Sensor RBR Failure (VHMS controller system)

• Exhaust gas temperature sensor (RB/R) signal voltage is below 0.5 V. • None in particular. • The snapshot data downloaded to the PC is not displayed normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n3 o 26 (codes are displayed by 2 digits) • Exhaust gas temperature can be checked by downloading data to PC after the snapshot. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor 24 V If failure code [DBB6KP] is displayed, carry out the troubleshooting first as 1 power supply system stated. a Prepare with starting switch OFF, then start engine and carry out trouDefective exhaust gas bleshooting. temperature sensor 2 Switch between the rear and front exhaust gas (RB/R) (Internal disVH18 connector temperature sensor connectors. If no error code connection) VH19 connector is displayed, that sensor is normal. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas P41D Voltage temperature Defective amplifier for (A) – (C) All temperature range 20 – 30 V exhaust gas tempera3 ture sensor (RB/R) 20°C Approx. 0.9 – 1.2 V (B) – (C) (Internal defect) 500°C Approx. 2.6 – 3.5 V Amplifier voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness or controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between P42D (male) (1) – VH19 Resistance Max. 1 z Disconnection in wiring (female) (1) harness (DisconnecWiring harness between P42D (male) (2) – VH19 4 Resistance Max. 1 z tion or defective con- (female) (2) tact in connector) Wiring harness between CV01 (female) (2) – Resistance Max. 1 z P41D (female) (A) Wiring harness between CV02A (female) (6) – Resistance Max. 1 z P41D (female) (B) a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 5 harness (Contact with Between wiring harness CV02A (female) (6) – GND circuit) Resistance Min. 1 Mz P41D (female) (B) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas Defective VHMS CV02A Voltage 6 temperature controller 20°C Approx. 0.9 – 1.2 V Between (16) and (13) 500°C Approx. 2.6 – 3.5 V

PC2000-8

40 Troubleshooting

SEN02100-00

Circuit diagram related to exhaust temperature sensor

PC2000-8

15

SEN02100-00

40 Troubleshooting

Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 23) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

16

Failure code DGT6KB

Trouble

Exhaust Temp. Sensor RBF Failure (VHMS controller system)

• Exhaust gas temperature sensor (RB/F) signal voltage is above 4.9 V. • None in particular. • The snapshot data downloaded to the PC is not displayed normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n3 o 23 (codes are displayed by 2 digits) • Exhaust gas temperature can be checked by downloading data to PC after the snapshot. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor 24 V If failure code [DBB6KP] is displayed, carry out the troubleshooting first as 1 power supply system stated. a Prepare with starting switch OFF, then start engine and carry out trouDefective exhaust gas bleshooting. temperature sensor 2 Switch between the rear and front exhaust gas (RB/F) (Internal disVH18 connector temperature sensor connectors. If no error code connection) VH19 connector is displayed, that sensor is normal. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas P41C Voltage temperature Defective amplifier for (A) – (C) All temperature range 20 – 30 V exhaust gas tempera3 ture sensor (RB/F) 20°C Approx. 0.9 – 1.2 V (B) – (C) (Internal defect) 500°C Approx. 2.6 – 3.5 V Amplifier voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness or controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 4 harness (Contact with Between wiring harness CV02A (female) (7) – GND circuit) Resistance Min. 1 Mz P41C (female) (B) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry Hot short in wiring harout troubleshooting. 5 ness (Contact with 24 Between wiring harness CV02A (female) (7) – V circuit) Voltage Max. 1 V P41C (female) (B) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas Defective VHMS CV02A Voltage 6 temperature controller 20°C Approx. 0.9 – 1.2 V Between (7) and (13) 500°C Approx. 2.6 – 3.5 V

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Circuit diagram related to exhaust temperature sensor

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Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

18

Failure code dGT6KB

Trouble

Exhaust Temp. Sensor RBR Failure (VHMS controller system)

• Exhaust gas temperature sensor (RB/R) signal voltage is above 4.9 V. • None in particular. • The snapshot data downloaded to the PC is not displayed normally. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: n3 o 26 (codes are displayed by 2 digits) • Exhaust gas temperature can be checked by downloading data to PC after the snapshot. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor 24 V If failure code [DBB6KP] is displayed, carry out the troubleshooting first as 1 power supply system stated. a Prepare with starting switch OFF, then start engine and carry out trouDefective exhaust gas bleshooting. temperature sensor 2 Switch between the rear and front exhaust gas (RB/R) (Internal disVH18 connector temperature sensor connectors. If no error code connection) VH19 connector is displayed, that sensor is normal. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas P41D Voltage temperature Defective amplifier for (A) – (C) All temperature range 20 – 30 V exhaust gas tempera3 ture sensor (RB/R) 20°C Approx. 0.9 – 1.2 V (B) – (C) (Internal defect) 500°C Approx. 2.6 – 3.5 V Amplifier voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness or controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 4 harness (Contact with Between wiring harness P42D (male) (1) – VH19 GND circuit) Resistance Min. 1 Mz (female) (1) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry Hot short in wiring harout troubleshooting. 5 ness (Contact with 24 Between wiring harness CV02A (female) (16) – V circuit) Voltage Max. 1 V P41D (female) (B) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Exhaust gas Defective VHMS CV02A Voltage 6 temperature controller 20°C Approx. 0.9 – 1.2 V Between (13) and (16) 500°C Approx. 2.6 – 3.5 V

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Circuit diagram related to exhaust temperature sensor

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Failure code [DH25KX] VR1/P1F J/S Dif Press Sensor Abnormality User code E07 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DH25KX

Trouble

• Restricts the pump control (NC control) function. • Part of the pump control (NC control) is disabled. • Input from the J/S differential pressure sensor can be checked with monitoring function. (Code: 13804 VR1 J/S differential pressure, Code: 13808 VR1 J/S differential pressure sensor voltage)

Defective VR1-P1F J/S differential pressure 2 sensor (Internal disconnection or short circuit)

Disconnection in wiring harness (Disconnec3 tion or defective contact in connector)

Ground fault in wiring 4 harness (Contact with GND circuit)

Hot short in wiring har5 ness (Contact with 24 V circuit)

6

20

VR1/P1F J/S Dif Press Sensor Abnormality (Pump controller 1 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V.

Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

1

Defective pump controller 1

Standard value in normal state/Remarks on troubleshooting If failure code [DA26KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. P36 Measurement condition Voltage Between (1) and (2) Engine stopped 4.5 – 5.5 V Between (3) and (2) Engine stopped 0.5 – 1.5 V Between (4) and (2) Engine stopped 0.5 – 1.5 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP01 (female) (8) – Resistance Max. 1 z P36 (female) (1) Wiring harness between CP01 (female) (21) – Resistance Max. 1 z P36 (female) (2) Wiring harness between CP03 (female) (34) – Resistance Max. 1 z P36 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness CP01 (female) (8) – P36 Resistance Min. 1 Mz (female) (1) and chassis ground Between wiring harness CP03 (female) (34) – Resistance Min. 1 Mz P36 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness CP01 (female) (8) – P36 Voltage Max. 1 V (female) (1) and chassis ground Between wiring harness CP03 (female) (34) – Voltage Max. 6 V P36 (female) (1) and chassis ground If causes 1 – 5 are not detected, pump controller may be defective. (Troubleshooting cannot be carried out since trouble is in system.)

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Circuit diagram related to VR1/P1F joystick differential sensor

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Failure code [DH26KX] VL1/P1R J/S Dif Press Sensor Abnormality User code E07 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DH26KX

Trouble

• Restricts the pump control (NC control) function. • Part of the pump control (NC control) is disabled. • Input from the J/S differential pressure sensor can be checked with monitoring function. (Code: 13805 VL1 J/S differential pressure, Code: 13809 VL1 J/S differential pressure sensor voltage)

Defective VL1-P1R J/S differential pressure 2 sensor (Internal disconnection or short circuit)

Disconnection in wiring harness (Disconnec3 tion or defective contact in connector)

Ground fault in wiring 4 harness (Contact with GND circuit)

Hot short in wiring har5 ness (Contact with 24 V circuit)

6

22

VL1/P1R J/S Dif Press Sensor Abnormality (Pump controller 1 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V.

Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

1

Defective pump controller 1

Standard value in normal state/Remarks on troubleshooting If failure code [DA26KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. P27 Measurement condition Voltage Between (1) and (2) Engine stopped 4.5 – 5.5 V Between (3) and (2) Engine stopped 0.5 – 1.5 V Between (4) and (2) Engine stopped 0.5 – 1.5 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP01 (female) (2) – Resistance Max. 1 z P27 (female) (1) Wiring harness between CP01 (female) (21) – Resistance Max. 1 z P27 (female) (2) Wiring harness between CP03 (female) (34) – Resistance Max. 1 z P27 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness CP01 (female) (2) – P27 Resistance Min. 1 Mz (female) (1) and chassis ground Between wiring harness CP03 (female) (34) – Resistance Min. 1 Mz P27 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness CP01 (female) (2) – P27 Voltage Max. 1 V (female) (1) and chassis ground Between wiring harness CP03 (female) (34) – Voltage Max. 6 V P27 (female) (1) and chassis ground If causes 1 – 5 are not detected, pump controller may be defective. (Troubleshooting cannot be carried out since trouble is in system.)

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Circuit diagram related to VL1/P1R joystick differential sensor

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Failure code [DH27KX] VR2/P2F J/S Dif Press Sensor Abnormality User code E07 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DH27KX

Trouble

• Restricts the pump control (NC control) function. • Part of the pump control (NC control) is disabled. • Input from the J/S differential pressure sensor can be checked with monitoring function. (Code: 13806 VR2 J/S differential pressure, Code: 13810 VR2 J/S differential pressure sensor voltage)

Defective VR2/P2F J/S differential pressure 2 sensor (Internal disconnection or short circuit)

Disconnection in wiring harness (Disconnec3 tion or defective contact in connector)

Ground fault in wiring 4 harness (Contact with GND circuit)

Hot short in wiring har5 ness (Contact with 24 V circuit)

6

24

VR2/P2F J/S Dif Press Sensor Abnormality (Pump controller 1 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V.

Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

1

Defective pump controller 1

Standard value in normal state/Remarks on troubleshooting If failure code [DA26KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. P28 Measurement condition Voltage Between (1) and (2) Engine stopped 4.5 – 5.5 V Between (3) and (2) Engine stopped 0.5 – 1.5 V Between (4) and (2) Engine stopped 0.5 – 1.5 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP01 (female) (19) – Resistance Max. 1 z P37 (female) (1) Wiring harness between CP01 (female) (21) – Resistance Max. 1 z P37 (female) (2) Wiring harness between CP03 (female) (34) – Resistance Max. 1 z P37 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness CP01 (female) (19) – Resistance Min. 1 Mz P37 (female) (1) and chassis ground Between wiring harness CP03 (female) (34) and Resistance Min. 1 Mz P37 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness CP01 (female) (19) – Voltage Max. 1 V P37 (female) (1) and chassis ground Between wiring harness CP03 (female) (34) – Voltage Max. 6 V P37 (female) (1) and chassis ground If causes 1 – 5 are not detected, pump controller may be defective. (Troubleshooting cannot be carried out since trouble is in system.)

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Circuit diagram related to VR2/P2F joystick differential sensor

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Failure code [DH28KX] VL2/P2R J/S Dif Press Sensor Abnormality User code E07 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DH28KX

Trouble

• Restricts the pump control (NC control) function. • Part of the pump control (NC control) is disabled. • Input from the J/S differential pressure sensor can be checked with monitoring function. (Code: 13807 VL2 J/S differential pressure, Code: 13811 VL2 J/S differential pressure sensor voltage)

Defective VL2-P2R J/S differential pressure 2 sensor (Internal disconnection or short circuit)

Disconnection in wiring harness (Disconnec3 tion or defective contact in connector)

Ground fault in wiring 4 harness (Contact with GND circuit)

Hot short in wiring har5 ness (Contact with 24 V circuit)

6

26

VL2/P2R J/S Dif Press Sensor Abnormality (Pump controller 1 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V.

Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

1

Defective pump controller 1

Standard value in normal state/Remarks on troubleshooting If failure code [DA26KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. P25 Measurement condition Voltage Between (1) and (2) Engine stopped 4.5 – 5.5 V Between (3) and (2) Engine stopped 0.5 – 1.5 V Between (4) and (2) Engine stopped 0.5 – 1.5 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP01 (female) (13) – Resistance Max. 1 z P28 (female) (1) Wiring harness between CP01 (female) (21) – Resistance Max. 1 z P28 (female) (2) Wiring harness between CP03 (female) (33) – Resistance Max. 1 z P28 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness CP01 (female) (13) – Resistance Min. 1 Mz P28 (female) (1) and chassis ground Between wiring harness CP03 (female) (33) – Resistance Min. 1 Mz P28 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness CP01 (female) (13) – Voltage Max. 1 V P28 (female) (1) and chassis ground Between wiring harness CP03 (female) (34) – Voltage Max. 6 V P28 (female) (1) and chassis ground If causes 1 – 5 are not detected, pump controller may be defective. (Troubleshooting cannot be carried out since trouble is in system.)

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Circuit diagram related to VL2/P2R joystick differential sensor

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Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 32) User code

Failure code

—

DHE5KB

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

Blowby Pres. Sensor Failure (VHMS controller system)

• The signal voltage of the blow-by pressure sensor is below 0.1 V. • None in particular. • The snap shot data downloaded to a personal computer are not displayed normally. • The error codes of the VHMS system are not recorded in the failure history of the machine monitor. • The 7-segment LED of the VHMS controller displays n3 o 32 (displays the code 2 characters by 2). • The blow-by pressure can be checked by downloading the data to a personal computer after performing the snap shot operation. Cause 1

Sensor 5-V power supply defective

Standard value in normal state/Remarks on troubleshooting If error code [DBB5KP] is displayed, perform troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Blow-by pressure sen2 sor defective (Internal defect)

VH08

Voltage

Between (B) and (A)

4.5 – 5.5 V

Between (C) and (A)

0.3 – 0.7 V

The voltage of the pressure sensor is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller for another cause of the trouble, and then judge.

Possible causes and standard value in normal state

Blow-by pressure 3 sensor defective (External defect)

Referring to TESTING AND ADJUSTING, check the sensor for sticking oil, dust, water, etc. and clean it.

Blow-by pressure 4 sensor defective (Installation defective)

Referring to TESTING AND ADJUSTING, check the sensor for defective installation and repair it.

a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection of wiring turning starting switch ON. harness Wiring harness between CV01 (female) (5) and Resistance 5 (Disconnection or Max. 1 z P43 (female) (B) value defective contact with Wiring harness between CV02A (female) (18) Resistance connector) Max. 1 z and P43 (female) (C) value Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ing harness 6 (Contact with ground- Between wiring harness between CV02A Resistance Min. 1 Mz ing (GND) circuit) (female) (18) and P43 (female) (C) value

7

28

VHMS controller defective

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CV02A

Voltage

Between (18) and (13)

0.3 – 0.7 V

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Circuit diagram related to blow-by pressure sensor

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Failure code [DHE5KY] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 31) User code

Failure code

—

DHE5KY

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

Blowby Pres. Sensor Failure (VHMS controller system)

• The signal voltage of the blow-by pressure sensor is above 4.7 V. • None in particular. • The snap shot data downloaded to a personal computer are not displayed normally. • The error codes of the VHMS system are not recorded in the failure history of the machine monitor. • The 7-segment LED of the VHMS controller displays n3 o 31 (displays the code 2 characters by 2). • The blow-by pressure can be checked by downloading the data to a personal computer after performing the snap shot operation. Cause 1

Standard value in normal state/Remarks on troubleshooting

Sensor 5-V power supIf error code [DBB5KP] is displayed, perform troubleshooting for it first. ply defective a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Blow-by pressure sen2 sor defective (Internal defect)

Possible causes and standard value in normal state

P43

Voltage

Between (B) and (A)

4.5 – 5.5 V

Between (C) and (A)

0.3 – 0.7 V

The voltage of the pressure sensor is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller for another cause of the trouble, and then judge. Blow-by pressure senReferring to TESTING AND ADJUSTING, check the sensor for sticking oil, 3 sor defective (External dust, water, etc. and clean it. defect) Blow-by pressure senReferring to TESTING AND ADJUSTING, check the sensor for defective 4 sor defective (Installainstallation and repair it. tion defective) a Prepare with starting switch OFF, then turn starting switch ON and carry Hot short circuit in wirout troubleshooting. 5 ing harness (Contact Between wiring harness between VC2A (female) with 24-V circuit) Voltage Max. 1 V (18) and P43 (female) (C) and grounding

6

30

VHMS controller defective

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CV02A

Voltage

Between (18) and (13)

0.3 – 0.7 V

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Circuit diagram related to blow-by pressure sensor

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Failure code [DHH2KA] Hydraulic oil filter Sensor Failure (or change of VHMS-LED display from n5 to 53) 1 User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code Hydraulic oil filter Sensor Failure Trouble (VHMS controller system) DHH2KA • While engine was stopped, signal circuit of hydraulic oil filter clogging sensor was disconnected (disconnected with GND). • None in particular. • None in particular. • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor. • VHMS controller 7-segment LED display: “n5” o “53” (codes are displayed by 2 digits) Cause Standard value in normal state/Remarks on troubleshooting Clogging of hydraulic 1 oil filter (when the sys- Check the hydraulic oil filter, and replace it if clogged. tem is normal) a Prepare with starting switch OFF, then carry out troubleshooting without Defective hydraulic oil turning starting switch ON. filter clogging switch P04 (male) Hydraulic oil filter Resistance 2 (Internal disconnecValue in normal state Max. 1 z tion or short circuit) Between (1) and (2) Value when clogged Min. 1 Mz Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. harness (Disconnec3 tion or defective con- Wiring harness between CV02B (female) (1) – Resistance Max. 1 z tact in connector) P40 (female) (1) a Prepare with starting switch OFF, then turn starting switch ON and carry Hot short in wiring harout troubleshooting. 4 ness (Contact with 24 Between wiring harness CV02B (female) (1) – V circuit) Voltage Max. 1 V P40 (female) (1) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective VHMS 5 Between CV02B Value in normal state Max. 1 V controller (female) (1) and chasValue when clogged 20 – 30 V sis ground

Circuit diagram related to hydraulic oil filter clogging sensor

32

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Failure code [DHPEKX] VR1/P1F Pump P. Sensor Abnormality User code E07 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHPEKX

Trouble

1

VR1/P1F Pump P. Sensor Abnormality (Pump controller 1 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V. • Restricts the pump control (PQ control) function. • Pump (PQ control) cannot be controlled. • Pump (CO control) cannot be controlled. • Input from the pump pressure sensor can be checked with monitoring function. (Code: 01124 P1F system pump pressure) Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

34

Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start Defective pump presengine and carry out troubleshooting in each case. sure sensor (Internal P32 Voltage 2 disconnection or short Between (3) and (1) Power supply 4.5 – 5.5 V circuit) Between (2) and (1) Signal 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 CP01 (female) (9) – Resistance Max. 1 z P32 (female) (2) harness (Disconnec3 tion or defective con- Wiring harness between CP01 (female) (21) – Resistance Max. 1 z tact in connector) P32 (female) (1) Wiring harness between CP01 (female) (22) – Resistance Max. 1 z P32 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between wiring harness CP01 (female) (9) – P32 Resistance Min. 1 Mz 4 harness (Contact with (female) (2) and chassis ground GND circuit) Between wiring harness CP01 (female) (22) – Resistance Min. 1 Mz P32 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP01 (female) (9) – P32 Voltage Max. 1 V 5 ness (Contact with 24 (female) (2) and chassis ground V circuit) Between wiring harness CP01 (female) (22) – Voltage Max. 6 V P32 (female) (3) and chassis ground Defective pump If causes 1 – 5 are not detected, pump controller may be defective. 6 controller 1 (Troubleshooting cannot be carried out since trouble is in system.)

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Circuit diagram related to VR1/P1F pump pressure sensor

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Failure code [DHPFKX] VL1/P1R Pump P. Sensor Abnormality User code E07 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHPFKX

Trouble

1

VL1/P1R Pump P. Sensor Abnormality (Pump controller 1 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V. • Restricts the pump control (PQ control) function. • Pump (PQ control) cannot be controlled. • Pump (CO control) cannot be controlled. • Input from the pump pressure sensor can be checked with monitoring function. (Code: 01125 P1R system pump pressure) Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

36

Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start Defective pump presengine and carry out troubleshooting in each case. sure sensor (Internal P25 Voltage 2 disconnection or short Between (3) and (1) Power supply 4.5 – 5.5 V circuit) Between (2) and (1) Signal 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 CP01 (female) (3) – Resistance Max. 1 z P25 (female) (2) harness (Disconnec3 tion or defective con- Wiring harness between CP01 (female) (21) – Resistance Max. 1 z tact in connector) P25 (female) (1) Wiring harness between CP01 (female) (22) – Resistance Max. 1 z P25 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between wiring harness CP01 (female) (9) – P25 Resistance Min. 1 Mz 4 harness (Contact with (female) (2) and chassis ground GND circuit) Between wiring harness CP01 (female) (22) – Resistance Min. 1 Mz P25 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP01 (female) (9) – P25 Voltage Max. 1 V 5 ness (Contact with 24 (female) (2) and chassis ground V circuit) Between wiring harness CP01 (female) (22) – Voltage Max. 6 V P25 (female) (3) and chassis ground Defective pump If causes 1 – 5 are not detected, pump controller may be defective. 6 controller 1 (Troubleshooting cannot be carried out since trouble is in system.)

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Circuit diagram related to VL1/P1R pump pressure sensor

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37

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Failure code [DHPGKX] VR2/P2F Pump P. Sensor Abnormality User code E07 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHPGKX

Trouble

1

VR2/P2F Pump P. Sensor Abnormality (Pump controller 1 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V. • Restricts the pump control (PQ control) function. • Pump (PQ control) cannot be controlled. • Pump (CO control) cannot be controlled. • Input from the pump pressure sensor can be checked with monitoring function. (Code: 01126 P2F system pump pressure) Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

38

Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start Defective pump presengine and carry out troubleshooting in each case. sure sensor (Internal P33 Voltage 2 disconnection or short Between (3) and (1) Power supply 4.5 – 5.5 V circuit) Between (2) and (1) Signal 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 CP01 (female) (20) – Resistance Max. 1 z P33 (female) (2) harness (Disconnec3 tion or defective con- Wiring harness between CP01 (female) (21) – Resistance Max. 1 z tact in connector) P33 (female) (1) Wiring harness between CP01 (female) (22) – Resistance Max. 1 z P33 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between wiring harness CP01 (female) (20) – Resistance Min. 1 Mz 4 harness (Contact with P33 (female) (2) and chassis ground GND circuit) Between wiring harness CP01 (female) (22) – Resistance Min. 1 Mz P33 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP01 (female) (20) – Voltage Max. 1 V 5 ness (Contact with 24 P33 (female) (2) and chassis ground V circuit) Between wiring harness CP01 (female) (22) – Voltage Max. 6 V P33 (female) (3) and chassis ground Defective pump If causes 1 – 5 are not detected, pump controller may be defective. 6 controller 1 (Troubleshooting cannot be carried out since trouble is in system.)

PC2000-8

40 Troubleshooting

SEN02100-00

Circuit diagram related to VR2/P2F pump pressure sensor

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39

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Failure code [DHPHKX] VL2/P2R Pump P. Sensor Abnormality User code E07 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHPHKX

Trouble

1

VL2/P2R Pump P. Sensor Abnormality (Pump controller 1 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V. • Restricts the pump control (PQ control) function. • Pump (PQ control) cannot be controlled. • Pump (CO control) cannot be controlled. • Input from the pump pressure sensor can be checked with monitoring function. (Code: 01127 P2R system pump pressure) Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

40

Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start Defective pump presengine and carry out troubleshooting in each case. sure sensor (Internal P26 Voltage 2 disconnection or short Between (3) and (1) Power supply 4.5 – 5.5 V circuit) Between (2) and (1) Signal 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 CP01 (female) (14) – Resistance Max. 1 z P26 (female) (2) harness (Disconnec3 tion or defective con- Wiring harness between CP01 (female) (21) – Resistance Max. 1 z tact in connector) P26 (female) (1) Wiring harness between CP01 (female) (22) – Resistance Max. 1 z P26 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between wiring harness CP01 (female) (14) – Resistance Min. 1 Mz 4 harness (Contact with P26 (female) (2) and chassis ground GND circuit) Between wiring harness CP01 (female) (22) – Resistance Min. 1 Mz P26 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP01 (female) (14) – Voltage Max. 1 V 5 ness (Contact with 24 P26 (female) (2) and chassis ground V circuit) Between wiring harness CP01 (female) (22) – Voltage Max. 6 V P26 (female) (3) and chassis ground Defective pump If causes 1 – 5 are not detected, pump controller may be defective. 6 controller 1 (Troubleshooting cannot be carried out since trouble is in system.)

PC2000-8

40 Troubleshooting

SEN02100-00

Circuit diagram related to VL2/P2R pump pressure sensor

PC2000-8

41

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40 Troubleshooting

Failure code [DHPSKX] Auto Grease Press Sensor Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHPSKX

Trouble

42

Auto Grease Press Sensor Abnormality (Pump controller 2 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V. • None in particular (Provides the error display alone). • Caution for automatic lubrication cannot be judged. • Input from the automatic greasing pressure sensor can be checked with monitoring function. (Code: 13901 Automatic lubrication pressure sensor voltage) Cause Defective sensor 1 power supply system

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting If failure code [dA25KP] is displayed, carry out troubleshooting for it first.

Defective grease pump a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. discharge pressure P48 (male) Voltage 2 sensor (Internal disconnection or short cir- Between (B) and (A) Power supply 4.5 – 5.5 V cuit) Between (C) and (A) Signal 0.5 – 4.5 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between CP04 (female) (3) – Resistance Max. 1 z P48 (female) (C) harness (Disconnec3 tion or defective con- Wiring harness between CP04 (female) (21) – Resistance Max. 1 z tact in connector) P48 (female) (A) Wiring harness between CP04 (female) (22) – Resistance Max. 1 z P48 (female) (B) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between wiring harness CP04 (female) (21) – Resistance Min. 1 Mz 4 harness (Contact with P48 (female) (A) and chassis ground GND circuit) Between wiring harness CP04 (female) (22) – Resistance Min. 1 Mz P48 (female) (B) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP04 (female) (21) – Voltage Max. 1 V 5 ness (Contact with 24 P48 (female) (A) and chassis ground V circuit) Between wiring harness CP04 (female) (22) – Voltage Max. 6 V P48 (female) (B) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective pump CP04 Voltage 6 controller 2 Between (22) and (21) 4.5 – 5.5 V Between (3) and (21) 0.5 – 4.5 V

PC2000-8

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Circuit diagram related to auto grease pressure sensor

PC2000-8

43

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Failure code [DHPTKX] Fan(RAD) Pump P. Sensor Open Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHPTKX

Trouble

1

Fan(RAD) Pump P. Sensor Open Circuit (Pump controller 1 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V. • Operates the system using the backup function • Data for the machine control cannot be acquired. • Input from the fan (radiator) pump pressure sensor can be checked with monitoring function. (Code: 01133 RAD fan pump pressure sensor voltage) Cause Defective 5 V sensor 1 power supply system

2

3 Possible causes and standard value in normal state

4

5

6

44

Standard value in normal state/Remarks on troubleshooting If failure code [dA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without Defective fan (radiaturning starting switch ON. tor) pump pressure P35 (male) Voltage sensor (Internal disconnection or short cirBetween (3) and (1) 4.5 – 5.5 V cuit) Between (2) and (1) 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 CP04 (female) (7) – Resistance Max. 1 z P35 (female) (2) harness (Disconnection or defective con- Wiring harness between CP04 (female) (21) – Resistance Max. 1 z tact in connector) P35 (female) (1) Wiring harness between CP04 (female) (22) – Resistance Max. 1 z P35 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between wiring harness CP04 (female) (7) – P35 Resistance Min. 1 Mz harness (Contact with (female) (2) and chassis ground GND circuit) Between wiring harness CP04 (female) (22) – Resistance Min. 1 Mz P35 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP04 (female) (7) – P35 Voltage Max. 1 V ness (Contact with 24 (female) (2) and chassis ground V circuit) Between wiring harness CP04 (female) (22) – Voltage Max. 6 V P35 (female) (3) and chassis ground Defective pump If causes 1 – 5 are not detected, engine controller may be defective. controller 1 (Troubleshooting cannot be carried out since trouble is in system.)

PC2000-8

40 Troubleshooting

SEN02100-00

Circuit diagram related to fan (radiator) pump pressure sensor

PC2000-8

45

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Failure code [DHPUKX] Fan(O/C) Pump P. Sensor Open Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHPUKX

Trouble

1

Fan(O/C) Pump P. Sensor Open Circuit (Pump controller 1 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V. • Operates the system using the backup function • Data for the machine control cannot be acquired. • Input from the fan (oil cooler) pump pressure sensor can be checked with monitoring function. (Code: 01135 Oil cooler fan pump pressure sensor voltage) Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

46

Standard value in normal state/Remarks on troubleshooting If failure code [dA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without Defective fan pump turning starting switch ON. pressure sensor (InterP35 (male) Voltage 2 nal disconnection or Between (3) and (1) 4.5 – 5.5 V short circuit) Between (2) and (1) 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 CP04 (female) (1) – Resistance Max. 1 z P34 (female) (2) harness (Disconnec3 tion or defective con- Wiring harness between CP04 (female) (21) – Resistance Max. 1 z tact in connector) P34 (female) (1) Wiring harness between CP04 (female) (22) – Resistance Max. 1 z P34 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between wiring harness CP04 (female) (1) – P34 Resistance Min. 1 Mz 4 harness (Contact with (female) (2) and chassis ground GND circuit) Between wiring harness CP04 (female) (22) – Resistance Min. 1 Mz P34 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP04 (female) (1) – P34 Voltage Max. 1 V 5 ness (Contact with 24 (female) (2) and chassis ground V circuit) Between wiring harness CP04 (female) (22) – Voltage Max. 6 V P34 (female) (3) and chassis ground Defective pump If causes 1 – 5 are not detected, engine controller may be defective. 6 controller 1 (Troubleshooting cannot be carried out since trouble is in system.)

PC2000-8

40 Troubleshooting

SEN02100-00

Circuit diagram related to fan (oil cooler) pump pressure sensor

PC2000-8

47

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40 Troubleshooting

Failure code [DHS3KX] Arm Dig PPC Press Sensor Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHS3KX

Trouble

• None in particular (Provides the error display alone). • Arm IN cannot be judged. • Input from arm IN PPC pressure sensor can be checked with monitoring function. (Code: 07201 Arm IN PPC pressure sensor voltage)

Defective arm IN PPC pressure sensor (Inter2 nal disconnection or short circuit)

Disconnection in wiring harness (Disconnec3 tion or defective contact in connector)

Ground fault in wiring 4 harness (Contact with GND circuit)

Hot short in wiring har5 ness (Contact with 24 V circuit)

6

48

Arm Dig PPC Press Sensor Abnormality (Pump controller 2 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V.

Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

1

Defective pump controller 2

Standard value in normal state/Remarks on troubleshooting If failure code [dA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P06 (male) Voltage Between (3) and (1) 4.5 – 5.5 V Between (2) and (1) 0.5 – 4.5 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP04 (female) (8) – Resistance Max. 1 z P06 (female) (2) Wiring harness between CP04 (female) (21) – Resistance Max. 1 z P06 (female) (1) Wiring harness between CP04 (female) (22) – Resistance Max. 1 z P06 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness CP04 (female) (8) – P06 Resistance Min. 1 Mz (female) (2) and chassis ground Between wiring harness CP04 (female) (22) – Resistance Min. 1 Mz P06 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness CP04 (female) (8) – P06 Voltage Max. 1 V (female) (2) and chassis ground Between wiring harness CP04 (female) (22) – Voltage Max. 6 V P06 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. CP04 Voltage Between (22) and (21) 4.5 – 5.5 V Between (8) and (21) 0.5 – 4.5 V

PC2000-8

40 Troubleshooting

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Circuit diagram related to arm IN PPC pressure sensor

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49

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Failure code [DHS4KX] Bucket Curl PPC Press Sensor Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHS4KX

Trouble

1

Bucket Curl PPC Press Sensor Abnormality (Pump controller 2 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V. • None in particular (Provides the error display alone). • Bucket Curl cannot be judged. • Input from bucket Curl PPC pressure sensor can be checked with monitoring function. (Code: 07302 Bucket Curl PPC pressure sensor voltage) Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

50

Standard value in normal state/Remarks on troubleshooting If failure code [dA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without Defective bucket Curl turning starting switch ON. PPC pressure sensor P03 (male) Voltage 2 (Internal disconnecBetween (3) and (1) 4.5 – 5.5 V tion or short circuit) Between (2) and (1) 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 CP04 (female) (19) – Resistance Max. 1 z P03 (female) (2) harness (Disconnec3 tion or defective con- Wiring harness between CP04 (female) (21) – Resistance Max. 1 z tact in connector) P03 (female) (1) Wiring harness between CP04 (female) (22) – Resistance Max. 1 z P03 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between wiring harness CP04 (female) (19) – Resistance Min. 1 Mz 4 harness (Contact with P03 (female) (2) and chassis ground GND circuit) Between wiring harness CP04 (female) (22) – Resistance Min. 1 Mz P03 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP04 (female) (19) – Voltage Max. 1 V 5 ness (Contact with 24 P03 (female) (2) and chassis ground V circuit) Between wiring harness CP04 (female) (22) – Voltage Max. 6 V P03 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective pump CP04 Voltage 6 controller 2 Between (22) and (21) 4.5 – 5.5 V Between (19) and (21) 0.5 – 4.5 V

PC2000-8

40 Troubleshooting

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Circuit diagram related to bucket curl PPC pressure sensor

PC2000-8

51

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Failure code [DHS8KX] Boom Raise PPC Press Sensor Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHS8KX

Trouble

1

Boom Raise PPC Press Sensor Abnormality (Pump controller 2 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V. • None in particular (Provides the error display alone). • Boom Raise cannot be judged. • Input from boom Raise PPC pressure sensor can be checked with monitoring function. (Code: 07401 Boom Raise PPC pressure sensor voltage) Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

52

Standard value in normal state/Remarks on troubleshooting If failure code [dA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without Defective boom Raise turning starting switch ON. PPC pressure sensor P01 (male) Voltage 2 (Internal disconnecBetween (3) and (1) 4.5 – 5.5 V tion or short circuit) Between (2) and (1) 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 CP04 (female) (20) – Resistance Max. 1 z P01 (female) (2) harness (Disconnec3 tion or defective con- Wiring harness between CP04 (female) (21) – Resistance Max. 1 z tact in connector) P01 (female) (1) Wiring harness between CP04 (female) (22) – Resistance Max. 1 z P01 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between wiring harness CP04 (female) (20) – Resistance Min. 1 Mz 4 harness (Contact with P01 (female) (2) and chassis ground GND circuit) Between wiring harness CP04 (female) (22) – Resistance Min. 1 Mz P01 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP04 (female) (20) – Voltage Max. 1 V 5 ness (Contact with 24 P01 (female) (2) and chassis ground V circuit) Between wiring harness CP04 (female) (22) – Voltage Max. 6 V P01 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective pump CP04 Voltage 6 controller 2 Between (22) and (21) 4.5 – 5.5 V Between (20) and (21) 0.5 – 4.5 V

PC2000-8

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Circuit diagram related to boom RAISE PPC pressure senso0

PC2000-8

53

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Failure code [DHS9KX] Boom Lower PPC Press Sensor Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHS9KX

Trouble

1

Boom Lower PPC Press Sensor Abnormality (Pump controller 2 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V. • None in particular (Provides the error display alone). • Boom Lower cannot be judged. • Input from boom Lower PPC pressure sensor can be checked with monitoring function. (Code: 07501 Boom Lower PPC pressure sensor voltage) Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

54

Standard value in normal state/Remarks on troubleshooting If failure code [dA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without Defective boom Lower turning starting switch ON. PPC pressure sensor P02 (male) Voltage 2 (Internal disconnecBetween (3) and (1) 4.5 – 5.5 V tion or short circuit) Between (2) and (1) 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 CP04 (female) (14) – Resistance Max. 1 z P02 (female) (2) harness (Disconnec3 tion or defective con- Wiring harness between CP04 (female) (21) – Resistance Max. 1 z tact in connector) P02 (female) (1) Wiring harness between CP04 (female) (22) – Resistance Max. 1 z P02 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between wiring harness CP04 (female) (14) – Resistance Min. 1 Mz 4 harness (Contact with P02 (female) (2) and chassis ground GND circuit) Between wiring harness CP04 (female) (22) – Resistance Min. 1 Mz P02 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP04 (female) (14) – Voltage Max. 1 V 5 ness (Contact with 24 P02 (female) (2) and chassis ground V circuit) Between wiring harness CP04 (female) (22) – Voltage Max. 6 V P02 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective pump CP04 Voltage 6 controller 2 Between (22) and (21) 4.5 – 5.5 V Between (14) and (21) 0.5 – 4.5 V

PC2000-8

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SEN02100-00

Circuit diagram related to boom LOWER PPC pressure sensor

PC2000-8

55

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Failure code [DHSAKX] Swing Right PPC Press Sensor Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHSAKX

Trouble

1

Swing Right PPC Press Sensor Abnormality (Pump controller 2 system)

• Signal voltage from the swing right PPC pressure sensor is below 0.3 V or above 4.42 V. • None in particular (Provides the error display alone). • Swing right cannot be judged. • Input from the swing right PPC pressure sensor can be checked with monitoring function. (Code: 09004 Swing right PPC pressure sensor voltage) Cause Defective sensor 1 power supply system

Possible causes and standard value in normal state

56

Standard value in normal state/Remarks on troubleshooting If failure code [dA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective swing right P08 Voltage 2 PPC pressure sensor (Internal defect) Between (3) and (1) 4.5 – 5.5 V Between (2) and (1) 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 CP04 (female) (22) – Resistance Max. 1 z A02 – P08 (female) (3) harness (Disconnec3 tion or defective con- Wiring harness between CP04 (female) (21) – Resistance Max. 1 z tact in connector) A02 – P08 (female) (1) Wiring harness between CP04 (female) (1) – Resistance Max. 1 z A02 – P07 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 4 harness (Contact with Between wiring harness CP04 (female) (1) – A02 GND circuit) Resistance Min. 1 Mz – P07 (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP04 (female) (22) – Voltage 4.5 – 5.5 V 5 ness (Contact with 24 A02 – P08 (female) (3) and chassis ground V circuit) Between wiring harness CP04 (female) (1) – A02 Voltage 0.5 – 4.5 V – P07 (female) (2) and chassis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective pump CP04 Voltage 6 controller 2 Between (22) and (21) 4.5 – 5.5 V Between (1) and (21) 0.5 – 4.5 V

PC2000-8

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Circuit diagram related to swing RIGHT PPC pressure sensor

PC2000-8

57

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40 Troubleshooting

Failure code [DHSBKX] Swing Left PPC Press Sensor Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHSBKX

Trouble

1

Swing Left PPC Press Sensor Abnormality (Pump controller 2 system)

• Signal voltage from the swing left PPC pressure sensor is below 0.3 V or above 4.42 V. • None in particular (Provides the error display alone). • Swing left cannot be judged. • Input from the swing left PPC pressure sensor can be checked with monitoring function. (Code: 09003 Swing left PPC pressure sensor voltage) Cause Defective sensor 1 power supply system

Possible causes and standard value in normal state

58

Standard value in normal state/Remarks on troubleshooting If failure code [dA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective swing left P07 Voltage 2 PPC pressure sensor (Internal defect) Between (3) and (1) 4.5 – 5.5 V Between (2) and (1) 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 CP04 (female) (22) – Resistance Max. 1 z A02 – P07 (female) (3) harness (Disconnec3 tion or defective con- Wiring harness between CP04 (female) (21) – Resistance Max. 1 z tact in connector) A02 – P07 (female) (1) Wiring harness between CP04 (female) (7) – Resistance Max. 1 z A02 – P07 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without Ground fault in wiring turning starting switch ON. 4 harness (Contact with Between wiring harness CP04 (female) (7) – A02 GND circuit) Resistance Min. 1 Mz – P07 (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP04 (female) (22) – Voltage 4.5 – 5.5 V 5 ness (Contact with 24 A02 – P03 (female) (3) and chassis ground V circuit) Between wiring harness CP04 (female) (7) – A02 Voltage 0.5 – 4.5 V – P03 (female) (2) and chassis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective pump CP04 Voltage 6 controller 2 Between (22) and (21) 4.5 – 5.5 V Between (7) and (21) 0.5 – 4.5 V

PC2000-8

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Circuit diagram related to swing LEFT PPC pressure sensor

PC2000-8

59

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Failure code [DHSCKX] Arm Dump PPC Press Sensor Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHSCKX

Trouble

1

Arm Dump PPC Press Sensor Abnormality (Pump controller 2 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V. • None in particular (Provides the error display alone). • Arm dump cannot be judged. • Input from the arm dump PPC pressure sensor can be checked with monitoring function. (Code: 07601 Arm dump PPC pressure sensor voltage) Cause Defective 5 V sensor 1 power supply system

Possible causes and standard value in normal state

60

Standard value in normal state/Remarks on troubleshooting If failure code [dA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without Defective arm dump turning starting switch ON. PPC pressure sensor P05 (male) Voltage 2 (Internal disconnecBetween (3) and (1) 4.5 – 5.5 V tion or short circuit) Between (2) and (1) 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 CP04 (female) (2) – Resistance Max. 1 z P05 (female) (2) harness (Disconnec3 tion or defective con- Wiring harness between CP04 (female) (21) – Resistance Max. 1 z tact in connector) P05 (female) (1) Wiring harness between CP04 (female) (22) – Resistance Max. 1 z P05 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between wiring harness CP04 (female) (2) – P05 Resistance Min. 1 Mz 4 harness (Contact with (female) (2) and chassis ground GND circuit) Between wiring harness CP04 (female) (22) – Resistance Min. 1 Mz P05 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP04 (female) (2) – P05 Voltage Max. 1 V 5 ness (Contact with 24 (female) (2) and chassis ground V circuit) Between wiring harness CP04 (female) (22) – Voltage Max. 6 V P05 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective pump CP04 Voltage 6 controller 2 Between (22) and (21) 4.5 – 5.5 V Between (2) and (21) 0.5 – 4.5 V

PC2000-8

40 Troubleshooting

SEN02100-00

Circuit diagram related to arm OUT PPC pressure sensor

PC2000-8

61

SEN02100-00

40 Troubleshooting

Failure code [DHSDKX] Bucket Dump PPC Press Sensor Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DHSDKX

Trouble

1

Bucket Dump PPC Press Sensor Abnormality (Pump controller 2 system)

• Pressure sensor output voltage is below 0.3 V or above 4.42 V. • None in particular (Provides the error display alone). • Bucket dump cannot be judged. • Input from bucket dump PPC pressure sensor can be checked with monitoring function. (Code: 07303 Bucket DUMP PPC pressure sensor voltage) Cause Defective 5 V sensor 1 power supply system

2

3

Possible causes and standard value in normal state 4

5

6

62

Standard value in normal state/Remarks on troubleshooting If failure code [dA25KP] is also indicated, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without Defective bucket turning starting switch ON. DUMP PPC pressure P04 (male) Voltage sensor (Internal disconnection or short cirBetween (3) and (1) 4.5 – 5.5 V cuit) Between (2) and (1) 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 CP04 (female) (13) – Resistance Max. 1 z P04 (female) (2) harness (Disconnection or defective con- Wiring harness between CP04 (female) (21) – Resistance Max. 1 z tact in connector) P04 (female) (1) Wiring harness between CP04 (female) (22) – Resistance Max. 1 z P04 (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between wiring harness CP04 (female) (13) – Resistance Min. 1 Mz harness (Contact with P04 (female) (2) and chassis ground GND circuit) Between wiring harness CP04 (female) (22) – Resistance Min. 1 Mz P04 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harBetween wiring harness CP04 (female) (13) – Voltage Max. 1 V ness (Contact with 24 P04 (female) (2) and chassis ground V circuit) Between wiring harness CP04 (female) (22) – Voltage Max. 6 V P04 (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective pump CP04 Voltage controller 2 Between (22) and (21) 4.5 – 5.5 V Between (13) and (21) 0.5 – 4.5 V

PC2000-8

40 Troubleshooting

SEN02100-00

Circuit diagram related to bucket DUMP PPC pressure sensor

PC2000-8

63

SEN02100-00

PC2000-8 Hydraulic excavator Form No. SEN02100-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

64

SEN02101-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

40 Troubleshooting

1

Troubleshooting by failure code, Part 6 Troubleshooting by failure code, Part 6 .......................................................................................................... 3 Failure code [DUM3KB] Auto Grease Caution LED Short Circuit ........................................................ 3 Failure code [DUM4KB] FAN Reverse LED Short Circuit .................................................................... 4 Failure code [DV20KB] Travel Alarm S/C ............................................................................................ 5 Failure code [DW41KA] Swing Priority Sol Open Circuit ..................................................................... 7 Failure code [DW41KB] Swing Priority Sol Short Circuit...................................................................... 9 Failure code [DW45KA] Swing Brake Sol. Disc. .................................................................................11 Failure code [DW45KB] Swing Brake Sol. S/C .................................................................................. 14 Failure code [DW91KA] Straight-Travel Sol. Disc. ............................................................................. 16 Failure code [DW91KB] Straight-Travel Sol. S/C ............................................................................... 18 Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc.................................................................. 20 Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C................................................................... 21 Failure code [DW7BKA] Fan Motor (RAD) Reverse Sol Open Circuit ............................................... 22 Failure code [DW7BKB] Fan Reverse Sol. S/C ................................................................................. 24 Failure code [DW7HKA] Fan Motor(O/C) Reverse Sol Open Circuit ................................................. 26 Failure code [DW7HKB] Fan Motor(O/C) Reverse Sol Short Circuit ................................................. 28

PC2000-8

1

SEN02101-00

40 Troubleshooting

Failure code [DWA3KA] Arm throttle Valve/L Sol Open Circuit .......................................................... 30 Failure code [DWA3KB] Arm throttle Valve/L Sol Short Circuit .......................................................... 32 Failure code [DWA4KA] Arm throttle Valve/R Sol Open Circuit ......................................................... 34 Failure code [DWA4KB] Arm throttle Valve/R Sol Short Circuit.......................................................... 36 Failure code [DWA5KA] Auto Grease Sol Open Circuit ..................................................................... 38 Failure code [DWA5KB] Auto Grease Sol Short Circuit ..................................................................... 40 Failure code [DWA6KA] Boom throttle Valve Sol Open Circuit .......................................................... 41 Failure code [DWA6KB] Boom throttle Valve Sol Short Circuit .......................................................... 43 Failure code [DWK0KA] 2-stage Relief Sol. Disc. .............................................................................. 45 Failure code [DWK0KB] 2-stage Relief Sol. S/C ................................................................................ 47 Failure code [DWK2KA] Back Press Comp Valve Sol Open Circuit................................................... 48 Failure code [DWK2KB] Back Press Comp Valve Sol Short Circuit ................................................... 49

2

PC2000-8

40 Troubleshooting

SEN02101-00

Troubleshooting by failure code, Part 6

1

Failure code [DUM3KB] Auto Grease Caution LED Short Circuit

1

User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DUM3KB

Trouble

• Short circuit was detected in the automatic lubrication abnormal LED circuit • Stops output to the circuit. • LED is not lit up • The input status (ON or OFF) from the automatic lubrication abnormality LED can be checked with the monitoring function. Monitoring code: 03702 Controller output 3 Cause

Possible causes and standard value in normal state

Auto Grease Caution LED Short Circuit (Pump controller 1 system)

Ground fault in wiring 1 harness (Short circuit with GND circuit) 2

Defective pump controller 1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP03 (female) (8) – L22 Resistance Min. 1 Mz (female) (1) and chassis ground If cause 1 is not found, the pump controller may be defected. (Troubleshooting cannot be carried out since the trouble is in the system.)

Circuit diagram related to auto greasing caution LED output

PC2000-8

3

SEN02101-00

40 Troubleshooting

Failure code [DUM4KB] FAN Reverse LED Short Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DUM4KB

Trouble

FAN Reverse LED Short Circuit (Pump controller 1 system)

• Short circuit was detected in the fan reverse rotation abnormality LED circuit • Stops output to the circuit. • LED is not lit up • The input status (ON or OFF) from the fan reverse rotation abnormality LED can be checked with the monitoring function. (Monitoring code: 03702 Controller output 3) Cause

Possible causes and standard value in normal state

1

Ground fault in wiring 1 harness (Contact with GND circuit) 2

Defective pump controller 1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP03 (female) (18) – Resistance Min. 1 Mz L22 (female) (1) and chassis ground If cause 1 is not found, the pump controller may be defected. (Troubleshooting cannot be carried out since the trouble is in the system.)

Circuit diagram related to fan reverse warning LED output

4

PC2000-8

40 Troubleshooting

SEN02101-00

Failure code [DV20KB] Travel Alarm S/C User code

Failure code

—

DV20KB

Contents of trouble

Trouble

1

Travel Alarm S/C (Pump controller 2 system)

• Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit.

Action of • Power to the travel alarm circuit is switched OFF. machine moni- • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, tor unless the engine starting switch is once turned OFF. Problem that appears on machine Related information

• The travel alarm does not sound. • Operation of the travel alarm (ON or OFF) can be checked in the monitoring function. (Code No. 03701: Controller output 2) Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Travel alarm defective 1 (Internal defect) Possible causes and standard value in normal state

Between (1) – (2)

Travel lever

Voltage

Neutral

Max. 1 V

Operated

20 – 30 V

If the above voltage is normal but the travel alarm does not operate, the travel alarm is defective. Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ing harness 2 (Contact with ground- Between wiring harness between CP06 (female) Resistance Min. 1 Mz ing circuit) (18) – M14 (female) (1) and grounding

3

PC2000-8

M14 (female)

Pump controller 2 defective

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP06

Travel lever

Voltage

Between (18) – chassis ground

Neutral

Max. 1 V

Operated

20 – 30 V

5

SEN02101-00

40 Troubleshooting

Circuit diagram related to travel alarm

6

PC2000-8

40 Troubleshooting

SEN02101-00

Failure code [DW41KA] Swing Priority Sol Open Circuit User code

Failure code

—

DW41KA

Contents of trouble

Trouble

1

Swing Priority Sol Open Circuit (Pump controller 2 system)

• No current flows to the swing priority solenoid circuit, when power is supplied to the circuit.

Action of • None in particular (The solenoid does not function as there is no current flowing to it) machine moni• When the failure cause disappears of itself, the machine operation returns to normalcy. tor Problem that appears on machine

• When the boom is raised and the machine is swung simultaneously in the swing priority mode, the swing speed is low (the oil flow in the swing circuit is kept low).

Related information

• Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02301: Solenoid 2) • 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 [DW41KB].) Cause

1

Possible causes and standard value in normal state

(Internal disconnection)

V02 (male)

Resistance

Between (2) – (1)

20 – 60 z

a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection of wiring turning starting switch ON. harness Wiring harness from CP06 (female) (38) – V02 2 (Disconnection or Resistance Max. 1 z (female) (1) defective contact with Wiring harness between V02 (female) (2) – connector) Resistance Max. 1 z CP06 (female) (3), (23) Short-circuiting of wir- a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ing harness 3 (Contact with 24 V cir- Between wiring harness between CP06 (female) Voltage Max. 1 V cuit) (38) – V02 (female) (1) and grounding Pump controller 2 4 defective

PC2000-8

Standard value in normal state/Remarks on troubleshooting

Swing priority solenoid a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. defective

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP06 (female)

Resistance

Between (38) – chassis ground

20 – 60 z

7

SEN02101-00

40 Troubleshooting

Electric circuit diagram related to swing priority solenoid

8

PC2000-8

40 Troubleshooting

SEN02101-00

Failure code [DW41KB] Swing Priority Sol Short Circuit User code

Failure code

—

DW41KB

Contents of trouble

Trouble

1

Swing Priority Sol Short Circuit (Pump controller 2 system)

• Abnormal current flew to the swing priority solenoid, when power was supplied to the circuit.

Action of • Power supply to the swing priority solenoid circuit is switched OFF. machine moni- • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, tor unless the engine starting switch is once turned OFF. Problem that appears on machine Related information

• When the boom is raised and the machine is swung simultaneously in the swing priority mode, the swing speed is low (the oil flow in the swing circuit is kept low). • Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02301: Solenoid 2) Cause Swing priority solenoid defective 1 (Internal short-circuiting or grounding fault)

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V02 (male) Between (1) – (2)

20 – 60 z

Between (1) and grounding

Min. 1 Mz

Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ing harness 2 (Contact with ground- Between wiring harness between CP06 (female) Resistance Min. 1 Mz ing circuit) (38) – V02 (female) (1) and grounding a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP06 Pump controller 2 3 defective Between (38) – chassis ground

PC2000-8

Resistance

Swing priority switch Left work equipment control lever

Voltage

OFF + NEUTRAL

Max. 1 V

Swing priority mode + Swing operation + (When boom or bucket is operated)

20 – 30 V

9

SEN02101-00

40 Troubleshooting

Electric circuit diagram related to swing priority solenoid

10

PC2000-8

40 Troubleshooting

SEN02101-00

Failure code [DW45KA] Swing Brake Sol. Disc. User code

Failure code

E03

DW45KA

Contents of trouble

Trouble

1

Swing Brake Sol. Disc. (Pump controller 2 system)

• No current flows at output to swing brake solenoid circuit.

Action of controller

• None in particular. (Since no current flows, solenoid does not operate.) • If cause of failure disappears, system resets itself.

Problem that appears on machine

• Machine cannot swing (The swing holding brake cannot be released).

Related information

Possible causes and standard value in normal state

• Operating condition of swing brake solenoid (ON/OFF) can be checked with monitoring function. (Code 02300: Solenoid 1) • If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing brake release switch in release position (Swing holding brake does not work, however, when machine stops). • Keep the swing lock switch in the OFF position and the swing holding brake release switch in the RELEASE position during troubleshooting. • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or OFF, refer to the troubleshooting under failure code [DW45KB].) Cause

Standard value in normal state/Remarks on troubleshooting

Defective swing holding brake solenoid 1 (Internal disconnection)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective assembledtype diode D01 2 (Internal disconnection)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective swing lock switch 3 (Internal disconnection)

V20 (male)

Resistance

Between (1) – (2)

20 – 60 z

D01 (male)

Digital circuit tester

Continuity

Between (7) – (3)

Diode mode

There is continuity

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S04 (female) Between (3) – (4)

Switch

Resistance

OFF

Max. 1 z

LOCK (ON)

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 4 (Disconnection in wiring or defective contact in connector)

PC2000-8

Wiring harness between CP03 (female) (13) – R12 (female) (2), (1)

Resistance

Max. 1 z

Wiring harness between CP06 (female) (7) – A03 Resistance – A01 – A04 – D01 (female) (7)

Max. 1 z

Wiring harness between D01 (female) (3) – JB2 – Resistance R12 (female) (3)

Max. 1 z

Wiring harness between R12 (female) (5) – JB72 Resistance – A05 – A09 – V20 (female) (1)

Max. 1 z

11

SEN02101-00

40 Troubleshooting

Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CP06 (female) (7) – D01 (female) (7)

Possible causes and standard value in normal state

Wiring harness between R12 (female) (5) – JB72 Resistance – A05 – A09 – V20 (female) (1)

6

12

Voltage

Hot short (Short circuit Wiring harness between CP06 (female) (7) – A03 Resistance 5 with 24V circuit) in wir– A01 – A04 – D01 (female) (7) ing harness Wiring harness between D01 (female) (3) – JB2 – Resistance R12 (female) (3)

Defective pump controller 2

Max. 1 V Max. 1 z Max. 1 z Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP06 (female) Between (7) – chassis ground

Disconnect D01 and connect pins (3) and (7) on female side directly.

Resistance 20 – 60 z

PC2000-8

40 Troubleshooting

SEN02101-00

Circuit diagram related to swing holding brake solenoid of pump controller

PC2000-8

13

SEN02101-00

40 Troubleshooting

Failure code [DW45KB] Swing Brake Sol. S/C User code

Failure code

E03

DW45KB

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Swing Brake Sol. S/C (Pump controller 2 system)

• Abnormal current flowed at output to swing brake solenoid circuit. • Turns output to swing brake solenoid circuit OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Machine cannot swing. (The swing holding brake cannot be released). • Operating condition of swing brake solenoid (ON/OFF) can be checked with monitoring function. (Code 02300: Solenoid 1) • If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing brake release switch to release position (Swing holding brake does not work, however, when machine stops). Cause Defective swing holding brake solenoid 1 (Internal short circuit or ground fault)

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V05A, V05B (male)

Resistance

Between (2) – (1)

20 – 60 z

Between (2) – chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Ground fault in wiring harness 2 (Short circuit with GND Wiring harness between CP06 (female) (7) – D01 (7), (3) – R12 (female) (3), (5) – V20 circuit) (female) (1) and chassis ground

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. CP06 Defective pump con3 troller 2

14

Between (7) – chassis ground

Swing lever

Voltage

All levers in neutral

Max. 1 V (12 sec. after setting in neutral)

Work equipment or swing operated

20 – 30 V

PC2000-8

40 Troubleshooting

SEN02101-00

Circuit diagram related to swing holding brake solenoid of pump controller

PC2000-8

15

SEN02101-00

40 Troubleshooting

Failure code [DW91KA] Straight-Travel Sol. Disc. User code

Failure code

—

DW91KA

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Straight-Travel Sol. Disc. (Pump controller 2 system)

• No current flows to the straight travel solenoid circuit, when power is supplied to the circuit. • None in particular (The solenoid does not function as there is current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy. • When both tracks and work equipment are operated simultaneously, the machine deviates. • Operation of the straight travel solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or OFF, refer to the troubleshooting under failure code [DW91KB].) Cause Straight travel solenoid defective 1 (Internal disconnection)

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V07 (male)

Resistance value

Between (1) and (2)

20 – 60 z

a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection of wiring turning starting switch ON. harness Wiring harness from CP06 (female) (5) to V07 Resistance 2 (Disconnection or Max. 1 z (female) (1) value defective contact with Wiring harness between V03 (female) (1) and Resistance connector) Max. 1 z grounding value Hot short circuit in wir- a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ing harness 3 (Contact with 24 V cir- Between wiring harness between CP06 (female) Voltage Max. 1 V cuit) (5) – V07 (female) (1) and grounding Pump controller 2 4 defective

16

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP06 (female)

Resistance value

Between (5) – (13)

20 – 60 z

PC2000-8

40 Troubleshooting

SEN02101-00

Electrical diagram related to straight travel solenoid

PC2000-8

17

SEN02101-00

40 Troubleshooting

Failure code [DW91KB] Straight-Travel Sol. S/C User code

Failure code

—

DW91KB

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Straight-Travel Sol. S/C (Pump controller 2 system)

• Abnormal current flew to the straight travel circuit, when power was supplied to the circuit. • Power supply to the straight travel circuit is switched OFF. • Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the engine starting switch is once turned OFF. • When both tracks and work equipment are operated simultaneously, the machine deviates. • Operation of the straight travel solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) Cause Straight travel solenoid defective 1 (Internal short-circuiting or grounding fault)

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V07 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and grounding

Min. 1 Mz

Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ing harness 2 (Contact with ground- Between wiring harness between CP06 (female) Resistance Min. 1 Mz ing circuit) (5) – V07 (female) (1) and grounding value a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3

18

Pump controller 2 defective

CP06

Control lever

Voltage

NEUTRAL

Max. 1 V

Between (5) and grounding

Both tracks operation + Work equipment operation

20 – 30 V

PC2000-8

40 Troubleshooting

SEN02101-00

Electrical diagram related to travel junction solenoid

PC2000-8

19

SEN02101-00

40 Troubleshooting

Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc. User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code DW4XKA

Trouble

1

Bucket Curl Hi Cancel Sol. Disc. (Pump controller 2 system)

• Open error was detected in the bucket digging Hi cancel solenoid circuit. • None in particular (Provides the error display alone) • The bucket Hi cancel valve cannot work. • The input status (ON or OFF) from the bucket digging Hi cancel circuit can be checked with the monitoring function. (Code: 02301 Solenoid 2 bucket Hi cancel) Cause Standard value in normal state/Remarks on troubleshooting Defective bucket dig- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ging Hi cancel solenoid 1 valve (Internal disconV19 (male) Resistance nection) Between (1) and (2) 20 – 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (DisconnecWiring harness between CP06 (female) (13) – 2 Resistance Max. 1 z tion or defective con- V19 (female) (2) tact in connector) Wiring harness between CP06 (female) (25) – Resistance Max. 1 z V19 (female) (1) a Prepare with starting switch OFF, then turn starting switch ON and carry Hot short in wiring harout troubleshooting 3 ness (Contact with 24 Wiring harness between CP06 (female) (25) – V circuit) Voltage Max. 1 V V19 (female) (1) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective pump con4 troller 2 CP06 Resistance Between (25) and chassis ground 20 – 60 z

Circuit diagram related to bucket CURL high cancel solenoid

20

PC2000-8

40 Troubleshooting

SEN02101-00

Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DW4XKB

Trouble

1

Bucket Curl Hi Cancel Sol. S/C (Pump controller 2 system)

• Short circuit was detected in the bucket digging Hi cancel solenoid circuit. • Stops output to the circuit. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • The bucket Hi cancel valve cannot work. • The input status (ON or OFF) from the bucket digging Hi cancel solenoid valve can be checked with the monitoring function. (Code: 02301 Solenoid 2 bucket Hi cancel) Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Defective bucket digturning starting switch ON. ging Hi cancel solenoid V19 (male) Resistance 1 valve (Internal disconBetween (1) and (2) 20 – 60 z nection) Between (1) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between CP06 (female) (13) – 2 harness (Contact with Resistance Min. 1 Mz V19 (female) (2) and chassis ground GND circuit) Wiring harness between CP06 (female) (25) – Resistance Min. 1 Mz V19 (female) (1) and chassis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Work equipment control CP06 Voltage Defective pump conlever 3 troller 2 At neutral Max. 1 V Between (25) and When boom raise + chassis ground 20 – 30 V Bucket curl

Circuit diagram related to bucket CURL high cancel solenoid

PC2000-8

21

SEN02101-00

40 Troubleshooting

Failure code [DW7BKA] Fan Motor (RAD) Reverse Sol Open Circuit User code

Failure code

—

DW7BKA

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy. • Fan does not rotate in reverse. • Operating condition (ON/OFF) of RAD fan reverse solenoid can be checked with monitoring function. (Code 02303: Solenoid 4) (fan (RAD) reverse solenoid) • Since disconnection of solenoid is detected while output is turned ON, be sure to turn output ON (rotate fan in reverse) when checking reproduction of failure after repair.

Defective RAD fan 1 reverse solenoid (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V18 (female)

Resistance

Between (1) – (2)

20 – 60 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection of wiring harness (DisconnecWiring harness between CP03 (female) (25) – 2 Resistance Max. 1 z tion of defective con- V18 (female) (1) tact with connector) Wiring harness between V18 (female) (2) – Resistance Max. 1 z CP03 (female) (13) Short-circuiting of wir3 ing harness (Contact with 24 V circuit)

4

22

Fan Motor (RAD) Reverse Sol Open Circuit (Pump controller 1 system)

• When signal is output to RAD fan reverse solenoid circuit, no current flows.

Cause

Possible causes and standard value in normal state

1

Pump controller 1 defective

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between CP03 (female) (25) – V18 (female) (1) and grounding

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP03 (female)

Resistance

Between (25) and grounding

20 – 60 z

PC2000-8

40 Troubleshooting

SEN02101-00

Circuit diagram related to RAD fan

PC2000-8

23

SEN02101-00

40 Troubleshooting

Failure code [DW7BKB] Fan Reverse Sol. S/C User code

Failure code

—

DW7BKB

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Fan Reverse Sol. S/C (Pump controller 1 system)

• When signal was output to RAD fan reverse solenoid circuit, abnormal current flowed. • Turns signal to RAD fan reverse solenoid circuit OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Fan does not rotate in reverse. • Operating condition (ON/OFF) of RAD fan reverse solenoid can be checked with monitoring function. (Code 02303: Solenoid 4) (fan (RAD) reverse solenoid) Cause Defective RAD fan 1 reverse solenoid (Internal disconnection)

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V18 (male)

Resistance

Between (1) – (2)

20 – 60 z

Between (1) and grounding

Min. 1 Mz

Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ing harness 2 (Contact with ground- Between wiring harness between CP03 (female) Resistance Min. 1 Mz ing circuit) (25), – V18 (female) (1) and grounding a Prepare with starting switch OFF, then turn starting switch START and carry out troubleshooting. 3

Pump controller 1 defective

CP03 Between (25) and grounding

24

1

Fan reverse rotation mode

Voltage

When reverse rotation is turned OFF

Max. 1 V

When reverse rotation is turned ON

20 – 30 V

PC2000-8

40 Troubleshooting

SEN02101-00

Circuit diagram related to RAD fan

PC2000-8

25

SEN02101-00

40 Troubleshooting

Failure code [DW7HKA] Fan Motor(O/C) Reverse Sol Open Circuit User code

Failure code

—

DW7HKA

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy. • Fan does not rotate in reverse. • Operating condition (ON/OFF) of O/C fan reverse solenoid can be checked with monitoring function. (Code 02303: Solenoid 4) • Since disconnection of solenoid is detected while output is turned ON, be sure to turn output ON (rotate fan in reverse) when checking reproduction of failure after repair.

Defective O/C fan 1 reverse solenoid (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V17 (male)

Resistance

Between (1) – (2)

20 – 60 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection of wiring harness (DisconnecWiring harness between CP03 (female) (35) – 2 Resistance Max. 1 z tion of defective con- V17 (female) (1) tact with connector) Wiring harness between V17 (female) (2) – JB55 Resistance Max. 1 z – JC14 – CP03 (female) (13) Short-circuiting of wir3 ing harness (Contact with 24 V circuit)

4

26

Fan Motor(O/C) Reverse Sol Open Circuit (Pump controller 1 system)

• When signal is output to O/C fan reverse solenoid circuit, no current flows.

Cause

Possible causes and standard value in normal state

1

Pump controller 1 defective

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between CP03 (female) (35) – V17 (female) (1) and grounding

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP03 (female)

Resistance

Between (35) and grounding

20 – 60 z

PC2000-8

40 Troubleshooting

SEN02101-00

Circuit diagram related to O/C fan

PC2000-8

27

SEN02101-00

40 Troubleshooting

Failure code [DW7HKB] Fan Motor(O/C) Reverse Sol Short Circuit User code

Failure code

—

DW7HKB

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Fan Motor(O/C) Reverse Sol Short Circuit (Pump controller 1 system)

• When signal was output to O/C fan reverse solenoid circuit, abnormal current flowed. • Turns signal to O/C fan reverse solenoid circuit OFF. • When the failure cause disappears of itself, the machine operation returns to normalcy. • Fan does not rotate in reverse. • Operating condition (ON/OFF) of O/C fan reverse solenoid can be checked with monitoring function. (Code 02303: Solenoid 4) Cause Defective O/C fan 1 reverse solenoid (Internal disconnection)

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V17 (male)

Resistance

Between (1) – (2)

20 – 60 z

Between (1) and grounding

Min. 1 Mz

Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ing harness 2 (Contact with ground- Between wiring harness between CP03 (female) Resistance Min. 1 Mz ing circuit) (35), – V17 (female) (1) and grounding a Prepare with starting switch OFF, then turn starting switch START and carry out troubleshooting. Pump controller 1 3 defective

CP03 Between (35) and grounding

28

1

Fan reverse rotation mode

Voltage

When reverse rotation is turned OFF

Max. 1 V

When reverse rotation is turned ON

20 – 30 V

PC2000-8

40 Troubleshooting

SEN02101-00

Circuit diagram related to O/C fan

PC2000-8

29

SEN02101-00

40 Troubleshooting

Failure code [DWA3KA] Arm throttle Valve/L Sol Open Circuit User code

Failure code

—

DWA3KA

Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Arm throttle Valve/L Sol Open Circuit (Pump controller 2 system)

• Any current does not flow in the arm throttle valve (L) solenoid circuit. • None in particular. (Since any current does not flow, the solenoid does not operate.) • If the cause of the failure disappears, the system resets itself. • The arm throttle valve (L) does not work. • The output to the arm throttle valve (L) solenoid (current) can be checked in the monitoring function. (Code: 02302 Solenoid 3) Cause

Standard value in normal state/Remarks on troubleshooting

Defective arm throttle valve (L) solenoid 1 (Internal short circuit or grounding fault)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Discon2 nection in wiring or defective contact in connector)

V04 (male)

Resistance value

Between (1) and (2)

20 – 60 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LP06 (female) (3), (23) and V04 (female) (2)

Resistance value

Max. 1 z

Wiring harness between CP06 (female) (27) and Resistance V04 (female) (1) value

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harBetween wiring harness between CP06 (female) 3 Voltage Max. 1 V ness (Contact with 24- (27) to V04 (female) (1) and grounding V circuit) Between wiring harness between CP06 (female) Voltage Max. 1 V (27) to V04 (female) (1) and grounding

4

30

Trouble

1

Pump controller 2 defective

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP06 (female)

Resistance value

Between (27) and (3) (23)

20 – 60 z

PC2000-8

40 Troubleshooting

SEN02101-00

Circuit diagram related to arm throttle valve (L) solenoid

PC2000-8

31

SEN02101-00

40 Troubleshooting

Failure code [DWA3KB] Arm throttle Valve/L Sol Short Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DWA3KB

Trouble

• Turns off the output to the arm throttle valve (L) solenoid circuit. • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • The arm throttle valve (L) does not work. • The output to the arm throttle valve (L) solenoid (current) can be checked in the monitoring function. (Code: 02302 Solenoid 3)

Defective arm throttle valve (L) solenoid 1 (Internal short circuit or grounding fault)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V09 (male) Between (1) and (2)

Resistance value 20 – 60 z

Between (1) and ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chasShort circuit of wiring harness between CP06 sis ground in wiring Resistance 2 (female) (3), (23) and V04 (female) (2) with Min. 1 Mz harness (Contact with value ground ground circuit) Short circuit of wiring harness between CP06 Resistance Min. 1 Mz (female) (27) and V04 (female) (1) with ground value a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3

32

Arm throttle Valve/L Sol Short Circuit (Pump controller 2 system)

• An abnormal current flowed in the arm throttle valve (L) solenoid circuit.

Cause

Possible causes and standard value in normal state

1

Pump controller 2 defective

CP06 (female) Between (27) and (3) (23)

Control lever At neutral

Voltage Max. 1 V

When Boom raise + Arm dump

20 – 30 V

PC2000-8

40 Troubleshooting

SEN02101-00

Circuit diagram related to arm throttle valve (L) solenoid

PC2000-8

33

SEN02101-00

40 Troubleshooting

Failure code [DWA4KA] Arm throttle Valve/R Sol Open Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

34

Failure code DWA4KA

Trouble

1

Arm throttle Valve/R Sol Open Circuit (Pump controller 1 system)

• Any current does not flow in the arm throttle valve (R) solenoid circuit. • None in particular. (Since any current does not flow, the solenoid does not operate.) • If the cause of the failure disappears, the system resets itself. • The arm throttle valve (R) does not work. • The output to the arm throttle valve (R) solenoid (current) can be checked in the monitoring function. (Code: 02302 Solenoid 3) Cause Standard value in normal state/Remarks on troubleshooting Defective arm throttle a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. valve (R) solenoid 1 (Internal short circuit or V04 (male) Resistance value grounding fault) Between (1) and (2) 20 – 60 z a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wirturning starting switch ON. ing harness (DisconWiring harness between CP06 (female) (3) and Resistance 2 nection in wiring or Max. 1 z V05 (female) (2) value defective contact in Wiring harness between CP06 (female) (37) and Resistance connector) Max. 1 z V05 (female) (1) value a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harBetween wiring harness between CP06 (female) 3 Voltage Max. 1 V ness (Contact with 24- (13) to V05 (female) (2) and grounding V circuit) Between wiring harness between CP06 (female) Voltage Max. 1 V (37) to V05 (female) (1) and grounding a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Pump controller 2 4 defective CP06 (female) Resistance value Between (37) and (13) 20 – 60 z

PC2000-8

40 Troubleshooting

SEN02101-00

Circuit diagram related to arm throttle valve (R) solenoid

PC2000-8

35

SEN02101-00

40 Troubleshooting

Failure code [DWA4KB] Arm throttle Valve/R Sol Short Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DWA4KB

Trouble

Arm throttle Valve/R Sol Short Circuit (Pump controller 2 system)

• An abnormal current flowed in the arm throttle valve (R) solenoid circuit. • Turns off the output to the arm throttle valve (R) solenoid circuit. • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • The arm throttle valve (R) does not work. • The output to the arm throttle valve (R) solenoid (current) can be checked in the monitoring function. (Code: 02302 Solenoid 3) Cause Defective arm throttle valve (L) solenoid 1 (Internal short circuit or grounding fault)

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V05 (male) Between (1) and (2)

Resistance value 20 – 60 z

Between (1) and ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring Short circuit of wiring harness between CP06 Resistance 2 Min. 1 Mz harness (Contact with (female) (13) and V05 (female) (1) with ground value ground circuit) Short circuit of wiring harness between CP06 Resistance Min. 1 Mz (female) (37) and V05 (female) (1) with ground value a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3

36

Pump controller 2 defective

CP06

Control lever At neutral

Voltage Max. 1 V

Between (37) and (13)

When Arm dump + Boom raise + Swing

20 – 30 V

PC2000-8

40 Troubleshooting

SEN02101-00

Circuit diagram related to arm throttle valve (R) solenoid

PC2000-8

37

SEN02101-00

40 Troubleshooting

Failure code [DWA5KA] Auto Grease Sol Open Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

38

Failure code DWA5KA

Trouble

1

Auto Grease Sol Open Circuit (Pump controller 1 system)

• Open error was detected in the automatic greasing solenoid valve circuit • None in particular. (Since no current flows, solenoid does not operate.) • If cause of failure disappears, the system resets itself. • The automatic greasing cannot work. • The input status (ON or OFF) from the automatic greasing solenoid valve can be checked with the monitoring function. (code: 02303 Solenoid 4) Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Defective automatic turning starting switch ON. greasing solenoid 1 valve (Internal disconV25 (male) Resistance nection) Between (1) and (2) 10 – 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (DisconnecWiring harness between CP03 (female) (7) – 2 Resistance Max. 1 z tion or defective con- V25 (female) (1) tact in connector) Wiring harness between CP03 (female) (13) – Resistance Max. 1 z V25 (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry Hot short in wiring harout troubleshooting 3 ness (Contact with 24 Wiring harness between CP03 (female) (7) – V circuit) Voltage Max. 1 V V25 (female) (1) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Automatic greasing CP03 Voltage operation Defective pump con4 troller 1 When automatic greasMax. 1 V ing is turned OFF Between (7) and chassis ground When automatic greas20 – 30 V ing is turned ON

PC2000-8

40 Troubleshooting

SEN02101-00

Circuit diagram related to auto grease solenoid

PC2000-8

39

SEN02101-00

40 Troubleshooting

Failure code [DWA5KB] Auto Grease Sol Short Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DWA5KB

Trouble

1

Auto Grease Sol Short Circuit (Pump controller 1 system)

• Short circuit was detected in the automatic greasing solenoid valve circuit. • Stops output to the automatic greasing solenoid circuit. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • The automatic greasing cannot work. • The input status (ON or OFF) from the automatic greasing solenoid valve can be checked with the monitoring function. (Monitoring code: 02303 Automatic greasing solenoid valve) Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Internal failure of the turning starting switch ON. automatic greasing V25 (male) Resistance 1 solenoid valve (Internal Between (1) and (2) 20 – 60 z disconnection) Between (1) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between CP03 (female) (7) – 2 harness (Contact with Resistance Min. 1 Mz V25 (female) (1) and ground chassis GND circuit) Wiring harness between CP03 (female) (13) – Resistance Min. 1 Mz V25 (female) (2) and ground chassis a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Automatic greasing CP03 Voltage operation Defective pump con3 troller 1 When automatic greasMax. 1 V Between (7) and chas- ing is turned OFF sis ground When automatic greas20 – 30 V ing is turned ON

Circuit diagram related to auto grease solenoid

40

PC2000-8

40 Troubleshooting

SEN02101-00

Failure code [DWA6KA] Boom throttle Valve Sol Open Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code DWA6KA

Trouble

Boom throttle Valve Sol Open Circuit (Pump controller 2 system)

• Any current does not flow in the boom throttle valve solenoid circuit. • None in particular. (Since any current does not flow, the solenoid does not operate.) • If the cause of the failure disappears, the system resets itself. • The boom throttle valve does not work. • The output to the boom throttle valve solenoid (current) can be checked in the monitoring function. (Code: 02303 Solenoid 2) Cause

Standard value in normal state/Remarks on troubleshooting

Defective boom throttle valve solenoid 1 (Internal short circuit or grounding fault)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Discon2 nection in wiring or defective contact in connector)

V06 (male)

Resistance value

Between (1) and (2) 20 – 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (13) and Resistance Max. 1 z V06 (female) (2) value Wiring harness between CP06 (female) (35) and Resistance Max. 1 z V06 (female) (1) value

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harBetween wiring harness between CP06 (female) Voltage Max. 1 V 3 ness (Contact with 24- (13) to V06 (female) (2) and grounding V circuit) Between wiring harness between CP06 (female) Voltage Max. 1 V (35) to V06 (female) (1) and grounding a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Pump controller 2 4 defective CP036 (female) Resistance value Between (35) and ground

PC2000-8

1

20 – 60 z

41

SEN02101-00

40 Troubleshooting

Circuit diagram related to boom throttle valve solenoid

42

PC2000-8

40 Troubleshooting

SEN02101-00

Failure code [DWA6KB] Boom throttle Valve Sol Short Circuit User code

Failure code

E06

DWA6KB

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Boom throttle Valve Sol Short Circuit (Pump controller 2 system)

• An abnormal current flowed in the boom throttle valve solenoid circuit. • Turns off the output to the boom throttle valve solenoid circuit. • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • The boom throttle valve does not work. • The output to the boom throttle valve solenoid (current) can be checked in the monitoring function. (Code: 02301 Solenoid 2) Cause Defective boom throttle valve solenoid 1 (Internal short circuit or grounding fault)

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V09 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring Short circuit of wiring harness between CP06 Resistance 2 Min. 1 Mz harness (Contact with (female) (13) and V06 (female) (2) with ground value ground circuit) Short circuit of wiring harness between CP06 Resistance Min. 1 Mz (female) (35) and V06 (female) (1) with ground value a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3

Pump controller 2 defective

CP06 Between (35) and (13)

PC2000-8

Control lever

Voltage

At neutral

Max. 1 V

When Boom raise + Swing

20 – 30 V

43

SEN02101-00

40 Troubleshooting

Circuit diagram related to boom throttle valve solenoid

44

PC2000-8

40 Troubleshooting

SEN02101-00

Failure code [DWK0KA] 2-stage Relief Sol. Disc. User code

Failure code

—

DWK0KA

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

2-stage Relief Sol. Disc. (Pump controller 2 system)

• No current flows at output to 2-stage relief solenoid circuit. • None in particular. (Since no current flows, solenoid does not operate.) • If cause of failure disappears, system resets itself. • Travel power of work equipment is low (The main relief valve is not set in the HIGH PRESSURE position). • Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function. (Code 02300: Solenoid 1) • Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure to turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code [DWK0KB].) Cause

Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting without Defective 2-stage relief turning starting switch ON. 1 solenoid V06 (male) Resistance (Internal disconnection) Between (2) – (1) 20 – 60 z

Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness Wiring harness between CP06 (female) (3), (23) Resistance Max. 1 z 2 (Disconnection in wiring – V03 (female) (2) or defective contact in Wiring harness between CP06 (female) (15) – connector) Resistance Max. 1 z J03 a Prepare with starting switch OFF, then turn starting switch ON and carry Hot short (short circuit out troubleshooting. 3 with 24V circuit) in wirWiring harness between CP06 (female) (15) – ing harness Voltage Max. 1 V V03 (female) (1) and chassis ground Defective pump con4 troller 2

PC2000-8

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP06 (female)

Resistance

Between (15) – chassis ground

20 – 60 z

45

SEN02101-00

40 Troubleshooting

Circuit diagram related to 2-stage relief solenoid of pump controller

46

PC2000-8

40 Troubleshooting

SEN02101-00

Failure code [DWK0KB] 2-stage Relief Sol. S/C User code

Failure code

—

DWK0KB

Contents of trouble Action of controller

Trouble

1

2-stage Relief Sol. S/C (Pump controller 2 system)

• Abnormal current flowed at output to 2-stage relief solenoid circuit. • Turns output to 2-stage relief solenoid circuit OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that appears on machine

• Travel power of work equipment is low (The main relief valve is not set in the HIGH PRESSURE position).

Related information

• Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function. (Code 02300: Solenoid 1) Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting without Defective 2-stage relief turning starting switch ON. solenoid V08 (male) Resistance 1 (Internal short circuit or Between (2) – (1) 20 – 60 z ground fault) Between (2) – chassis ground Min. 1 Mz Ground fault in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. harness 2 (Short circuit with GND Wiring harness between CP06 (female) (15) – Resistance Min. 1 Mz circuit) V03 (female) (1) and chassis ground

3

Defective pump controller 2

a Prepare with starting switch OFF, then keep the engine running and carry out troubleshooting. CP06

Travel control lever

Voltage

Between (3) – chassis ground

NEUTRAL

Max. 1 V

Travel operation

20 – 30 V

Circuit diagram related to 2-stage relief solenoid of pump controller

PC2000-8

47

SEN02101-00

40 Troubleshooting

Failure code [DWK2KA] Back Press Comp Valve Sol Open Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code DWK2KA

Trouble

1

Back Press Comp Valve Sol Open Circuit (Pump controller 2 system)

• Open error was detected in the variable back pressure solenoid valve circuit. • None in particular. (Since no current flows, solenoid does not operate.) • If cause of failure disappears, the system resets itself. • Relief pressure except that for the swing and travel sometimes deviates from the standard set pressure. • The input status (ON or OFF) from the variable backpressure solenoid valve can be checked with the monitoring function. (Monitoring code: 02300 Solenoid 3) Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Defective variable turning starting switch ON. back pressure solenoid 1 valve (Internal disconV01 (male) Resistance nection) Between (1) and (2) 20 – 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (DisconnecWiring harness between CP06 (female) (3) (23) 2 Resistance Max. 1 z tion or defective con- – V01 (female) (2) tact in connector) Wiring harness between CP06 (female) (28) – Resistance Max. 1 z V01 (female) (1) a Prepare with starting switch OFF, then turn starting switch ON and carry Hot short in wiring harout troubleshooting 3 ness (Contact with 24 Wiring harness between CP06 (female) (28) – V circuit) Voltage Max. 1 V V01 (female) (1) and ground chassis a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective pump conCP06 Swing control lever Voltage 4 troller 2 At neutral Max. 1 V Between (28) and chassis ground In swing operation 20 – 30 V

Circuit diagram related to back pressure compensation valve solenoid

48

PC2000-8

40 Troubleshooting

SEN02101-00

Failure code [DWK2KB] Back Press Comp Valve Sol Short Circuit User code — Contents of trouble Action of controller Problem that appears on machine Related information

Possible causes and standard value in normal state

Failure code DWK2KB

Trouble

1

Back Press Comp Valve Sol Short Circuit (Pump controller 1 system)

• Short circuit was detected in the variable backpressure solenoid valve circuit. • Variable back pressure solenoid stops output to the circuit. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Relief pressure except that for the swing and travel sometimes deviates from the standard set pressure. • The input status (ON or OFF) from the variable back pressure solenoid valve can be checked with the monitoring function. (Monitoring code: 02302 Solenoid 3) Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Defective variable turning starting switch ON. back pressure solenoid 1 valve (Internal disconV01 (male) Resistance nection) Between (1) and (2) 20 – 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Wiring harness between CP06 (female) (3), (23) 2 harness (Contact with Resistance Max. 1 z – V01 (female) (2) and ground chassis GND circuit) Wiring harness between CP06 (female) (28) – Resistance Max. 1 z V01 (female) (1) and ground chassis a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective pump conCP06 Swing control lever Voltage 3 troller 2 At neutral Max. 1 V Between (28) and chassis ground In swing operation 20 – 30 V

Circuit diagram related to back pressure compensation valve solenoid

PC2000-8

49

SEN02101-00

PC2000-8 Hydraulic excavator Form No. SEN02101-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

50

SEN02102-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

40 Troubleshooting

1

Troubleshooting by failure code, Part 7 Troubleshooting by failure code, Part 7 .......................................................................................................... 3 Failure code [DWN5KA] Fan(RAD) Pump EPC Sol Open Circuit........................................................ 3 Failure code [DWN5KB] Fan(RAD) Pump EPC Sol Short Circuit ........................................................ 5 Failure code [DWNCKA] Fan(O/C) Pump EPC Sol Open Circuit ........................................................ 6 Failure code [DWNCKB] Fan(O/C) Pump EPC Sol Short Circuit......................................................... 7 Failure code [DXAAKA] P1F EPC Sol Disc.......................................................................................... 8 Failure code [DXAAKB] P1F EPC Sol S/C......................................................................................... 10 Failure code [DXABKA] P1R Pump EPC Sol. Disc............................................................................ 12 Failure code [DXABKB] P1R Pump EPC Sol. S/C............................................................................. 14 Failure code [DXACKA] P2F Pump EPC Sol. Disc. ........................................................................... 16 Failure code [DXACKB] P2F Pump EPC Sol. S/C ............................................................................. 18 Failure code [DXADKA] P2R Pump EPC Sol. Disc............................................................................ 20 Failure code [DXADKB] P2R Pump EPC Sol. S/C............................................................................. 22 Failure code [DY2CKB] Washer Drive S/C ........................................................................................ 24 Failure code [DY20MA] Low Wiper Working Abnormality .................................................................. 26 Failure code [DY2FMA] Upper Wiper Working Abnormality............................................................... 29

PC2000-8

1

SEN02102-00

40 Troubleshooting

Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38) .... 32 Failure code [F@BYNR] Very High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 62)..................................................................... 34 Failure code [f@BYNR] Very High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 72)..................................................................... 36 Failure code [F@BYNS] High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 61)..................................................................... 38 Failure code [f@BYNS] High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 71)..................................................................... 40 Failure code [F@BZNR] Very High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 82)..................................................................... 42 Failure code [f@BZNR] Very High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 92)..................................................................... 44 Failure code [F@BZNS] High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 81)..................................................................... 46 Failure code [f@BZNS] High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 91)..................................................................... 48 Failure code [LA10ZL] RAD system fan pump relief pressure high error........................................... 50 Failure code [LA20ZL] O/C system pump relief pressure high error .................................................. 51

2

PC2000-8

40 Troubleshooting

SEN02102-00

Troubleshooting by failure code, Part 7

1

Failure code [DWN5KA] Fan(RAD) Pump EPC Sol Open Circuit

1

User code

Failure code

E11

DWN5KA

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

• No current flows into RAD fan pump EPC solenoid circuit. • When the solenoid is disconnected and power is OFF, fan pump becomes max. swash plate angle. • Fan motor speed cannot be controlled. • Output (Current) to RAD fan pump EPC solenoid can be checked with monitoring function. (Code 31624: RAD fan pump EPC solenoid current) Cause Defective RAD fan pump EPC solenoid 1 (Internal disconnection)

Possible causes and standard value in normal state

Fan(RAD) Pump EPC Sol Open Circuit (Pump controller 1 system)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V15 (male)

Resistance

Between (1) – (2)

10 – 22 z

a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection of wiring turning starting switch ON. harness Wiring harness between CP03 (female) (5) – 2 (Disconnection or Resistance Max. 1 z V15 (female) (1) defective contact with Wiring harness between V15 (female) (2) – JC11 connector) Resistance Max. 1 z – JC14 – CP03 (female) (13) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Short-circuiting of wirBetween wiring harness between CP03 (female) ing harness 3 (5) – V15 (female) (1) and grounding (Contact with 24 V cirBetween wiring harness between V13 (female) cuit) (2) – JC11 – JC14 – CP03 (female) (13) and grounding Pump controller 1 4 defective

PC2000-8

Voltage

Max. 1 V

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP03 (female)

Resistance

Between (5) – (13)

7 – 14 z

3

SEN02102-00

40 Troubleshooting

Circuit diagram related to RAD fan pump EPC solenoid

4

PC2000-8

40 Troubleshooting

SEN02102-00

Failure code [DWN5KB] Fan(RAD) Pump EPC Sol Short Circuit User code

Failure code

E11

DWN5KB

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Fan(RAD) Pump EPC Sol Short Circuit (Pump controller 1 system)

• Abnormal current flowed in RAD fan pump EPC solenoid circuit. • When the short circuit is detected and power is OFF, fan pump becomes max. swash plate angle. • Fan motor speed cannot be controlled. • Output (Current) to RAD fan pump EPC solenoid can be checked with monitoring function. (Code 31624: RAD fan pump EPC solenoid current) Cause Defective RAD fan pump EPC solenoid 1 (Internal short-circuiting or grounding fault)

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V15 (male)

Resistance

Between (1) – (2)

7 – 14 z

Between (1) and grounding

Min. 1 Mz

Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ing harness 2 (Contact with ground- Between wiring harness between CP03 (female) Resistance Min. 1 Mz ing circuit) (5) – V15 (female) (1) and grounding

3

Pump controller 1 defective

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. C03 (female)

Resistance

Between (5) – (13)

7 – 14 z

Between (5) and grounding

Min. 1 Mz

Circuit diagram related to RAD fan pump EPC solenoid

PC2000-8

5

SEN02102-00

40 Troubleshooting

Failure code [DWNCKA] Fan(O/C) Pump EPC Sol Open Circuit User code

Failure code

E11

DWNCKA

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Fan(O/C) Pump EPC Sol Open Circuit (Pump controller 1 system)

• No current flows into O/C fan pump EPC solenoid circuit. • When the short circuit is detected and power is OFF, fan pump becomes max. swash plate angle. • Fan motor speed cannot be controlled. • Output (Current) to O/C fan pump EPC solenoid can be checked with monitoring function. (Code 31623: O/C fan pump EPC solenoid current) Cause Defective O/C fan pump EPC solenoid 1 (Internal disconnection)

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V16 (male)

Resistance

Between (1) – (2)

10 – 22 z

a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection of wiring turning starting switch ON. harness Wiring harness between CP03 (female) (15) – 2 (Disconnection or Resistance Max. 1 z V16 (female) (1) defective contact with Wiring harness between V13 (female) (2) – JC11 connector) Resistance Max. 1 z – JC14 – CP03 (female) (13) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Short-circuiting of wirBetween wiring harness between CP03 (female) ing harness 3 (45) – V16 (female) (1) and grounding (Contact with 24 V cirBetween wiring harness between V13 (female) cuit) (2) – JC11 – JC14 – CP03 (female) (13) and grounding Pump controller 1 4 defective

Voltage

Max. 1 V

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP03 (female)

Resistance

Between (15) – (13)

7 – 14 z

Circuit diagram related to O/C fan pump EPC solenoid

6

PC2000-8

40 Troubleshooting

SEN02102-00

Failure code [DWNCKB] Fan(O/C) Pump EPC Sol Short Circuit User code

Failure code

E11

DWNCKB

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Fan(O/C) Pump EPC Sol Short Circuit (Pump controller 1 system)

• Abnormal current flowed in O/C fan pump EPC solenoid circuit. • When the short circuit is detected and power is OFF, fan pump becomes max. swash plate angle. • Fan motor speed cannot be controlled. • Output (Current) to O/C fan pump EPC solenoid can be checked with monitoring function. (Code 31623: O/C fan pump EPC solenoid current) Cause Defective O/C fan pump EPC solenoid 1 (Internal short-circuiting or grounding fault)

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V16 (male)

Resistance

Between (1) – (2)

7 – 14 z

Between (1) and grounding

Min. 1 Mz

Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ing harness 2 (Contact with ground- Between wiring harness between CP03 (female) Resistance Min. 1 Mz ing circuit) (15) – V16 (female) (1) and grounding

3

Pump controller 1 defective

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. C03 (female)

Resistance

Between (15) – (13)

7 – 14 z

Between (15) and grounding

Min. 1 Mz

Circuit diagram related to O/C fan pump EPC solenoid

PC2000-8

7

SEN02102-00

40 Troubleshooting

Failure code [DXAAKA] P1F EPC Sol Disc User code

Failure code

E07

DXAAKA

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

P1F EPC Sol Disc (Pump controller 1 system)

• When P1F pump EPC solenoid was energized, disconnection was detected in solenoid. • Turns on the protection mode (including forcibly turning on the straight travel solenoid) • If cause of failure disappears, system does not reset itself until starting switch is turned OFF. • The swing speed is reduced. • Work equipment and travel speed is reduced. • The machine deviates during travel. • Current to energize P1F pump EPC solenoid can be checked with monitoring function. (Code: 01307 P1F pump EPC current) • Method of reproducing failure code: Turn starting switch ON. Cause Defective P1F pump 1 EPC solenoid (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V11 (male)

Resistance

Between (1) – (2)

7 – 14 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective emergency pump drive switch 2 (pump 1) (Internal disconnection) Possible causes and standard value in normal state

Emergency pump drive switch (pump 1)

Between (3) – (2) Between (6) – (5)

Resistance

Normal

Max. 1 z

Emergency

Min. 1 Mz

Normal

Max. 1 z

Emergency

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

Defective pump con4 troller 1

8

A33 (male)

Wiring harness between CP03 (female) (6) – A33 (female) (3)

Resistance

Max. 1 z

Wiring harness between A33 (female) (2) – V11 (female) (1)

Resistance

Max. 1 z

Wiring harness between CP03 (female) (13) – JC14 – A33 (female) (6)

Resistance

Max. 1 z

Wiring harness between A33 (female) (5) – V11 (female) (2)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP03 (female)

Resistance

Between (6) – (13)

7 – 14 z

PC2000-8

40 Troubleshooting

SEN02102-00

Circuit diagram related to P1F pump EPC solenoid

PC2000-8

9

SEN02102-00

40 Troubleshooting

Failure code [DXAAKB] P1F EPC Sol S/C User code

Failure code

E07

DXAAKB

Trouble

1

P1F EPC Sol S/C (Pump controller 1 system)

Contents of trouble

• When P1F pump control EPC solenoid was energized, short circuit was detected in solenoid.

Action of controller

• Turns on the protection mode (including forcibly turning on the straight travel solenoid) • If cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that appears on machine Related information

• The swing speed is reduced. • Work equipment and travel speed is reduced. • The machine deviates during travel. • Current to energize P1F pump control EPC solenoid can be checked with monitoring function. (Code: 01307 P1F pump EPC current) • Method of reproducing failure code: Turn starting switch ON. Cause Defective P1F pump control EPC solenoid 1 (Internal short circuit or ground fault)

Possible causes and standard value in normal state

Defective emergency pump (pump 1) drive 2 switch (Internal short circuit or ground fault)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V11 (male)

Resistance

Between (1) – (2)

7 – 14 z

Between (6) – chassing ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. A33 (male)

Emergency pump drive switch (pump 1)

Between (2), (3) – (4) Between (2), (3) – chassing ground

Ground fault in wiring 3 harness (Short circuit with GND circuit)

4

10

Standard value in normal state/Remarks on troubleshooting

Defective pump controller 1

Resistance Min. 1 Mz

Normal

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP03 (female) (6) – A33 (female) (3) – chassis ground

Resistance Min. 1 Mz

Wiring harness between A33 (female) (2) – V11 (female) (1) – chassis ground

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP03 (female)

Resistance

Between (6) – (13)

7 – 14 z

Between (6) – chassis ground

Min. 1Mz

PC2000-8

40 Troubleshooting

SEN02102-00

Circuit diagram related to P1F pump EPC solenoid

PC2000-8

11

SEN02102-00

40 Troubleshooting

Failure code [DXABKA] P1R Pump EPC Sol. Disc. User code

Failure code

E07

DXABKA

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

P1R Pump EPC Sol. Disc. (Pump controller 1 system)

• When P1R pump EPC solenoid was energized, disconnection was detected in solenoid. • Turns on the protection mode (including forcibly turning on the straight travel solenoid) • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Work equipment, swing speed and machine travel speed are reduced. • The machine deviates during travel. • Current to energize P1R pump control EPC solenoid can be checked with monitoring function. (Code: 01309 P1R pump EPC current) • Method of reproducing failure code: Turn starting switch ON. Cause Defective P1R pump control EPC solenoid 1 (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V12 (male)

Resistance

Between (1) – (2)

7 – 14 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective emergency pump (pump 1) drive 2 switch (Internal disconnection) Possible causes and standard value in normal state

Emergency pump drive switch (pump 1)

Between (9) – (8) Between (12) – (11)

Resistance

Normal

Max. 1 z

Emergency

Min. 1 Mz

Normal

Max. 1 z

Emergency

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

Defective pump con4 troller 1

12

A33 (male)

Wiring harness between CP03 (female) (16) – A33 (female) (9)

Resistance

Max. 1 z

Wiring harness between A33 (female) (8) – V12 (female) (1)

Resistance

Max. 1 z

Wiring harness between CP03 (female) (13) – JC14 – A33 (female) (12)

Resistance

Max. 1 z

Wiring harness between A33 (female) (11) – V12 Resistance (female) (2)

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP03 (female)

Resistance

Between (16) – (13)

7 – 14 z

PC2000-8

40 Troubleshooting

SEN02102-00

Circuit diagram related to P1R pump EPC solenoid

PC2000-8

13

SEN02102-00

40 Troubleshooting

Failure code [DXABKB] P1R Pump EPC Sol. S/C User code

Failure code

E07

DXABKB

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

• Turns on the protection mode (including forcibly turning on the straight travel solenoid) • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Work equipment, swing speed and machine travel speed are reduced. • The machine deviates during travel. • Current to energize P1R pump control EPC solenoid can be checked with monitoring function. (Code: 01309 P1R pump EPC current) • Method of reproducing failure code: Turn starting switch ON.

Defective P1R pump control EPC solenoid 1 (Internal short circuit or ground fault)

Defective emergency pump (pump 1) drive 2 switch (Internal short circuit or ground fault)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V12 (male)

Resistance

Between (1) – (2)

7 – 14 z

Between (1) – chassis ground

Min 1. Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. A33 (male)

Emergency pump drive switch (pump 1)

Between (8), (9) – (10) Between (8), (9) – chassis ground

Ground fault in wiring 3 harness (Short circuit with GND circuit)

4

14

P1R Pump EPC Sol. S/C (Pump controller 1 system)

• When P1R pump control EPC solenoid was energized, short circuit was detected in solenoid.

Cause

Possible causes and standard value in normal state

1

Defective pump controller 1

Resistance Min. 1 Mz

Normal

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP03 (female) (16) – A33 (female) (9) – chassis ground

Resistance Min. 1 Mz

Wiring harness between A33 (female) (8) – V12 (female) (1) – chassis ground

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP03 (female)

Resistance

Between (16) – (13)

7 – 14 z

Between (16) – chassis ground

Min. 1 Mz

PC2000-8

40 Troubleshooting

SEN02102-00

Circuit diagram related to P1R pump EPC solenoid

PC2000-8

15

SEN02102-00

40 Troubleshooting

Failure code [DXACKA] P2F Pump EPC Sol. Disc. User code

Failure code

E07

DXACKA

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

P2F Pump EPC Sol. Disc. (Pump controller 1 system)

• When P2F pump control EPC solenoid was energized, disconnection was detected in solenoid. • Turns on the protection mode (including forcibly turning on the straight travel solenoid) • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Work equipment, swing speed and machine travel speed are reduced. • The machine deviates during travel. • Current to energize P2F pump control EPC solenoid can be checked with monitoring function. (Code: 01311 P2F pump EPC current) • Method of reproducing failure code: Turn starting switch ON. Cause Defective P2F pump control EPC solenoid 1 (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V11 (male)

Resistance

Between (1) – (2)

7 – 14 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective emergency pump (pump 2) drive 2 switch (Internal disconnection) Possible causes and standard value in normal state

Emergency pump drive switch (pump 2)

Between (3) – (2) Between (6) – (5)

Resistance

Normal

Max. 1 z

Emergency

Min. 1 Mz

Normal

Max. 1 z

Emergency

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

Defective pump con4 troller 1

16

A34 (male)

Wiring harness between CP03 (female) (26) – A34 (female) (3)

Resistance

Max. 1 z

Wiring harness between A34 (female) (2) – V13 (female) (1)

Resistance

Max. 1 z

Wiring harness between CP03 (female) (13) – JC14 – A34 (female) (6)

Resistance

Max. 1 z

Wiring harness between A34 (female) (5) – V13 (female) (2)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP03 (female)

Resistance

Between (26) – (13)

7 – 14 z

PC2000-8

40 Troubleshooting

SEN02102-00

Circuit diagram related to P2F pump EPC solenoid

PC2000-8

17

SEN02102-00

40 Troubleshooting

Failure code [DXACKB] P2F Pump EPC Sol. S/C User code

Failure code

E07

DXACKB

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

P2F Pump EPC Sol. S/C (Pump controller 1 system)

• When P2F pump control EPC solenoid was energized, short circuit was detected in solenoid. • Stops output to circuit. • Turns on the protection mode (including forcibly turning on the straight travel solenoid) • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Work equipment, swing speed and machine travel speed are reduced. • The machine deviates during travel. • Current to energize P2F pump control EPC solenoid can be checked with monitoring function. (Code: 01311 P2F pump EPC current) • Method of reproducing failure code: Turn starting switch ON. Cause Defective P2F pump control EPC solenoid 1 (Internal short circuit or ground fault)

Possible causes and standard value in normal state

1

Defective emergency pump (pump 2) drive 2 switch (Internal short circuit or ground fault)

Ground fault in wiring 3 harness (Short circuit with GND circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V11 (male)

Resistance

Between (1) – (2)

7 – 14 z

Between (6) – chassing ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. A34 (male)

Emergency pump drive switch (pump 2)

Between (2), (3) – (4) Between (2), (3) – chassing ground

Resistance Min. 1 Mz

Normal

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP03 (female) (26) – A34 (female) (3) – chassis ground

Resistance Min. 1 Mz

Wiring harness between A34 (female) (2) – V13 (female) (1) – chassis ground

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4

18

Defective pump controller 1

CP03 (female)

Resistance

Between (26) – (13)

7 – 14 z

Between (26) – chassis ground

Min. 1Mz

PC2000-8

40 Troubleshooting

SEN02102-00

Circuit diagram related to P2F pump EPC solenoid

PC2000-8

19

SEN02102-00

40 Troubleshooting

Failure code [DXADKA] P2R Pump EPC Sol. Disc. User code

Failure code

E07

DXADKA

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

P2R Pump EPC Sol. Disc. (Pump controller 1 system)

• When P2R pump control EPC solenoid was energized, disconnection was detected in solenoid. • Turns on the protection mode (including forcibly turning on the straight travel solenoid) • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Work equipment, swing speed and machine travel speed are reduced. • The machine deviates during travel. • Current to energize P2R pump control EPC solenoid can be checked with monitoring function. (Code: 01311 P2R pump EPC current) • Method of reproducing failure code: Turn starting switch ON. Cause Defective P2R pump control EPC solenoid 1 (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V14 (male)

Resistance

Between (1) – (2)

7 – 14 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective emergency pump (pump 2) drive 2 switch (Internal disconnection) Possible causes and standard value in normal state

Emergency pump drive switch (pump 2)

Between (9) – (8) Between (12) – (11)

Resistance

Normal

Max. 1 z

Emergency

Min. 1 Mz

Normal

Max. 1 z

Emergency

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

Defective pump con4 troller 1

20

A34 (male)

Wiring harness between CP03 (female) (36) – A34 (female) (9)

Resistance

Max. 1 z

Wiring harness between A34 (female) (8) – V14 (female) (1)

Resistance

Max. 1 z

Wiring harness between CP03 (female) (13) – JC14 – A34 (female) (12)

Resistance

Max. 1 z

Wiring harness between A34 (female) (11) – V12 Resistance (female) (2)

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CP03 (female)

Resistance

Between (36) – (13)

7 – 14 z

PC2000-8

40 Troubleshooting

SEN02102-00

Circuit diagram related to P2R pump EPC solenoid

PC2000-8

21

SEN02102-00

40 Troubleshooting

Failure code [DXADKB] P2R Pump EPC Sol. S/C User code

Failure code

E07

DXADKB

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

P2R Pump EPC Sol. S/C (Pump controller 1 system)

• When P2R pump control EPC solenoid was energized, short circuit was detected in solenoid. • Stops output to circuit. • Turns on the protection mode (including forcibly turning on the straight travel solenoid) • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Work equipment, swing speed and machine travel speed are reduced. • The machine deviates during travel. • Current to energize P2R pump control EPC solenoid can be checked with monitoring function. (Code: 01302 P2R pump EPC current) • Method of reproducing failure code: Turn starting switch ON. Cause Defective P2R pump control EPC solenoid 1 (Internal short circuit or ground fault)

Possible causes and standard value in normal state

1

Defective emergency pump (pump 2) drive 2 switch (Internal short circuit or ground fault)

Ground fault in wiring 3 harness (Short circuit with GND circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V14 (male)

Resistance

Between (1) – (2)

7 – 14 z

Between (1) – chassis ground

Min 1. Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. A34 (male)

Emergency pump drive switch (pump 2)

Between (8), (9) – (10) Between (8), (9) – chassis ground

Resistance Min. 1 Mz

Normal

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP03 (female) (36) – A34 (female) (9) – chassis ground

Resistance Min. 1 Mz

Wiring harness between A34 (female) (8) – V14 (female) (1) – chassis ground

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4

22

Defective pump controller 1

CP03 (female)

Resistance

Between (36) – (13)

7 – 14 z

Between (36) – chassis ground

Min. 1 Mz

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SEN02102-00

Circuit diagram related to P2R pump EPC solenoid

PC2000-8

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Failure code [DY2CKB] Washer Drive S/C User code

Failure code

—

DY2CKB

Contents of trouble

Trouble

1

Washer Drive S/C (Pump controller 2 system)

• Abnormal current flowed in washer drive circuit.

Action of • Stops output to washer motor circuit. monitor panel Problem that appears on machine

• Window washer operation stops.

Related information Cause Defective washer 1 motor (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M06A, M06B (male)

Resistance

Between (2) – (1)

5 – 40 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state

Wiring harnesses between CP06 (female) (17) – Resistance Min. 1 Mz Ground fault (Short cir- RW5 (female) (1) and chassis ground 2 cuit with GND circuit) Wiring harnesses between F01 – A03 – H02 – in wiring harness Resistance Min. 1 Mz RW5 (female) (3) and chassis ground Wiring harnesses between RW5 (female) (5) – M06A, M06B (female) (1)

3

24

Defective pump controller 2

Resistance Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CP06

Washer switch

Voltage

Between (17) – chassis ground

OFF

Max. 1 V

ON

20 – 30 V

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Circuit diagram related to window washer motor

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25

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40 Troubleshooting

Failure code [DY20MA] Low Wiper Working Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DY20MA

Trouble

1

Low Wiper Working Abnormality (Pump controller 2 system)

• The lower wiper contact does not close in 8 or more seconds after the lower wiper is turned on. • Turns output to wiper motor circuit OFF. • Wiper motor does not operate • If failure code [D1E9KB] or [D1EBKB] is displayed, carry out troubleshooting for it first. • State of the output to the wiper motor can be checked with monitoring function. (Code 02308 SWITCH INPUT 5 LOWER WIPER LIMIT SWITCH, 03700 CONTROLLER OUTPUT 1 WIPER LOWER ON, WIPER LOWER BRAKE) Cause

1

2

3

Possible causes and standard value in normal state

4

26

Standard value in normal state/Remarks on troubleshooting Monitoring code: Check that the monitoring code 02308: SWITCH INPUT Defective lower wiper 5 is indicated and that the lower wiper limit switch is ON. storage position (If OFF, adjust the storage position to turn the switch ON.) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective lower wiper Replace the lower wiper Normal state is recovDefective drive relay drive relay ered drive relay with the upper drive relay or the Normal state is not Failure on other upper brake relay. recovered equipment or circuit a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective lower wiper Replace the lower wiper Normal state is recovDefective brake relay brake relay ered drive relay with the upper drive relay or the Normal state is not Failure on other equipupper brake relay. recovered ment or circuit a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (26) – Resistance Max. 1 z relay terminal SR3 Wiring harness between relay terminal SR1 – Resistance Max. 1 z M05B (female) (2) Wiring harness between CP06 (female) (20) – Resistance Max. 1 z M05B (female) (5) Wiring harness between F01-10 – A03 – relay Resistance Max. 1 z terminal SR2 Disconnection in wiring Wiring harness between relay terminal SR4 – Resistance Max. 1 z harness RW3 – JC57A – A03 (Disconnection or Wiring harness between CP06 (female) (26) – defective contact in Resistance Max. 1 z RES3 (1) connector) Wiring harness between RES3 (2) and chassis Resistance Max. 1 z ground Wiring harness between CP06 (female) (36) – Resistance Max. 1 z relay terminal SR3 Wiring harness between relay terminal SR1 – Resistance Max. 1 z M05B (female) (4) Wiring harness between CP06 (female) (36) – Resistance Max. 1 z RES4 (female) (1) Wiring harness between RES4 (female) (2) and Resistance Max. 1 z chassis ground

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SEN02102-00

Cause

Ground fault in wiring 5 harness (Short circuit with GND circuit)

Possible causes and standard value in normal state

PC2000-8

6

Defective lower wiper motor

7

Defective pump controller

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF (disconnect the related connectors), then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (26) – Resistance Min. 1 Mz relay terminal SR3 and chassis ground Wiring harness between relay terminal SR1 – Resistance Min. 1 Mz M05B (female) (2) and chassis ground Wiring harness between CP06 (female) (20) – Resistance Min. 1 Mz chassis ground Wiring harness between CP06 (female) (26) – Resistance Min. 1 Mz chassis ground Wiring harness between CP06 (female) (36) – Resistance Min. 1 Mz chassis ground Wiring harness between CP06 (female) (36) – Resistance Min. 1 Mz RES4 (female) (1) and chassis ground Wiring harness between F01-10 – A03 – relay Resistance Min. 1 Mz terminal SR2 and chassis ground a Prepare with starting switch OFF (disconnect the related connectors), then carry out troubleshooting without turning starting switch ON. Between M05B (male) (2) – (4) Resistance Max. 5 z If above resistance is normal, the lower wiper motor may be defective. The wiper motor should also be suspected when there was no position in Troubleshooting 1 that can turn on the lower wiper limit switch. a Prepare with starting switch OFF, then turn it ON and carry out troubleshooting (While wiper is in operation) CP06 Voltage Between (26) and chas20 – 30 V (While wiper is in operation) sis ground Between (36) and chas20 – 30 V (For 2 seconds after wiper is stopped) sis ground Max. 3 V 20 – 30 V Between (20) and chas(At a constant cycle) sis ground (Lower limit switch: (Lower limit switch: ON) OFF)

27

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Circuit diagram related to lower wiper motor

28

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SEN02102-00

Failure code [DY2FMA] Upper Wiper Working Abnormality User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DY2FMA

Trouble

1

Upper Wiper Working Abnormality (Pump controller 2 system)

• The upper wiper contact does not close in 8 or more seconds after the upper wiper is turned on. • Turns output to wiper motor circuit OFF. • Wiper motor does not operate. • If failure code [D1EAKB] or [D1ECKB] is displayed, carry out troubleshooting for it first. • State of the output to the wiper motor can be checked with monitoring function. (Code: 02308 SWITCH INPUT 5 UPPER WIPER LIMIT SWITCH, 03700 CONTROLLER OUTPUT 1 WIPER UPPER ON, WIPER UPPER BRAKE) Cause

Possible causes and standard value in normal state

PC2000-8

Standard value in normal state/Remarks on troubleshooting • Turn the starting switch OFF once and turn it ON again. • Monitoring code: Check that the monitoring code 02308: SWITCH INPUT 5 is indicated and that the limit switch or proximity switch is ON. (When both are turned ON and the upper wiper is at the storage posiDefective upper wiper, tion, the proximity switch is defective. If the opposite of above was 1 proximity switch or observed, the limit switch is defective.) upper limit switch • Then move the upper wiper up to the opposite position. When it stops there, confirm the upper limit switch or the proximity switch is turned ON. If the upper wiper does not stop at the above position, the upper wiper motor or proximity switch is defective. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective upper wiper Normal state is recov2 Defective drive relay Replace with the upper drive relay ered wiper brake relay with Normal state is not Failure on other the upper brake relay. recovered equipment or circuit a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective upper wiper Normal state is recov3 Defective brake relay Replace with the upper brake relay ered wiper brake relay with Normal state is not Failure on other the upper drive relay. recovered equipment or circuit a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (6) – Resistance Max. 1 z relay terminal SR3 Wiring harness between relay terminal SR1 – Resistance Max. 1 z M05A (female) (4) Wiring harness between CP06 (female) (10) – Resistance Max. 1 z M05A (female) (5) Wiring harness between F01-10 – A03 – relay Resistance Max. 1 z Disconnection in wiring terminal SR2 harness (Disconnec4 Wiring harness between relay terminal SR4 – tion or defective conResistance Max. 1 z RW1 – JC57A – A01 and chassis ground tact in connector) Wiring harness between CP06 (female) (10) – Resistance Max. 1 z RES1 (1) Wiring harness between CP06 (female) (6) – Resistance Max. 1 z P45 (female) (B) Wiring harness between P45 (female) (C) and Resistance Max. 1 z chassis ground Wiring harness between P45 (female) (A) – F01-4 Resistance Max. 1 z Wiring harness between CP06 (female) (16) – Resistance Max. 1 z RES2 (female) (1)

29

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Cause

Possible causes and standard value in normal state

30

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (DisconnecWiring harness between RES2 (female) (2) and 4 Resistance Max. 1 z tion or defective con- chassis ground tact in connector) Wiring harness between RES1 (female) (2) and Resistance Max. 1 z chassis ground a Prepare with starting switch OFF (disconnect the related connectors), then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (6) – Resistance Min. 1 Mz relay terminal SR3 and chassis ground Wiring harness between relay terminal SR1 – Resistance Min. 1 Mz M05A (female) (2) and chassis ground Ground fault in wiring Wiring harness between CP06 (female) (10) – 5 harness (Short circuit Resistance Min. 1 Mz M05A (female) (5) and chassis ground with GND circuit) Wiring harness between CP06 (female) (16) – Resistance Min. 1 Mz relay terminal SR3 and chassis ground Wiring harness between relay terminal SR1 – Resistance Min. 1 Mz M05A (female) (4) and chassis ground Wiring harness between F01-10 – A03 – relay Resistance Min. 1 Mz terminal SR2 and chassis ground a Prepare with starting switch OFF (disconnect the related connectors), then carry out troubleshooting without turning starting switch ON. Defective upper wiper Between M05A (male) (2) – (4) Resistance Max. 5 z 6 motor If above resistance is normal, the upper wiper motor may be defective. The wiper motor should also be suspected when there was no position in Troubleshooting 1 that can turn on the upper wiper limit switch. a Prepare with starting switch OFF, then turn it ON and carry out troubleshooting (While wiper is in operation) CP06 Voltage Between (6) – chassis 20 – 30 V (While wiper is in operation) ground Defective pump con7 Between (16) and chastroller 20 – 30 V (For 2 seconds after wiper is stopped) sis ground Max. 3 V 20 – 30 V Between (10) and chas(At constant cycle) sis ground (Upper limit switch: (Upper limit switch: ON) OFF)

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Circuit diagram related to upper wiper motor

PC2000-8

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Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38) 1 User code

Failure code

—

F@BBZL

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

• The signal circuit of the blow-by pressure sensor detected pressure of 7.06 kPa {720 mmAg} or higher. • None in particular. • If the machine is used as it is, the engine may be broken. • The failure codes of the VHMS system are not recorded in the failure history of the machine monitor. • The 7-segment LED of the VHMS controller displays n3 o 38 (displays the code 2 characters by 2). • The blow-by pressure can be checked by downloading the data to a personal computer after performing the snap shot operation. Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

Abnormal rise of blowby pressure Check the engine and repair all abnormality (including the orifice in the 1 (While system is nor- breather). mal) 2

Blow-by pressure sen- If failure code [DHE5KB] is displayed, perform troubleshooting for it first. sor system defective If failure code [DHE5KY] is displayed, perform troubleshooting for it first.

VHMS controller 3 defective

32

High Blowby Pressure (VHMS controller system)

Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case.ooting. CV02A (female) (18) – (13)

Voltage

0.3 – 0.7 V

PC2000-8

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SEN02102-00

Electrical diagram related to blow-by pressure sensor

PC2000-8

33

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Failure code [F@BYNR] Very High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 62) 1 User code

Failure code

—

F@BYNR

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Very High LBF CYL Exhaust Temp (VHMS controller system)

• The signal circuit of the front exhaust temperature sensor detected that the temperature had exceeded exhaust temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: The straight line connecting 750°C point in the speed range above the rated output speed and 800°C point in the speed range below the maximum torque speed) • None in particular. • If the machine is used as it is, the engine may be broken. • The failure codes of the VHMS system are not recorded in the failure history of the machine monitor. • The 7-segment LED of the VHMS controller displays n3 o 62 (displays the code 2 characters by 2). • The exhaust temperature can be checked by downloading the data to a personal computer after performing the snap shot operation. Cause

Standard value in normal state/Remarks on troubleshooting

Abnormal rise of left front exhaust tempera1 Check the engine and repair all abnormality. ture (While system is normal) Possible causes and standard value in normal state

Left front exhaust tem- If failure code [DGT5KA] is displayed, perform troubleshooting for it first. 2 perature sensor sysIf failure code [DGT5KB] is displayed, perform troubleshooting for it first. tem defective a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case.ooting. 3

VHMS controller defective

CV02A Between (5) and (13)

34

Exhaust temperature

Voltage

At 20°C

Approx. 0.9 – 1.2 V

At 500°C

Approx. 2.6 – 3.5 V

PC2000-8

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SEN02102-00

Electrical diagram related to exhaust temperature sensor

PC2000-8

35

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Failure code [f@BYNR] Very High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 72) 1 User code

Failure code

—

f@BYNR

Contents of trouble Action of controller Problem that appears on machine

Related information

Trouble

Very High LBR CYL Exhaust Temp (VHMS controller system)

• The signal circuit of the front exhaust temperature sensor detected that the temperature had exceeded exhaust temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: The straight line connecting 750°C point in the speed range above the rated output speed and 800°C point in the speed range below the maximum torque speed) • None in particular. • If the machine is used as it is, the engine may be broken. • The failure codes of the VHMS system are not recorded in the failure history of the machine monitor. • The 7-segment LED of the VHMS controller displays n3 o 72 (displays the code 2 characters by 2). • The exhaust temperature can be checked by downloading the data to a personal computer after performing the snap shot operation. Cause

Standard value in normal state/Remarks on troubleshooting

Abnormal rise of left rear exhaust tempera1 Check the engine and repair all abnormality. ture (While system is normal) Possible causes and standard value in normal state

Left rear exhaust tem- If failure code [dGT5KA] is displayed, perform troubleshooting for it first. 2 perature sensor sysIf failure code [dGT5KB] is displayed, perform troubleshooting for it first. tem defective a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case.ooting. 3

VHMS controller defective

CV02A Between (6) and (13)

36

Exhaust temperature

Voltage

At 20°C

Approx. 0.9 – 1.2 V

At 500°C

Approx. 2.6 – 3.5 V

PC2000-8

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SEN02102-00

Electrical diagram related to exhaust temperature sensor

PC2000-8

37

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Failure code [F@BYNS] High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 61) User code

Failure code

—

F@BYNS

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

High LBF CYL Exhaust Temp (VHMS controller system)

• The signal circuit of the left front exhaust temperature sensor detected that the temperature had exceeded exhaust temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: The straight line connecting 700°C point in the speed range above the rated output speed and 750°C point in the speed range below the maximum torque speed) • None in particular. • If the machine is used as it is, the engine may be broken. • The failure codes of the VHMS system are not recorded in the failure history of the machine monitor. • The 7-segment LED of the VHMS controller displays n3 o 61 (displays the code 2 characters by 2). • The exhaust temperature can be checked by downloading the data to a personal computer after performing the snap shot operation. Cause

Standard value in normal state/Remarks on troubleshooting

Abnormal rise of left front exhaust tempera1 Check the engine and repair all abnormality. ture (While system is normal) Possible causes and standard value in normal state

Left front exhaust tem- If failure code [DGT5KA] is displayed, perform troubleshooting for it first. 2 perature sensor sysIf failure code [DGT5KB] is displayed, perform troubleshooting for it first. tem defective a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case.ooting. 3

VHMS controller defective

CV02A Between (5) and (13)

38

Exhaust temperature

Voltage

At 20°C

Approx. 0.9 – 1.2 V

At 500°C

Approx. 2.6 – 3.5 V

PC2000-8

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SEN02102-00

Electrical diagram related to exhaust temperature sensor

PC2000-8

39

SEN02102-00

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Failure code [f@BYNS] High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 71) User code

Failure code

—

f@BYNS

Contents of trouble Action of controller Problem that appears on machine

Related information

Trouble

1

High F cyl. Exhaust Temp. 1 (VHMS controller system)

• The signal circuit of the left rear exhaust temperature sensor detected that the temperature had exceeded exhaust temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: The straight line connecting 700°C point in the speed range above the rated output speed and 750°C point in the speed range below the maximum torque speed) • None in particular. • If the machine is used as it is, the engine may be broken. • The failure codes of the VHMS system are not recorded in the failure history of the machine monitor. • The 7-segment LED of the VHMS controller displays n3 o 71 (displays the code 2 characters by 2). • The exhaust temperature can be checked by downloading the data to a personal computer after performing the snap shot operation. Cause

Standard value in normal state/Remarks on troubleshooting

Abnormal rise of left rear exhaust tempera1 Check the engine and repair all abnormality. ture (While system is normal) Possible causes and standard value in normal state

Left rear exhaust tem- If failure code [dGT5KA] is displayed, perform troubleshooting for it first. 2 perature sensor sysIf failure code [dGT5KB] is displayed, perform troubleshooting for it first. tem defective a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case.ooting. 3

VHMS controller defective

CV02A Between (6) and (13)

40

Exhaust temperature

Voltage

At 20°C

Approx. 0.9 – 1.2 V

At 500°C

Approx. 2.6 – 3.5 V

PC2000-8

40 Troubleshooting

SEN02102-00

Electrical diagram related to exhaust temperature sensor

PC2000-8

41

SEN02102-00

40 Troubleshooting

Failure code [F@BZNR] Very High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 82) 1 User code

Failure code

—

F@BZNR

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

High R cyl. Exhaust Temp. 2 (VHMS controller system)

• The signal circuit of the right front exhaust temperature sensor detected that the temperature had exceeded exhaust temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: The straight line connecting 750°C point in the speed range above the rated output speed and 800°C point in the speed range below the maximum torque speed) • None in particular. • If the machine is used as it is, the engine may be broken. • The failure codes of the VHMS system are not recorded in the failure history of the machine monitor. • The 7-segment LED of the VHMS controller displays n3 o 82 (displays the code 2 characters by 2). • The exhaust temperature can be checked by downloading the data to a personal computer after performing the snap shot operation. Cause

Standard value in normal state/Remarks on troubleshooting

Abnormal rise of right front exhaust tempera1 Check the engine and repair all abnormality. ture (While system is normal) Possible causes and standard value in normal state

Right front exhaust 2 temperature sensor system defective

If failure code [DGT6KA] is displayed, perform troubleshooting for it first. If failure code [DGT6KB] is displayed, perform troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case.ooting.

3

VHMS controller defective

CV02A Between (7) and (13)

42

Exhaust temperature

Voltage

At 20°C

Approx. 0.9 – 1.2 V

At 500°C

Approx. 2.6 – 3.5 V

PC2000-8

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SEN02102-00

Electrical diagram related to exhaust temperature sensor

PC2000-8

43

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Failure code [f@BZNR] Very High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 92) 1 User code

Failure code

—

f@BZNR

Contents of trouble Action of controller Problem that appears on machine

Related information

Trouble

Very High RBR CYL Exhaust Temp (VHMS controller system)

• The signal circuit of the right rear exhaust temperature sensor detected that the temperature had exceeded exhaust temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: The straight line connecting 750°C point in the speed range above the rated output speed and 800°C point in the speed range below the maximum torque speed) • None in particular. • If the machine is used as it is, the engine may be broken. • The failure codes of the VHMS system are not recorded in the failure history of the machine monitor. • The 7-segment LED of the VHMS controller displays n3 o 92 (displays the code 2 characters by 2). • The exhaust temperature can be checked by downloading the data to a personal computer after performing the snap shot operation. Cause

Standard value in normal state/Remarks on troubleshooting

Abnormal rise of right rear exhaust tempera1 Check the engine and repair all abnormality. ture (While system is normal) Possible causes and standard value in normal state

Right rear exhaust 2 temperature sensor system defective

If failure code [dGT6KA] is displayed, perform troubleshooting for it first. If failure code [dGT6KB] is displayed, perform troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case.ooting.

3

VHMS controller defective

CV02A Between (16) and (13)

44

Exhaust temperature

Voltage

At 20°C

Approx. 0.9 – 1.2 V

At 500°C

Approx. 2.6 – 3.5 V

PC2000-8

40 Troubleshooting

SEN02102-00

Electrical diagram related to exhaust temperature sensor

PC2000-8

45

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Failure code [F@BZNS] High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 81) User code

Failure code

—

F@BZNS

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

High RBF CYL Exhaust Temp (VHMS controller system)

• The signal circuit of the right front exhaust temperature sensor detected that the temperature had exceeded exhaust temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: The straight line connecting 700°C point in the speed range above the rated output speed and 750°C point in the speed range below the maximum torque speed) • None in particular. • If the machine is used as it is, the engine may be broken. • The failure codes of the VHMS system are not recorded in the failure history of the machine monitor. • The 7-segment LED of the VHMS controller displays n3 o 81 (displays the code 2 characters by 2). • The exhaust temperature can be checked by downloading the data to a personal computer after performing the snap shot operation. Cause

Standard value in normal state/Remarks on troubleshooting

Abnormal rise of right front exhaust tempera1 Check the engine and repair all abnormality. ture (While system is normal) Possible causes and standard value in normal state

Right front exhaust 2 temperature sensor system defective

If failure code [DGT6KA] is displayed, perform troubleshooting for it first. If failure code [DGT6KB] is displayed, perform troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case.ooting.

3

VHMS controller defective

CV02A Between (7) and (13)

46

Exhaust temperature

Voltage

At 20°C

Approx. 0.9 – 1.2 V

At 500°C

Approx. 2.6 – 3.5 V

PC2000-8

40 Troubleshooting

SEN02102-00

Electrical diagram related to exhaust temperature sensor

PC2000-8

47

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40 Troubleshooting

Failure code [f@BZNS] High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 91) User code

Failure code

—

f@BZNS

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

High RBR CYL Exhaust Temp (VHMS controller system)

• The signal circuit of the right rear exhaust temperature sensor detected that the temperature had exceeded exhaust temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: The straight line connecting 700°C point in the speed range above the rated output speed and 750°C point in the speed range below the maximum torque speed) • None in particular. • If the machine is used as it is, the engine may be broken. • The failure codes of the VHMS system are not recorded in the failure history of the machine monitor. • The 7-segment LED of the VHMS controller displays n3 o 91 (displays the code 2 characters by 2). • The exhaust temperature can be checked by downloading the data to a personal computer after performing the snap shot operation. Cause

Standard value in normal state/Remarks on troubleshooting

Abnormal rise of right rear exhaust tempera1 Check the engine and repair all abnormality. ture (While system is normal) Possible causes and standard value in normal state

Right rear exhaust 2 temperature sensor system defective

If failure code [dGT6KA] is displayed, perform troubleshooting for it first. If failure code [dGT6KB] is displayed, perform troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case.ooting.

3

VHMS controller defective

CV02A Between (16) and (13)

48

Exhaust temperature

Voltage

At 20°C

Approx. 0.9 – 1.2 V

At 500°C

Approx. 2.6 – 3.5 V

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40 Troubleshooting

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Electrical diagram related to exhaust temperature sensor

PC2000-8

49

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40 Troubleshooting

Failure code [LA10ZL] RAD system fan pump relief pressure high error1 User code

Failure code

—

LA10ZL

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

• The RAD system fan pump pressure sensor signal circuit detected the pressure 37.3 MPa or above {380 kg/cm2 or above}. • None in particular (Provides the error display alone) • If machine is operated as it is, hydraulic components may be damaged. • Input from the RAD fan pump pressure sensor can be checked with monitoring function. (Code: 01133 RAD FAN PUMP PRESSURE SENSOR VOLTAGE) Cause Abnormal increase of RAD fan pump pres1 sure (When system is normal)

Possible causes and standard value in normal state

RAD system fan pump relief pressure high error (Pump controller 1 system)

Standard value in normal state/Remarks on troubleshooting Check the RAD fan pump for the relief pressure. Correct, if abnormality was found. Refer to "Testing and adjusting, Part 2."

If failure code [DHPTKX] is displayed, carry out the troubleshooting first as Defective RAD fan stated. 2 pump pressure sensor If failure code [DA25KP] is displayed, carry out the troubleshooting first as system stated. Defective pump con3 troller 1

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between CP01 (7) – (21)

Voltage

0.5 – 4.5 V

Circuit diagram related to RAD fan pump system

50

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40 Troubleshooting

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Failure code [LA20ZL] O/C system pump relief pressure high error User code

Failure code

—

LA20ZL

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

• None in particular (Provides the error display alone) • If machine is operated as it is, hydraulic components may be damaged. • Input from the O/C fan pump pressure sensor can be checked with monitoring function. Code: 01135 O/C fan pump pressure sensor voltage)

Abnormal increase of O/C fan pump pres1 sure (When system is normal)

Standard value in normal state/Remarks on troubleshooting Check the RAD fan pump for the relief pressure. Correct, if abnormality was found. Refer to "Testing and adjusting, Part 2."

If failure code [DHPUKX] is displayed, carry out the troubleshooting first Defective O/C fan as stated. 2 pump pressure sensor If failure code [DA25KP] is displayed, carry out the troubleshooting first as system stated. Defective pump con3 troller 1

PC2000-8

Abnormal high-pressure of O/C system pump relief (pump controller 1 system)

• The O/C system fan pump pressure sensor signal circuit detected the pressure 37.3 MPa or above (380 kg/cm2 or above).

Cause

Possible causes and standard value in normal state

1

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between CP01 (1) – (21)

Voltage

0.5 – 4.5 V

51

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40 Troubleshooting

Circuit diagram related to O/C fan pump system

52

PC2000-8

SEN02102-00

PC2000-8 Hydraulic excavator Form No. SEN02102-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

54

SEN02103-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

40 Troubleshooting

1

Troubleshooting of electrical system (E-mode) Troubleshooting of electrical system (E-mode)............................................................................................... 4 Contents of troubleshooting table......................................................................................................... 6 E-1 When starting switch is turned ON, machine monitor displays nothing ......................................... 8 E-2 When starting switch turned ON (before starting engine), basic check item lights up................. 10 E-3 Engine does not start (Engine does not turn) .............................................................................. 12 E-4 Auto-decelerator does not operate .............................................................................................. 16 E-5 Automatic warm-up system does not operate ............................................................................. 17 E-6 Preheater does not work ............................................................................................................. 18 E-7 Whole work equipment, swing operation and machine travel operation are disabled ................. 20 E-8 Machine push-up function does not work .................................................................................... 22 E-9 Boom shockless function cannot be released ............................................................................. 24 E-10 Machine monitor does not display some items.......................................................................... 26 E-11 Contents of display by machine monitor are different from applicable machine........................ 27 E-12 Fuel level monitor lights up in red while engine is running ........................................................ 28

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40 Troubleshooting

E-13 Hydraulic oil temperature gauge does not indicate normally ..................................................... 29 E-14 Fuel level gauge does not indicate normally.............................................................................. 30 E-15 Swing lock monitor does not indicate normally.......................................................................... 32 E-16 Machine monitor display anything even when operated on monitor switch section .................. 34 E-17 Wiper does not work .................................................................................................................. 35 E-18 Monitoring function does not display "Travel" normally ............................................................. 42 E-19 Travel alarm does not sound ..................................................................................................... 44 E-20 All of room lamp, headlamp and working lamp do not light up .................................................. 45 E-21 Air conditioner does not work .................................................................................................... 50 E-22 Step light does not light up or goes off....................................................................................... 52

2

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40 Troubleshooting

Troubleshooting of electrical system (E-mode)

1

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

Switch power supply circuit breaker (B) (2) (60A) (B13-B14)

Switch power supply circuit breaker (B) (1) (60A) (B11-B12) Switch power supply circuit breaker (B) (2) (60A) (B13-B14) Fuse in the circuit diagram

Constant power supply circuit breaker (B) (3) (60A) (B17-B18)

*

4

Fuse No.

Fuse capacity

Destination of power

1

10A

2

10A

3

10A

4

10A

5

10A

6

10A

Bottom dump

7

10A

Rotary lamp

Emergency swing holding brake solenoid valve Machine push-up switch Boom damping solenoid valve PPC oil pressure lock solenoid valve Starter cut relay Cigarette lighter Horn Flash light

8

10A

Auxiliary lamp

9

10A

Radio

10

30A

Wiper Windshield washer

11

20A

Air conditioner unit (upper)

12

20A

Air conditioner unit (lower)

13

20A

12 V power supply

14

5A

Left bank engine controller (ACC) circuit

15

5A

Right bank engine controller (ACC) circuit

16

10A

Radio backup

17

10A

Network bus power supply Engine controller

18

20A

Pump controller Room lamp (cab base)

19

20A

20

10A

Room lamp (cab) Emergency stop circuit Step light

The bracket ( ) under the breaker shows a breaker terminal number

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40 Troubleshooting

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Location of fuse Located in the distribution board inside the cab base.

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5

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40 Troubleshooting

Contents of troubleshooting table a

The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. User code

Failure code

Machine monitor display

Machine monitor display

Contents of trouble

Trouble

Names of the failure symptoms displayed in the failure history on the machine monitor

State where the machine monitor or controller detects the trouble

Action of controller

Action to be taken to protect the system and equipment when the machine monitor or controller detects a trouble

Problem that appears on machine

Problem that appears as an abnormality in the machine by the action (above) taken by monitor or controller

Related information

Information related to troubles occurred or troubleshooting Cause

1

Possible causes and standard value in normal state

6

1

Standard value in normal state/Remarks on troubleshooting • Standard value when normal required to judge the possible cause • Remarks required to judge whether any cause is right or not

• Disconnection in wiring The connector connection is defective or the wiring harness is disconnected. • Defective grounding A harness not connected to GND (ground) circuit comes into contact with the GND (ground) circuit. • Hot short defect A harness not connected to the electric power supply (24V) cir2 cuit comes into contact with the electric power supply (24V) circuit. Cause by which a trou• Short circuit ble is assumed to be A harness abnormally comes into contact with a harness of sepadetected rate circuit. (The order number indicates a serial num ber, not a priority (1) Method of indicating connector numbers and handling sequence.) T-adapter For troubleshooting, insert or connect the T-adapter as 3 described below unless especially specified. • When “male” or “female” is not indicated for a connector number, disconnect the connector, and insert the T- adapter in both the male and female. • When “male” or “female” is indicated for a connector number, disconnect the connector, and insert the T-adapter in only either the male or female. (2) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) leads of the tester as described below unless especially specified. • Connect the plus (+) lead to a pin number or harness indi4 cated in the front. • Connect the minus (–) lead to a pin number or harness indicated in the rear.

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40 Troubleshooting

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Related circuit diagram

This drawing is a part of the electric circuit diagram related to troubleshooting. • Connector No.: Indicates (Model - Number of pins) and (Color). • “Connector No. and pin No.“ from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow (io): Roughly shows the location on the machine.

PC2000-8

7

SEN02103-00

E-1

40 Troubleshooting

When starting switch is turned ON, machine monitor displays nothing

Trouble

Related information

1

• When starting switch turned ON, machine monitor displays nothing. • As the starting switch of the machine monitor is turned on, following screens are displayed sequentially: KOMATSU logo mark – Password input display (when a password is specified) – Work mode/ Travel speed confirmation display – Ordinary screen. • When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, however. Cause

Possible causes and standard value in normal state

8

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Low charge level of 1 battery Battery voltage (2 pieces) Specific gravity of battery (1 piece) Min. 24 V Min. 1.26 Defective circuit If the circuit breaker is shut down, the circuit probably has a grounding 2 breaker fault. Improper connector Machine monitor connector is connected improperly. Check it directly. 3 connection (Collate the plate of the mounting bracket against the connector.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery (–) terminal and Resistance Max. 1 z chassis ground Disconnection in wiring Wiring harness between battery (+) terminal – Resistance Max. 1 z B17 harness 4 (Disconnection in wir- Wiring harness between B18 – B28A Resistance Max. 1 z ing or defective contact Wiring harness between B28B – CM01(female) Resistance Max. 1 z in connector) (1), (2) Wiring harness between CM01 (female) (3), (4) – JB10 – A24 – battery (–) terminal and chassis Resistance Max. 1 z ground Wiring harness between B28B – H11 (female) (1) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery (+) terminal – Resistance Min. 1 Mz B17 (1) and chassis ground Ground fault in wiring Between wiring harness B18 – B28A and chassis Resistance Min. 1 Mz 5 harness (Short circuit ground with GND circuit) Wiring harness between B28 – CM01 (female) Resistance Min. 1 Mz (1) and (2) and chassis ground Wiring harness between B28B – H11 (female) (1) Resistance Min. 1 Mz and chassis ground a Prepare with starting switch OFF, then hold starting switch OFF and ON and carry out troubleshooting in each case. Defective machine CM01 Starting switch Voltage 6 monitor Between (1), (2) – OFF 20 – 30 V (3), (4)

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40 Troubleshooting

SEN02103-00

Circuit diagram related to machine monitor

PC2000-8

9

SEN02103-00

E-2

40 Troubleshooting

When starting switch turned ON (before starting engine), basic check item lights up

Trouble Related information

1

(1) Radiator coolant level monitor lights up in red. • The radiator coolant level monitor is included in the basic check items. However, it must be also checked for abnormality while the engine is run. (This troubleshooting must be implemented when it lights up in red while the engine is run, too.) • The signal from the radiator coolant level switch can be checked with monitoring function. (Code 04500: MONITOR INPUT 1) Cause Lowering of radiator 1 coolant level (when system is normal)

Standard value in normal state/Remarks on troubleshooting Radiator coolant level may be low. Check it and add coolant if it is low.

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P24 (male) Sub-tank coolant level Resistance Between FULL – LOW Max. 1 z Between (1) – (2) Below LOW Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness Wiring harness between OLLV (female) (3) – P24 3 (Disconnection in wirResistance Max. 1 z (female) (1) ing or defective contact Wiring harness between P24 (female) (2) and in connector) Resistance Max. 1 z chassis ground (TE04) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective machine CM02 Sub-tank coolant level Voltage 4 monitor Max. 1 V Between (3) and chas- Between FULL – LOW sis ground Below LOW 20 – 30 V

Defective radiator cool2 ant level sensor (internal disconnection) Possible causes and standard value in normal state

Circuit diagram related to radiator coolant level switch

10

PC2000-8

40 Troubleshooting

Trouble Related information

Possible causes and standard value in normal state

SEN02103-00

(2) Engine oil level monitor lights up in red. • Signal from the engine oil level switch signal can be checked with monitoring function. Code: 04501 MONITOR INPUT 2) Cause Standard value in normal state/Remarks on troubleshooting Lowering of engine oil 1 level (when system is Engine oil level may be low. Check it and add new oil if it is low. normal) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine oil OLLV (male) Engine oil level Resistance 2 level sensor (internal disconnection) Between H – L Max. 1 z Between (1) and chassis ground Below L Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection of wiring turning starting switch ON. harness Wiring harness between CM02 (female) (2) – 3 (Disconnection of wirResistance Max. 1 z OLLV (female) (1) ing or defective contact Wiring harness between OLLV (female) (2) and in connector) Resistance Max. 1 z chassis ground (TE07) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective machine CM02 Engine oil level Voltage 4 monitor Between H – L Max. 1 V Between (2) and chassis ground Below L 20 – 30 V

Circuit diagram related to engine oil level switch

PC2000-8

11

SEN02103-00

E-3

40 Troubleshooting

Engine does not start (Engine does not turn)

Trouble Related information

1

• Engine does not start (Engine does not turn). • Following 2 systems of the starting lock mechanisms are installed on the engine starting circuit. (PPC clock switch and starting motor cutoff relay) Cause

Standard value in normal state/Remarks on troubleshooting Battery voltage Specific gravity of battery Min. 24 V Min. 1.26 If the circuit breaker is shut down or the fuse is blown, circuit probably has Defective circuit ground fault. 2 breaker or fuse No. 3 If the machine monitor does not light up, carry out troubleshooting of E-1 first. a Prepare with starting switch OFF, then carry out troubleshooting without Defective starting turning starting switch ON. switch H11 (male) Position Resistance 3 (internal disconnecOFF Min. 1 Mz tion) (Between B – C) Between (1) and (4) START Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective PPC lock S41 (female) Lock lever Resistance 4 switch (internal short circuit) Released Min. 1 Mz Between (1) – (3) Lock Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without Defective starting turning starting switch ON. motor cutoff relay R05 R05 (female), R06 (male) Resistance 5 or R06 Between (1) – (2) 100 – 500 z (internal disconnection Between (3) – (5) Min. 1 Mz or short circuit) Between (3) – (6) Max. 1 z a Prepare with starting switch OFF, hold starting switch ON and start engine and carry out troubleshooting. (If power supply, grounding system, power generating signal and starting input are normal but the starting output is abnormal, starting motor relay is defective.) Starting Safety relay Voltage Defective starting switch motor safety relay Power supply: Between terminal B and chassis 6 20 – 30V (Internal disconnecground tion or short circuit) ON Power generating signal: Between R terminal or Max. 12 V ST1 (2), ST2(2) and chassis ground Starting input: Between S terminal or ST1 (1), 20 – 30V ST2 (1) and chassis ground START Starting output: Between terminal C and chassis 20 – 30V ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. (If the power supply and starting input normal but the starting motor does not run, the starting motor is defective.) Starting Defective starting Starting motor switch Voltage 7 motor (Internal disconACC nection or breakage) Power supply: Between terminal B and chassis ON 20 – 30V ground Starting input: Between terminal C and chassis START 20 – 30V ground

Low charge level of 1 battery

Possible causes and standard value in normal state

12

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40 Troubleshooting

SEN02103-00

Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective alternator 8 Alternator Voltage (Defective regulator) Between r terminal R and chassis Max. 12 V ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between B28B – H11 (female) (1) Resistance Max. 1 z Wiring harness between H1 (female) (4) – R05 Resistance Max. 1 z (female) (5) Wiring harness between R05 (harness) (3) – R06 Resistance Max. 1 z Disconnection in wiring (female) (3), (5) – ST1, ST2 (female) (1) harness Wiring harness between safety relay C terminal – Resistance Max. 1 z 9 (Disconnection in wir- starting motor C terminal ing or defective contact Wiring harness between F01-3 – S41 (female) Resistance Max. 1 z in connector) (1) Wiring harness between S41 (female) (3) – R05 Resistance Max. 1 z (female) (1) Possible Wiring harness between R05 (female) (2) and Resistance Max. 1 z causes and chassis ground (TB04) standard value Wiring harness between R06 (female) (2) – P40 Resistance Max. 1 z in normal state (male) (2) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery relay B terminal Resistance Min. 1 Mz – circuit breaker B28A and chassis ground Wiring harness between B28B – H11 (female) (1) Resistance Min. 1 Mz and chassis ground Wiring harness between H11 (female) (4) – R05 Resistance Min. 1 Mz (female) (5) and chassis ground Grounding fault in wirWiring harness between R05 (female) (3) – R06 ing harness 10 (female) (3), (5) – ST1, ST2 (female) (1) and Resistance Min. 1 Mz (Short circuit with chassis ground ground circuit) Wiring harness between safety relay C terminal – Resistance Min. 1 Mz starting motor C terminal and chassis ground Wiring harness between F01-3 – S41 (female) Resistance Min. 1 Mz (1) and chassis ground Wiring harness between S41 (female) (3) – R05 Resistance Min. 1 Mz (female) (1) and chassis ground Wiring harness between R06 (female) (2) – P40 Resistance Min. 1 Mz (female) (1) and chassis ground

PC2000-8

13

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40 Troubleshooting

Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between battery relay B terminal Voltage Max. 1 V – circuit breaker B28A and chassis ground Wiring harness between B28B – H11 (female) (1) Voltage Max. 1 V and chassis ground Wiring harness between H11 (female) (4) – R05 Voltage Max. 1 V Hot short circuit in wir- (female) (5) and chassis ground Possible ing harness causes and 11 Wiring harness between R05 (female) (3) – R06 (Contact with 24V cirstandard value (female) (3), (5) – ST1, ST2 (female) (1) and Voltage Max. 1 V cuit) in normal state chassis ground. Wiring harness between safety relay C terminal – Voltage Max. 1 V starting motor C terminal and chassis ground Wiring harness between F01-3 – S41 (female) Voltage Max. 1 V (1) and chassis ground Wiring harness between S41 (female) (3) – R05 Voltage Max. 1 V (female) (1) and chassis ground Defective power sup- Defective engine controller power supply is suspected. Carry out trouble12 ply of engine controller shooting for failure codes [CA441], [CB441], [CA442] and [CB442].

14

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40 Troubleshooting

SEN02103-00

Related electrical circuit diagram

PC2000-8

15

SEN02103-00

E-4

40 Troubleshooting

Auto-decelerator does not operate

Trouble Related information

1

• Auto-decelerator does not operate. • Set speed of auto-decelerator is 1,400 rpm. Thus, the fuel control dial must be set above this speed when operating the auto-decelerator. • Check all the monitoring indications after starting the engine. Cause

Possible causes and standard value in normal state

16

Standard value in normal state/Remarks on troubleshooting If the monitoring display is not normal, proceed to troubleshooting of failure code [DHS8KX]. Defective boom raise 1 Monitoring code Item Normal display signal Lever operation: ON 01900 Boom Raise Lever at neutral: OFF If the monitoring display is not normal, proceed to troubleshooting of failure code [DHS9KX]. Defective boom lower 2 Monitoring code Item Normal display signal Lever operation: ON 01900 Boom lower Lever at neutral: OFF If the monitoring display is not normal, proceed to troubleshooting of failure code [DHS3KX]. 3 Defective arm IN signal Monitoring code Item Normal display Lever operation: ON 01900 Arm IN Lever at neutral: OFF If the monitoring display is not normal, proceed to troubleshooting of failure code [DHSCKX]. Defective arm dump 4 Monitoring code Item Normal display signal Lever operation: ON 01900 Arm OUT Lever at neutral: OFF If the monitoring display is not normal, proceed to troubleshooting of failure code [DHS4KX]. Defective bucket Monitoring code Item Normal display 5 CURL signal Lever operation: ON 01901 Bucket Curl Lever at neutral: OFF If the monitoring display is not normal, proceed to troubleshooting of failure code [DHSDKX]. Defective bucket dump 6 Monitoring code Item Normal display signal Lever operation: ON 01901 Bucket dump Lever at neutral: OFF If the monitoring display is not normal, proceed to troubleshooting of failure code [DHSAKX]. Defective swing right 7 Monitoring code Item Normal display signal Lever operation: ON 01902 Right swing Lever at neutral: OFF If the monitoring display is not normal, proceed to troubleshooting of failure code [DHSBKX]. Defective swing left Monitoring code Item Normal display 8 signal Lever operation: ON 01902 Left swing Lever at neutral: OFF If monitoring display is not normal, proceed to troubleshooting No. E-18. Defective R.H travel Monitoring code Item Normal display 9 signal Lever operation: ON 01902 R.H travel Lever at neutral: OFF

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40 Troubleshooting

SEN02103-00

Cause Possible Defective L.H travel causes and 10 signal standard value in normal state Defective pump 11 controller

E-5

Standard value in normal state/Remarks on troubleshooting If monitoring display is not normal, proceed to troubleshooting No. E-18. Monitoring code Item Normal display Lever operation: ON 01902 L.H travel Lever at neutral: OFF Since trouble is in system, troubleshooting cannot be carried out. (If above causes are not detected, controller may be defective.)

Automatic warm-up system does not operate

Trouble Related information

1

• Automatic warm-up system does not operate. • When engine coolant temperature is below 30°C, automatic warm-up system raises engine speed to 1,200 rpm. • If fuel control dial is opened more than 70% for 3 seconds or longer when starting switch is turned ON or after engine is started, automatic warm-up system is turned OFF. Cause

Possible causes and standard value in normal state

PC2000-8

Standard value in normal state/Remarks on troubleshooting If the monitoring display is not normal, proceed to troubleshooting of failure code [CA144]. Defective engine coolMonitoring Item Normal display 1 ant temperature signal Compare with Engine coolant 04107 actual engine temperature coolant temperature Defective pump Since trouble is in system, troubleshooting cannot be carried out. 2 controller (If above causes are not detected, controller may be defective.)

17

SEN02103-00

E-6

40 Troubleshooting

Preheater does not work

Trouble (1) Related information

1

• When starting switch is turned to HEAT position, preheating monitor does not light up. • Input of preheating signal (ON/OFF) can be checked with monitoring function. (Code: 04500 MONITOR INPUT 1) Cause Defective starting 1 switch system

Possible causes and standard value in normal state

Trouble (2) Related information

Standard value in normal state/Remarks on troubleshooting If preheating fails to operate (the heater does not warm up), refer to Trouble (2) Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. harness (Disconnec2 tion or defective con- Wiring harness between CM01 (female) (16) – Resistance Max. 1 z tact in connector) A01 (male) (35) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective machine CM01 Starting switch ACC Voltage 3 monitor OFF Max. 1V Between (16) and chassis ground HEAT 20 – 30 V

• When starting switch is turned to HEAT position, preheater does not warm up. • If failure code [CA2555] or [CA2556] is displayed, carry out troubleshooting for it first. Cause Defective starting 1 switch (Internal disconnection)

Possible causes and standard value in normal state

Defective heater relays 2 (Internal disconnection)

Defective air heater 3 (Internal disconnection). Disconnection in wiring harness (Disconnec4 tion in wiring or defective contact in connector)

18

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. H11 (male) Starting switch Resistance OFF Min. 1 Mz Between (1) – (3) HEAT Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Heater relays (R15), (R16) Resistance Between coil terminal R16C and There is continuity chassis ground Between contact terminals Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between heater terminals Normal if conductive a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between H11 (female) (3) – JC25 Resistance Max. 1 z – heater relay terminals R16C, R15C Wiring harness between battery relay terminal M Resistance Max. 1 z – Heater relay terminals R15B, R16B

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40 Troubleshooting

SEN02103-00

Related electrical circuit diagram

PC2000-8

19

SEN02103-00

E-7

40 Troubleshooting

Whole work equipment, swing operation and machine travel operation are disabled

Trouble Related information

1

• Whole work equipment, swing operation and machine travel operation are disabled. – Cause 1 Defective fuse No. 3

Possible causes and standard value in normal state

20

Standard value in normal state/Remarks on troubleshooting If fuse is blown, circuit probably has ground fault. a Prepare with starting switch OFF, then carry out troubleshooting without Defective PPC lock turning starting switch ON. switch S41 (female) Lock lever Resistance 2 (internal disconnecLock Min. 1 Mz tion) Between (1) – (2) Released Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without Defective PPC lock turning starting switch ON. solenoid V21A and V21B (male) Resistance 3 (internal disconnection Between (2) – (1) 20 – 60 z or short circuit) Between (2) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without Defective assembledturning starting switch ON. 4 type diode D01 D02 (male) Resistance (Internal short circuit) Between (4) – (8) Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between F01-3 outlet – S41 Resistance Max. 1 z harness (male) (1) 5 (Disconnection in wirWiring harness between S41 (male) (2) – JB25 – ing or defective contact Resistance Max. 1 z V21A (female) (1), V21B (female) (1) in connector) Wiring harness between V21A, V21B (female) Resistance Max. 1 z (2) and chassis ground (TB04) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in Wiring harness between F01-3 outlet – S41 wiring harness Resistance Min. 1 Mz 6 (male) (1) and chassis ground (Short circuit with Wiring harness between S41 (male) (2) – JB25 – ground circuit) V21A (male) (1), V21B (female) (1) and chassis Resistance Min. 1 Mz ground

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40 Troubleshooting

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Circuit diagram related to PPC lock solenoid

PC2000-8

21

SEN02103-00

E-8

40 Troubleshooting

Machine push-up function does not work

Trouble Related information

• Machine push-up function does not work. – Cause 1 Defective fuse No.2 Defective machine 2 push-up switch (Internal disconnection)

Defective machine push-up solenoid 3 (Internal short circuit or ground fault) Possible causes and standard value in normal state

Defective assembled4 type diode D04 (Internal short circuit)

Disconnection in wiring harness (Disconnec5 tion in wiring or defective contact of connector)

Grounding fault in wir6 ing harness (Short circuit with ground circuit)

22

1

Standard value in normal state/Remarks on troubleshooting If fuse is blown, circuit probably has ground fault. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Machine push-up S05 (male) Resistance switch OFF Min. 1 Mz Between (5) – (6) ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V08 (male) Resistance Between (2) – (12) 20 – 60 z Between (1) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D02 (male) Resistance Between (1) – (5) Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-2 outlet – S05 Resistance Max. 1 z (male) (5) Wiring harness between S05 (male) (6) – JB4 – Resistance Max. 1 z V08 (female) (1) Wiring harness between V08 (female) (2) – A05 Resistance Max. 1 z and chassis ground (TB04) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-2 outlet – S05 Resistance Max. 1 z (male) (5) and chassis ground Wiring harness between S05 (male) (6) – JB4 – Resistance Max. 1 z V08 (female) (1) and chassis ground

PC2000-8

40 Troubleshooting

SEN02103-00

Circuit diagram related to machine push-up

PC2000-8

23

SEN02103-00

E-9

40 Troubleshooting

Boom shockless function cannot be released

Trouble Related information

• Boom shockless function cannot be released. – Cause 1 Defective fuse No.2 Defective boom shock2 less switch (internal disconnection)

Defective machine push-up solenoid 3 (Internal short circuit or ground fault)

Possible causes and standard value in normal state

Defective assembled4 type diode D04 (Internal short circuit)

Disconnection in wiring harness 5 (Disconnection in wiring or defective contact of connector)

Grounding fault in wir6 ing harness (Short circuit with ground circuit)

24

1

Standard value in normal state/Remarks on troubleshooting If fuse is blown, circuit probably has ground fault. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S06 (male) Boom shockless switch Resistance OFF Min. 1 Mz Between (3) – (4) ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V09 and V10 (male) Resistance Between (1) – (2) 20 – 60 z Between (1) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D02 (male) Resistance Between (3) – (7) Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-2 outlet – S06 Resistance Max. 1 z (female) (3) Wiring harness between S06 (female) (4) – A01 Resistance Max. 1 z – JB3 – V09 , V10 (female) (1) Wiring harness between V09, V10 (female) (2) Resistance Max. 1 z and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-2 outlet – S06 Resistance Max. 1 z (female) (3) and chassis ground Wiring harness between S06 (female) (4) – A01 – JB3 – V09, V10 (female) (2) and chassis Resistance Max. 1 z ground

PC2000-8

40 Troubleshooting

SEN02103-00

Related electrical circuit diagram

PC2000-8

25

SEN02103-00

40 Troubleshooting

E-10 Machine monitor does not display some items Trouble Related information

• Machine monitor does not display some items. • The LCD panel sometimes has black points (points which do not light) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points do not exceed 10, points are not a failure or a defect. Cause

Possible causes and standard value in normal state

26

1

1

Defective machine monitor (LCD panel)

2

Defective machine monitor (Monitor unit)

Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and carry out troubleshooting. When following switches are operated, if all LCD panel lights up (entire screen becomes white), LCD panel is normal. • Switch operation: [4] + [F2] (Press them simultaneously) If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

PC2000-8

40 Troubleshooting

SEN02103-00

E-11 Contents of display by machine monitor are different from applicable machine Trouble Related information

• Contents of display by machine monitor are different from applicable machine.

Cause Possible causes and standard value in normal state

PC2000-8

1

1

Defective model code signal

2

Defective machine monitor

Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and carry out troubleshooting (Monitoring function) Monitoring code Normal display 00200 Controller model mode PC2000-8 (1st) If the monitoring display is not normal, proceed to troubleshooting of failure code [DA29KQ]. If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

27

SEN02103-00

40 Troubleshooting

E-12 Fuel level monitor lights up in red while engine is running Trouble Related information

1

• Fuel level monitor lights up in red while engine is running. • If fuel level gauge on the machine monitor indicates red range, fuel level monitor turns red. • Input signal (voltage) from the fuel level sensor can be checked with monitoring function. (Code 04200: Fuel sensor voltage) Cause Low fuel level (when 1 the system is normal)

Standard value in normal state/Remarks on troubleshooting a Add fuel.

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P21A (male) Fuel level Resistance FULL (Upper limit) Approximately 12 z Between (1) and chassis ground EMPTY (Lower limit) 85 – 110 z Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without harness turning starting switch ON. 3 (Disconnection in wiring or defective contact Wiring harness between CM01 (female) (9) – Resistance Max. 1 z P21A (female) (1) in connector) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective machine CM01 (female) Fuel level Resistance 4 monitor FULL (Upper limit) Approximately 12 z Between (9) and chassis ground EMPTY (Lower limit) 85 – 110 z Defective fuel level 2 sensor (Internal disconnection)

Possible causes and standard value in normal state

Circuit diagram related to fuel level sensor

28

PC2000-8

40 Troubleshooting

SEN02103-00

E-13 Hydraulic oil temperature gauge does not indicate normally Trouble Related information

• While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C). • While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H). • If failure code [DA2RMC] or [dA2RMC] is displayed, carry out troubleshooting for those codes first. • Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring function (Code: 04401 Hydraulic oil temperature). Cause Defective hydraulic oil temperature sensor 1 (Internal disconnection or short circuit)

Possible causes and standard value in normal state

1

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Grounding fault in wir3 ing harness (Short circuit with ground circuit) Hot short circuit in wir4 ing harness (Contact with 24V circuit)

5

Defective pump controller 2

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Hydraulic oil P22 (male) Resistance temperature Between (1) – (2) 90 – 3.5 kz 10 – 100°C Between (1) and Min. 1 Mz chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP04 (female) (9) – Resistance Max. 1 z P22 (female) (1) Wiring harness between CP04 (female) (4) – Resistance Max. 1 z P22 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness CP04 (female) (9) – P22 Resistance Min. 1 Mz (female) (1) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness CP04 (female) (9) – P22 Voltage Max. 1 V (female) (1) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Hydraulic oil Resistance temperature Between (9) – (4) 90 – 3.5 kz 10 – 100°C Between (9) and Min. 1 Mz chassis ground

Circuit diagram related to hydraulic oil temperature sensor

PC2000-8

29

SEN02103-00

40 Troubleshooting

E-14 Fuel level gauge does not indicate normally Trouble Related information

• • • •

1

While fuel is added, fuel level gauge does not rise from red range (E). While fuel level is low, fuel level gauge does not lower from green range (F). If failure code [DA2RMC] or [dA2RMC] is displayed, carry out troubleshooting for those codes first. Input from the fuel level sensor (voltage) can be checked with monitoring function (Code: 04200 Fuel sensor voltage). Cause

1

2 Possible causes and standard value in normal state

3

4

5

6

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Monitoring code: Check the state of the incoming signal from the fuel level switch from 02307 SWITCH INPUT 4. Defective fuel level Hi switch: ON switch When normal (When fuel tank is full) Mid switch: ON Lo switch: ON * If either the Mid switch or Lo switch is OFF, the full-tank indication does not appear. a Prepare with starting switch OFF, then carry out troubleshooting without Defective fuel level turning starting switch ON. sensor P21A (male) Fuel level Resistance (internal disconnection FULL (Upper limit) Approximately 12 z Between (1) and or short circuit) chassis ground EMPTY (Lower limit) 85 – 110 z Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without harness turning starting switch ON. (Disconnection in wirWiring harness between CM01 (female) (9) – ing or defective contact Resistance Max. 1 z P21A (female) (1) of connector) a Prepare with starting switch OFF, then carry out troubleshooting without Grounding fault in wirturning starting switch ON. ing harness (Short cirBetween harness CM01 (female) (9) – P21A cuit with ground circuit) Resistance Min. 1 Mz (female) (1) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry Hot short circuit in wirout troubleshooting. ing harness (Contact Between harness CM01 (female) (9) – P21A with 24V circuit) Voltage Max. 1 V (female) (1) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective machine CM01 Fuel level Resistance monitor FULL (Upper limit) Approximately 12 z Between (9) and chassis ground EMPTY (Lower limit) 85 – 110 z

Remarks: For PC 2000, shift in the fuel level up to the present time is interpolated based on the calculation done on the present value indicated by the fuel level switch. If any of the Hi, Mid and Lo switches fails, above calculation is disabled.

30

q

Relationship between the level switches and fuel

PC2000-8

40 Troubleshooting

SEN02103-00

Circuit diagram related to fuel level switch

PC2000-8

31

SEN02103-00

40 Troubleshooting

E-15 Swing lock monitor does not indicate normally Trouble Related information

• When swing lock switch is turned ON, swing lock monitor does not light up. • When swing lock switch is turned ON, swing lock monitor lights up. • Input (ON/OFF) from the swing lock switch can be checked with monitoring function (Code: 04502 Monitor input 3). Cause Defective swing lock 1 switch (internal disconnection or short circuit)

Possible causes and standard value in normal state

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact of connector) Grounding fault in wir3 ing harness (Short circuit with ground circuit) Hot short circuit in wir4 ing harness (Contact with 24V circuit)

5

32

1

Defective machine monitor

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S04 (male) Swing lock switch Resistance OFF Min. 1 Mz Between (5) – (6) ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CM02 (female) (5) – Resistance Max. 1 z JB1 – S04 (female) (5) Wiring harness between S04 (female) (6) – JC33 Resistance Max. 1 z and chassis ground (TB05) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CM02 (female) (5) – Resistance Min. 1 Mz JB1 – S04 (female) (5) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (5) – Voltage Max. 1 V JB1 – S04 (female) (5) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CM02 Swing lock switch Voltage OFF 20 – 30 V Between (5) and chassis ground ON Max. 1 V

PC2000-8

40 Troubleshooting

SEN02103-00

Circuit diagram related to swing lock switch

PC2000-8

33

SEN02103-00

40 Troubleshooting

E-16 Machine monitor display anything even when operated on monitor switch section 1 Trouble (1) Related information Possible causes and standard value in normal state

Trouble (2) Related information Possible causes and standard value in normal state

Trouble (3) Related information Possible causes and standard value in normal state

Trouble (4) Related information Possible causes and standard value in normal state

• Operating the working mode select switch fails to display working mode monitor. – Cause 1

Defective machine monitor

Standard value in normal state/Remarks on troubleshooting Since trouble is in system, troubleshooting cannot be carried out.

• When auto-decelerator switch is operated, auto-decelerator monitor is not displayed. • If auto-decelerator fails to operate, proceed with troubleshooting No. E-4. Cause 1

Defective machine monitor

Standard value in normal state/Remarks on troubleshooting Since trouble is in system, troubleshooting cannot be carried out.

• When heavy lift switch is operated, heavy lift is not displayed. – Cause 1

Defective machine monitor

Standard value in normal state/Remarks on troubleshooting Since trouble is in system, troubleshooting cannot be carried out.

• When wiper switch is operated, wiper monitor is not displayed. a If wiper fails to operate, too, proceed with troubleshooting No. E-17. Cause 1

Defective machine monitor

Standard value in normal state/Remarks on troubleshooting Since trouble is in system, troubleshooting cannot be carried out.

Trouble (5)

• When select switch is operated, adjust screen is not displayed. • When LCD monitor adjust switch is operated, adjust screen is not displayed. • When maintenance switch is operated, maintenance item screen is not displayed.

Related information

–

Possible causes and standard value in normal state

34

Cause 1

Defective machine monitor

Standard value in normal state/Remarks on troubleshooting Since trouble is in system, troubleshooting cannot be carried out.

PC2000-8

40 Troubleshooting

SEN02103-00

E-17 Wiper does not work Trouble Related information

1

• Wiper does not work. (1) Upper wiper does not work. • If failure code [DY2FMA] is displayed, carry out troubleshooting for it first. • State of the output to the wiper motor can be checked with monitoring function. Code: 02308 SWITCH INPUT 5 UPPER WIPER LIMIT SWITCH, 03700 CONTROLLER OUTPUT 1 WIPER UPPER ON, WIPER UPPER BRAKE) Cause

Possible causes and standard value in normal state

PC2000-8

Standard value in normal state/Remarks on troubleshooting • Turn the starting switch OFF once and turn it ON again. • Monitoring code: Check that the monitoring code 02308: SWITCH INPUT 5 is indicated and that the limit switch or proximity switch is ON. (When both are turned ON and the upper wiper is at the storage posiDefective upper wiper, tion, the proximity switch is defective. If the opposite of above was 1 proximity switch or observed, the limit switch is defective.) upper limit switch • Then move the upper wiper up to the opposite position. When it stops there, confirm the upper limit switch or the proximity switch is turned ON. If the upper wiper does not stop at the above position, the upper wiper motor or proximity switch is defective. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective upper wiper Normal state is recov2 Defective drive relay Replace with the upper drive relay ered wiper brake relay with Normal state is not Failure on other the upper brake relay. recovered equipment or circuit a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective upper wiper Normal state is recov3 Defective brake relay Replace with the upper brake relay ered wiper brake relay with Normal state is not Failure on other the drive relay. recovered equipment or circuit a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (6) – Resistance Max. 1 z relay terminal SR3 Wiring harness between relay terminal SR1 – Resistance Max. 1 z M05A (female) (4) Wiring harness between CP06 (female) (10) – Resistance Max. 1 z M05A (female) (5) Wiring harness between F01-10 – A03 – relay Resistance Max. 1 z Disconnection in wiring terminal SR2 harness (Disconnec4 Wiring harness between relay terminal SR4 – tion or defective conResistance Max. 1 z RW1 – JC57A – A01 and chassis ground tact in connector) Wiring harness between CP06 (female) (10) – Resistance Max. 1 z RES1 (1) Wiring harness between CP06 (female) (6) – Resistance Max. 1 z P45 (female) (B) Wiring harness between P45 (female) (C) and Resistance Max. 1 z chassis ground Wiring harness between P45 (female) (A) – F01-4 Resistance Max. 1 z Wiring harness between CP06 (female) (16) – Resistance Max. 1 z RES2 (female) (1)

35

SEN02103-00

40 Troubleshooting

Cause

Possible causes and standard value in normal state

36

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (DisconnecWiring harness between RES2 (female) (2) and 4 Resistance Max. 1 z tion or defective con- chassis ground tact in connector) Wiring harness between RES1 (female) (2) and Resistance Max. 1 z chassis ground a Prepare with starting switch OFF (disconnect the related connectors), then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (6) – Resistance Min. 1 Mz relay terminal SR3 and chassis ground Wiring harness between relay terminal SR1 – Resistance Min. 1 Mz M05A (female) (2) and chassis ground Ground fault in wiring Wiring harness between CP06 (female) (10) – 5 harness (Short circuit Resistance Min. 1 Mz M05A (female) (5) and chassis ground with GND circuit) Wiring harness between CP06 (female) (16) – Resistance Min. 1 Mz relay terminal SR3 and chassis ground Wiring harness between relay terminal SR1 – Resistance Min. 1 Mz M05A (female) (4) and chassis ground Wiring harness between F01-10 – A03 – relay Resistance Min. 1 Mz terminal SR2 and chassis ground a Prepare with starting switch OFF (disconnect the related connectors), then carry out troubleshooting without turning starting switch ON. Resistance Max. 5 z Defective upper wiper Between M05A (male) (2) – (4) 6 motor If above resistance is normal, the upper wiper motor may be defective. The wiper motor should also be suspected when there was no position in Troubleshooting 1 that can turn on the upper wiper limit switch. a Prepare with starting switch OFF, then turn it ON and carry out troubleshooting (While wiper is in operation) CP06 Voltage Between (6) – 20 – 30 V (While wiper is in operation) chassis ground Defective pump 7 controller Between (16) and 20 – 30 V (For 2 seconds after wiper is stopped) chassis ground Max. 3 V 20 – 30 V Between (10) and (At constant cycle) chassis ground (Upper limit switch: ON) (Upper limit switch: OFF)

PC2000-8

40 Troubleshooting

SEN02103-00

Circuit diagram related to upper wiper motor

PC2000-8

37

SEN02103-00

Trouble Related information

40 Troubleshooting

• Wiper does not work. (2) Lower wiper does not work. • If failure code [DY20MA] is displayed, carry out troubleshooting for it first. • State of the output to the wiper motor can be checked with monitoring function. (Code 02308 SWITCH INPUT 5 LOWER WIPER LIMIT SWITCH, 03700 CONTROLLER OUTPUT 1 WIPER LOWER ON, WIPER LOWER BRAKE) Cause

1

2

3

Possible causes and standard value in normal state

4

38

Standard value in normal state/Remarks on troubleshooting Monitoring code: Check that the monitoring code 02308: SWITCH INPUT Defective lower wiper 5 is indicated and that the lower wiper limit switch is ON. storage position (If OFF, adjust the storage position to turn the switch ON.) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective lower wiper Replace the lower wiper Normal state is recovDefective drive relay drive relay ered drive relay with the upper drive relay or the Normal state is not Failure on other upper brake relay. recovered equipment or circuit a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective lower wiper Replace the lower wiper Normal state is recovDefective brake relay brake relay ered drive relay with the upper drive relay or the Normal state is not Failure on other equipupper brake relay. recovered ment or circuit a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (26) – Resistance Max. 1 z relay terminal SR3 Wiring harness between relay terminal SR1 – Resistance Max. 1 z M05B (female) (2) Wiring harness between CP06 (female) (20) – Resistance Max. 1 z M05B (female) (5) Wiring harness between F01-10 – A03 – relay Resistance Max. 1 z terminal SR2 Disconnection in wiring Wiring harness between relay terminal SR4 – Resistance Max. 1 z harness RW3 – JC57A – A03 (Disconnection or Wiring harness between CP06 (female) (26) – defective contact in Resistance Max. 1 z RES3 (1) connector) Wiring harness between RES3 (2) and chassis Resistance Max. 1 z ground Wiring harness between CP06 (female) (36) – Resistance Max. 1 z relay terminal SR3 Wiring harness between relay terminal SR1 – Resistance Max. 1 z M05B (female) (4) Wiring harness between CP06 (female) (36) – Resistance Max. 1 z RES4 (female) (1) Wiring harness between RES4 (female) (2) and Resistance Max. 1 z chassis ground

PC2000-8

40 Troubleshooting

SEN02103-00

Cause

Ground fault in wiring 5 harness (Short circuit with GND circuit)

Possible causes and standard value in normal state

PC2000-8

6

Defective lower wiper motor

7

Defective pump controller

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF (disconnect the related connectors), then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (26) – Resistance Min. 1 Mz relay terminal SR3 and chassis ground Wiring harness between relay terminal SR1 – Resistance Min. 1 Mz M05B (female) (2) and chassis ground Wiring harness between CP06 (female) (20) – Resistance Min. 1 Mz chassis ground Wiring harness between CP06 (female) (26) – Resistance Min. 1 Mz chassis ground Wiring harness between CP06 (female) (36) – Resistance Min. 1 Mz chassis ground Wiring harness between CP06 (female) (36) – Resistance Min. 1 Mz RES4 (female) (1) and chassis ground Wiring harness between F01- 10 – A03 – relay Resistance Min. 1 Mz terminal SR2 and chassis ground a Prepare with starting switch OFF (disconnect the related connectors), then carry out troubleshooting without turning starting switch ON. Between M05B (male) (2) – (4) Resistance Max. 5 z If above resistance is normal, the lower wiper motor may be defective. The wiper motor should also be suspected when there was no position in Troubleshooting 1 that can turn on the lower wiper limit switch. a Prepare with starting switch OFF, then turn it ON and carry out troubleshooting (While wiper is in operation) CP06 Voltage Between (26) and 20 – 30 V (While wiper is in operation) chassis ground Between (36) and 20 – 30 V (For 2 seconds after wiper is stopped) chassis ground Min. 3 V 20 – 30 V Between (20) and (At constant cycle) chassis ground (Lower limit switch: ON) (Lower limit switch: OFF)

39

SEN02103-00

40 Troubleshooting

Circuit diagram related to lower wiper motor

40

PC2000-8

SEN02103-00

40 Troubleshooting

E-18 Monitoring function does not display "Travel" normally Trouble Related information

• "Travel" is not displayed normally with the machine monitoring function (special functions). • Monitoring code: 01902 Pressure switch 3 Cause Defective travel PPC oil pressure switch 1 (Internal disconnection or short circuit)

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)

Possible causes and standard value in normal state

Grounding fault in wir3 ing harness (Short circuit with ground circuit)

Hot short circuit in wir4 ing harness (Contact with 24V circuit)

5

42

1

Defective pump controller

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. P09, P10, P11 and P12 Travel lever Resistance (male) Neutral Min. 1 Mz Between (1) – (2) Forward or reverse Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (29) – Resistance Max. 1 z P11, P12 (female) (1) Wiring harness between CP06 (female) (39) – Resistance Max. 1 z P09, P10 (female) (1) Wiring harness between P09, P10, P11, P12 Resistance Max. 1 z (female) (1) – CP04 (female) (21) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (29) – Resistance Min. 1 Mz P11, P12 (female) (2) and chassis ground Wiring harness between CP06 (female) (39) – Resistance Min. 1 Mz P09, P10 (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CP06 (female) (29) – Voltage Max. 1 V P11, P12 (female) (2) and chassis ground Wiring harness between CP06 (female) (39) – Voltage Max. 1 V P09, P10 (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Control connector Travel lever Voltage Between CP06 (29) and Neutral 20 – 30 V chassis ground Between CP06 (29) and Forward or reverse Max. 1 V chassis ground Between CP06 (39) and Neutral 20 – 30 V chassis ground Between CP06 (39) and Forward or reverse Max. 1 V chassis ground

PC2000-8

40 Troubleshooting

SEN02103-00

Circuit diagram related to travel PPC oil pressure switch

PC2000-8

43

SEN02103-00

40 Troubleshooting

E-19 Travel alarm does not sound Trouble Related information

• Alarm does not sound during travel. • Alarm sounds in stopped state. – Cause 1 Defective travel signal

Possible causes and standard value in normal state

1

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Grounding fault in wir3 ing harness (Short circuit with ground circuit) 4 Defective travel alarm

5

Defective pump controller

Standard value in normal state/Remarks on troubleshooting If monitoring display is not normal, proceed to troubleshooting No. E-18. Monitoring Item Normal display 01902 R.H travel Lever operation: ON Lever at neutral: OFF 01902 L.H travel a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (18) – Resistance Max. 1 z M14 (female) (1) Wiring harness between M14 (female) (2) – Resistance Max. 1 z CP06 (female) (3), (23) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CP06 (female) (18) – Resistance Min. 1 Mz M14 (female) (1) and chassis ground Since trouble is in system, troubleshooting cannot be carried out. (If above 1 – 3 and 4 are not detected, travel alarm may be defective.) a Prepare with starting switch OFF, then travel and carry out troubleshooting. CP06 Travel lever Voltage Neutral Max. 1 V Between (18) and chas- In L.H forward and L.H sis ground reverse or R.H forward 20 – 30 V and R.H reverse

Circuit diagram related to travel alarm

44

PC2000-8

40 Troubleshooting

SEN02103-00

E-20 All of room lamp, headlamp and working lamp do not light up Trouble (1) Related information

Possible causes and standard value in normal state

PC2000-8

1

• All of room lamp, headlamp and working lamp do not light up. – Cause Standard value in normal state/Remarks on troubleshooting Shut down of circuit breakers No. B21, B22 If the circuit breakers and fuses are shut down, the circuit probably has a 1 and B23 and fuses F01 grounding fault. (3), (8) and (19) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance 2 Defective light switch Between S02 (female) (5) – (4), (5) – (6) Light switch ON Max. 1 z Light switch OFF Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective room lamp Between S16 (female) (5) – (6) Resistance 3 switch Room lamp switch ON Max. 1 z Room lamp switch OFF Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective fog lamp Between S17 (female) (5) – (6) Resistance 4 switch Fog lamp switch ON Max. 1 z Fog lamp switch OFF Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between S02 (female) (5) – F01Resistance Max. 1 z harness 3 5 (Disconnection in wiring or defective contact Wiring harness between S16 (female) (5) – F01- Resistance Max. 1 z 19 in connector) Wiring harness between S17 (female) (5) – F01Resistance Max. 1 z 19 a Prepare with starting switch OFF, and then carry out troubleshooting without turning starting switch ON. Wiring harness between S02 (female) (5) – F01Resistance Min. 1 Mz Grounding fault in wir3 and chassis ground 6 ing harness (Short circuit with ground circuit) Wiring harness between S16 (female) (5) – F01- Resistance Min. 1 Mz 19 and chassis ground Wiring harness between S17 (female) (5) – F01Resistance Min. 1 Mz 19 and chassis ground

45

SEN02103-00

Trouble (2) Related information

40 Troubleshooting

• Headlamp and working lamp do not light up. – Cause Defective headlamp 1 and working lamp (Bulb burnout)

Possible causes and standard value in normal state

46

Standard value in normal state/Remarks on troubleshooting The headlamp and working lamps can be defective. Check the bulbs for burnout.

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S02 (female) (4) – D06 Resistance Max. 1 z (female) (6) Wiring harness between D06 (female) (2) – R08 Resistance Max. 1 z (female) (5), R10 (female) (5), R11 (female) (5) Wiring harness between S02 (female) (6) – Resistance Max. 1 z CM01 (female) (13), D06 (female) (5) Wiring harness between circuit breaker B21B – Resistance Max. 1 z R11 (female) (4) Wiring harness between circuit breaker B21C – Resistance Max. 1 z R11 (female) (2) Wiring harness between circuit breaker B23B – Resistance Max. 1 z R08 (female) (2), (4) Wiring harness between R08 (female) (1) – A13 (3) – L01C (female) (1), – A13 (4) – L01A Resistance Max. 1 z (female) (1) Wiring harness between S08 (female) (3) – A13 (1) – L01B (female) (1), – A13 (2) – L01D Resistance Max. 1 z Disconnection in wiring (female) (1) harness (DisconnecWiring harness between R11 (female) (1) – A14 2 tion in wiring or defec(10) – L04B (female) (1), – A14 (11) – L04A Resistance Max. 1 z tive contact in (female) (1) connector) Wiring harness between R11 (female) (3) – A14 (8) – L04D (female) (1), – A14 (9) – L04C Resistance Max. 1 z (female) (1) Wiring harness between L01B (female) (2) – A13 Resistance Max. 1 z (female) (12) and chassis ground Wiring harness between L01D (female) (2) – A13 Resistance Max. 1 z (female) (11) and chassis ground Wiring harness between L01C (female) (2) – A13 Resistance Max. 1 z (female) (10) and chassis ground Wiring harness between L01A (female) (2) – A13 Resistance Max. 1 z (female) (9) and chassis ground Wiring harness between L04A (female) (2) – Resistance Max. 1 z chassis ground (T12) and chassis ground Wiring harness between L04B (female) (2) – Resistance Max. 1 z chassis ground (T11) and chassis ground Wiring harness between L04C (female) (2) – Resistance Max. 1 z chassis ground (T12) and chassis ground Wiring harness between L04D (female) (2) – Resistance Max. 1 z chassis ground (T11) and chassis ground

PC2000-8

40 Troubleshooting

SEN02103-00

Cause

Possible causes and standard value in normal state

Trouble (3) Related information

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between R08 (female) (1) – A13 (1) – L01B (female) (1), – A13 (2) – L01D Resistance Min. 1 Mz (female) (1) and chassis ground Wiring harness between R08 (female) (3) – A13 Grounding fault in wir(3) – L01C (female) (1), – A13 (4) – L01A Resistance Min. 1 Mz 3 ing harness (Short cir(female) (1) and chassis ground cuit with ground circuit) Wiring harness between R11 (female) (1) – A14 (10) – L04B (female) (1), – A14 (11) – L04A Resistance Min. 1 Mz (female) (1) and chassis ground Wiring harness between R11 (female) (3) – A14 (8) – L04D (female) (1), – A14 (9) – L04C Resistance Min. 1 Mz (female) (1) and chassis ground

• Room lamp does not light up. • If the headlamp and working lamp can be lit Cause Defective room lamp 1 (Bulb burnout)

Possible causes and standard value in normal state

PC2000-8

Standard value in normal state/Remarks on troubleshooting The room lamp can be defective. Check the bulbs for burnout.

a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness Wiring harness between S16 (female) (6) – L03 2 (Disconnection in wirResistance Max. 1 z (female) (1) ing or defective contact Wiring harness between L03 (female) (2) – JC50 in connector) Resistance Max. 1 z – JC57A – JB66 – JB62 – chassis ground (TB04) Prepare with starting switch OFF, then carry out troubleshooting without Grounding fault in wirturning starting switch ON. 3 ing harness (Short cirWiring harness between S16 (female) (6) – L03 cuit with ground circuit) Resistance Min. 1 Mz (female) (1) and chassis ground

47

SEN02103-00

40 Troubleshooting

Circuit diagram relevant to room lamp, headlamp and working lamp

48

PC2000-8

SEN02103-00

40 Troubleshooting

E-21 Air conditioner does not work Trouble (1) Related information

• Upper air conditioner does not work. • For the electrical circuit inside the air-conditioner unit, refer to "Air conditioning system" in "Structure, function and maintenance standard." Cause Defective fuse or cir1 cuit breaker

Possible causes and standard value in normal state

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Grounding fault in wir3 ing harness (Short circuit with ground circuit)

4

Trouble (2) Related information

Defective upper air conditioner unit

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Grounding fault in wir3 ing harness (Short circuit with ground circuit)

4

50

Standard value in normal state/Remarks on troubleshooting If fuse is blown or if circuit breaker is shut down, the circuit probably has a grounding fault (Refer to cause 3). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-11 – M33A (female) Resistance Max. 1 z (3) Wiring harness between M33A (female) (2) – Resistance Max. 1 z chassis ground (TB14) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-11 – M33A (female) Resistance Min. 1 Mz (3) and chassis ground a Prepare with starting switch OFF, then a turn starting switch ON and carry out troubleshooting. M33A (female) Voltage Between (3) – (2) 20 – 30 V

• Lower air conditioner does not work. • For the electrical circuit inside the air conditioner unit, refer to "Air conditioning system" in "Structure, function and maintenance standard." Cause Defective fuse or cir1 cuit breaker

Possible causes and standard value in normal state

1

Defective lower air conditioner unit

Standard value in normal state/Remarks on troubleshooting If fuse is blown or if circuit breaker is shut down, the circuit probably has a grounding fault (Refer to cause 3). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-12 – M33B Resistance Max. 1 z (female) (3) Wiring harness between M33B (female) (2) – Resistance Max. 1 z chassis ground (TB14) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-12 – M33B Resistance Min. 1 Mz (female) (3) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. M33B (female) Voltage Between (3) – (2) 20 – 30 V

PC2000-8

40 Troubleshooting

SEN02103-00

Circuit diagram relevant to air conditioner

PC2000-8

51

SEN02103-00

40 Troubleshooting

E-22 Step light does not light up or goes off Trouble Related information

Possible causes and standard value in normal state

52

1

(1) Step light does not light up for 1 minute even if the switch is pressed. • If failure code [D195KA] or [D195KY] of the step light relay (R07) is displayed, carry out troubleshooting for it first.

• Step light does not light up or goes off.

Cause Standard value in normal state/Remarks on troubleshooting 1 Defective fuse F01-20 If the fuse is blown, circuit probably has grounding fault. Defective step light 2 The step light can be defective. Check the bulbs for burnout. (Bulb burnout) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S13 (male) Step light switch Resistance Released Min. 1 Mz Between (5) – (6) Pressed Max. 1 z Defective step light S30 (male) Step light switch Resistance switch or maintenance 3 switch (Internal disconOFF Min. 1 Mz Between (1) – (2) nection) ON Max. 1 z Maintenance light S30A (male) Resistance switch OFF Min. 1 Mz Between (1) – (2) ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without Defective step light turning starting switch ON. 4 relay (Internal disconWhen step light relay is replaced with another relay, if the connection) R07 dition becomes normal, the relay (5-pole relay) is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-20 outlet – S13 (female) (5) – R07 (female) (1), (3) – S30 Resistance Max. 1 z (female) (1) – S30A (female) (1) Disconnection in wiring Wiring harness between S13 (female) (6) – harness (DisconnecCP04 (female) (11) – S30 (female) (2) – S30A Resistance Max. 1 z 5 tion in wiring or defec- (female) (2) – CP06 (female) (14), (24) tive contact in Wiring harness between R07 (female) (2) – connector) Resistance Max. 1 z CP05 (female) (8) Wiring harness between R07 (female) (5) – L06 Resistance Max. 1 z (female) (1) Wiring harness between L06 (female) (2) and Resistance Max. 1 z chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-20 outlet – S13 (female) (5) – R07 (female) (1), (3) – S30 Resistance Min. 1 Mz (female) (1) – S30A (female) (1) and chassis Grounding fault in wirground 6 ing harness (Short circuit with ground circuit) Wiring harness between S13 (female) (6) – CP04 (female) (11) – S30 (female) (2) – S30A Resistance Min. 1 Mz (female) (2) – CP06 (female) (14), (24) and chassis ground Wiring harness between R07 (female) (5) – L06 Resistance Min. 1 Mz (female) (1) and chassis ground

PC2000-8

40 Troubleshooting

SEN02103-00

Cause

Possible causes and standard value in normal state

PC2000-8

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective pump conCP04 Step light switch Voltage troller (Step light switch input system) Released Max. 1 V Between (11) and chassis ground Pressed Min. 5 V 7 a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective pump conCP05 Step light switch Voltage troller (Step light switch Released Min. 5V output system) Between (8) and Max. 1 V chassis ground Pressed (For 60 seconds)

53

SEN02103-00

Trouble Related information

40 Troubleshooting

• Step light does not light up or goes off – Cause

Defective step light switch or maintenance 1 switch (Internal disconnection)

Possible causes and standard value in normal state

Defective step light 2 relay (Internal disconnection)

Hot short circuit in wir3 ing harness (Contact with 24V circuit)

Defective pump controller (Step light switch input system) 4 Defective pump controller (Step light switch output system)

54

(2) Step light lights up without the switch being pressed.

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S13 (male) Step light switch Resistance Released Min. 1 Mz Between (5) – (6) Pressed Max. 1 z S30 (male) Step light switch Resistance OFF Min. 1 Mz Between (1) – (2) ON Max. 1 z Maintenance light S30A (male) Resistance switch OFF Min. 1 Mz Between (1) – (2) ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When step light relay is replaced with another relay, if the conR07 dition becomes normal, the relay (5-pole relay) is defective. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between R06 (female) (1) – R07 Voltage Max. 1 V (female) (5) and chassis ground Wiring harness between S13 (female) (6) – CP04 (female) (11) – S30 (female) (2) – S30A Voltage Max. 1 V (female) (2) – CP06 (female) (14), (24) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CP04 Step light switch Voltage Released Max. 1 V Between (11) and chassis ground Pressed 20 – 30 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CP05 Step light switch Voltage Released 20 – 30 V Between (8) and Max. 1 V chassis ground Pressed (For 60 seconds)

PC2000-8

40 Troubleshooting

SEN02103-00

Circuit diagram relevant to step light

PC2000-8

55

SEN02103-00

PC2000-8 Hydraulic excavator Form No. SEN02103-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

56

SEN02104-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

40 Troubleshooting

1

Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 3 Before troubleshooting for hydraulic and mechanical systems ............................................................ 3 Table of failure modes and causes ...................................................................................................... 8 Information in troubleshooting table ................................................................................................... 10 H-1 Speed or power of whole work equipment, travel, and swing is low ........................................... 11 H-2 Engine speed lowers remarkably or engine stalls ....................................................................... 13 H-3 Work equipment, swing, and travel mechanism do not move ..................................................... 14 H-4 Abnormal noise comes from around hydraulic pump .................................................................. 16 H-5 Speed or power of boom is low ................................................................................................... 17 H-6 Speed or power of arm is low...................................................................................................... 19 H-7 Speed or power of bucket is low ................................................................................................. 20 H-8 Boom does not move .................................................................................................................. 21 H-9 Arm does not move ..................................................................................................................... 21 H-10 Bucket does not move............................................................................................................... 21

PC2000-8

1

SEN02104-00

40 Troubleshooting

H-11 Hydraulic drift of work equipment is large.................................................................................. 22 H-12 Time lag of work equipment is large.......................................................................................... 23 H-13 Heavy lift function does not work or is not reset. ....................................................................... 24 H-14 Machine push-up function does not work or is not reset ........................................................... 24 H-15 Boom shockless function does not work or is not reset............................................................. 24 H-16 Machine gradually deviates during traveling ............................................................................. 26 H-17 Machine deviates excessively when started to travel................................................................ 29 H-18 Machine deviates excessively during multiple operations ......................................................... 30 H-19 Traveling speed or power is low ................................................................................................ 30 H-20 Travel system does not move (only one side) ........................................................................... 31 H-21 Upper structure does not swing................................................................................................. 32 H-22 Swing speed or acceleration is low ........................................................................................... 34 H-23 In compound operation of work equipment, swing speed or acceleration is low....................... 36 H-24 Upper structure overruns remarkably when it stops swinging ................................................... 37 H-25 Large shock is made when upper structure stops swinging ...................................................... 38 H-26 Large abnormal sound comes from when upper structure stops swinging ............................... 39 H-27 Hydraulic drift of work equipment is large in swing operation.................................................... 40 H-28 Fan rotation is abnormal (large noise or vibration of fans, or fan overheating) ......................... 41

2

PC2000-8

40 Troubleshooting

SEN02104-00

Troubleshooting of hydraulic and mechanical system (H-mode)1 Before troubleshooting for hydraulic and mechanical systems

1

Combination of hydraulic pumps and control valves, and hydraulic pressure measuring points

PC2000-8

3

SEN02104-00

1. Combination and operation of hydraulic pumps q The work equipment, travel and swing circuit consists of two HPV375+375 tandem pumps and two HE40 control valves for port surface alignment. q The P1-F pump feeds hydraulic oil to the R1 control valve, the P1-R pump feeds oil to the L1 control valve, the P2-F pump feeds oil to the R2 control valve, and P2-R pump feeds oil to the L2 control valve. q The flow rate of oil from P1 and P2 pumps is controlled by the EPC solenoid valve that is mounted on each pump. q The P1-F pump operates under NC control. The R1 control valve has a differential pressure sensor, and the pump controller calculates sensor signals and controls the EPC solenoid valve of P1-F pump by sending control signals to the valve. q The P1-R pump also operates under NC control. The L1 control valve has a differential pressure sensor, and the pump controller calculates sensor signals and controls the EPC solenoid valve of P1-R pump by sending control signals to the valve. q The P2-F pump also operates under NC control. The R2 control valve has a differential pressure sensor, and the pump controller calculates sensor signals and controls the EPC solenoid valve of P2-F pump by sending control signals to the valve. q The P2-R pump also operates under NC control. The L2 control valve has a differential pressure sensor, and the pump controller calculates sensor signals and controls the EPC solenoid valve of P2-R pump by sending control signals to the valve. q The pump controller calculates signals from each pump pressure sensor, and outputs control signals to the EPC solenoid valve of each pump for equal horsepower control and cutoff control. q The fan driving circuit consists of a single HPV95+95 tandem pump and two LMF75(110) fan motors. q The PF-F pump feeds oil to the fan motor at the radiator side, and the PF-R pump feeds oil to the fan motor at the oil cooler side.

4

40 Troubleshooting

2. Troubleshooting procedure when “work equipment speed is low and machine gradually turns to the left during traveling” q Possible causes are: 1) Defective main relief valve of L1 or L2 control valve 2) Defective jet sensor of L1 or L2 control valve 3) Defective differential pressure sensor of L1 or L2 control valve 4) Defective EPC solenoid valve of P1R or P2R pump 5) Defective servo valve of P1R or P2R pump 6) Defective P1R or P2R pump itself q In these cases, locate the failure by measuring the relief pressure of main relief valve, by measuring the differential pressure of jet sensor, or by measuring the output voltage of differential pressure sensor. q To check the EPC solenoid valve of the pump, measure the solenoid valve output pressure. q To check the servo valve and the pumps, remove the servo pump and perform the unit test, or measure the stroke of servo pump pistons. a Actual troubleshooting is carried out following Section 4 “Troubleshooting chart when the work equipment speed is low or machine deviates during traveling”.

PC2000-8

40 Troubleshooting

3. Troubleshooting when “work equipment speed is low and machine gradually turns to the right during traveling” q Possible causes are: 1) Defective main relief valve of R1 or R2 control valve 2) Defective jet sensor of R1 or R2 control valve 3) Defective differential pressure sensor of R1 or R2 control valve 4) Defective EPC solenoid valve of P1F or P2F pump 5) Defective servo valve of P1F or P2F pump 6) Defective P1F or P2F pump itself q In these cases, locate the failure by measuring the relief pressure of main relief valve, by measuring the differential pressure of jet sensor, or by measuring the output voltage of differential pressure sensor. q To check the EPC solenoid valve of the pump, measure the solenoid valve output pressure. q To check the servo valve and the pumps, remove the servo pump and perform the unit test, or measure the stroke of servo pump pistons. a Actual troubleshooting is carried out following Section 4 “Troubleshooting chart when the work equipment speed is low or deviates during traveling”.

PC2000-8

SEN02104-00

4. Troubleshooting chart when the work equipment speed is low or machine deviates during traveling (the next page) a Sequentially check the nature of trouble on the list, and locate the possible cause indicated by the largest number of Q symbols. 1) To check the servo valve, remove the servo valve and perform the unit test, or measure the stroke of servo pump pistons. a The unit test of servo pump pistons shall be made in the authorized service shop only. 2) If the work equipment speed drops excessively and its pump is susceptible, check the line filter and drain filter, too. 3) If the work equipment speed drops not so much but its operation is still abnormal after each device adjustment, check the line filter and drain filter, too. 4) Check the servo motor pistons by removing caps from both sides and by manually operating the pistons.

5

SEN02104-00

40 Troubleshooting

Cause

q

q

3 4

Travel (Turn to LEFT)

2

X

X

q

q

q

q

q

q

q

The travel relief pressure of P1R or P2R pump circuit is low.

q

The differential pressure of jet sensor mounted on the L1 or L2 control valve is abnormal.

q

The output voltage of differential pressure sensor mounted on the L1 or L2 control valve is abnormal.

q

q

q

q

7

The machine gradually turns to right, and the swing speed of work equipment is very low.

q

q

q

Travel (Turn to RIGHT)

X

q

The machine gradually turns to right and the work equipment speed is low.

q

The machine gradually turns to right, but the swing speed of work equipment is normal.

q

The travel relief pressure of P1F or P2F pump circuit is low.

q

The differential pressure of jet sensor mounted on the R1 or R2 control valve is abnormal.

11

The output voltage of differential pressure sensor mounted on the R1 or R2 control valve is abnormal.

12

The output pressure of EPC solenoid valve mounted on the P1F or P2F pump is abnormal.

Remedy

6

A X

A X

6

10

A X

A X

The output pressure of EPC solenoid valve mounted on the P1R or P2R pump is abnormal.

9

X

X

5

8

Right travel motor

q

Left travel motor

The machine gradually turns to left and the work equipment speed is low.

1

Defective differential pressure sensor

Diagnosis

Defective jet sensor

X

Defective main relief valve

X

Remedy No.

Defective differential pressure sensor

Defective servo valve

X

Defective jet sensor

Defective EPC solenoid valve

X

Defective main relief valve

Defective pump itself

X

Defective pump itself

Defective servo valve

P1F or P2F L1 or L2 R1 or R2 pump control valve control valve

Defective EPC solenoid valve

P1R or P2R pump

A: Adjust

q q q

X: Repair or replace

PC2000-8

SEN02104-00

40 Troubleshooting

Table of failure modes and causes

1

Q Q

Abnormal noise comes from around hydraulic pump

Q

Q

Q Q

Speed or power of boom is low

Q

Q

Q

Q

Q

Speed or power of arm is low

Q

Q

Q

Q

Q

Speed or power of bucket is low

Q

Q

Q

Q

Q

Q

Boom does not move

Q

Q

Arm does not move

Q

Q

Bucket does not move

Q

Hydraulic drift of work equipment is large

Q

Q Q Q

Time lag of work equipment is large Q

Heavy lift function does not work or is not reset

Q

Machine push-up function does not work or is not reset

Q Q

Travel

Boom shockless function does not work or is not reset Machine deviates to the same side Q Machine gradually during forward and backward traveling deviates during travelMachine deviates to different sides ing during forward and backward traveling Machine deviates excessively when started to travel

Boom shockless valve

Q

PPC valve

Q

Main body

Differential pressure sensor

Whole work equipment Travel Swing

Q

Jet sensor

Q

Work equipment, swing, and travel mechanism do not move

Suction valve

Engine speed lowers excessively or engine stalls

Safety valve

Q

Main relief valve

Q

Spool

Self pressure reducing valve

Q

PTO

Main body

Q

Strainer

Servo valve

Speed or power of whole work equipment, travel, and swing is low

Failure mode

Work equipment

Control valve

EPC valve

Part that can cause failure Main pump

Q

Q

Q

Q

Q

Q Q

Q

Q Q

Q

Q

Q

Machine deviates excessively during multiple operations Q

Traveling speed is low or power is low Q

Q

Q

To one side only

Q

Q

Q

Swing speed or accel- To both sides eration is low To one side only

Q

Q

Q

Upper structure over- To both sides runs remarkably when To one side only it stops swinging

Q

Q

Q

Large shock is made when upper structure stops swinging

Q

Q

Large abnormal sound comes from when upper structure stops swinging

Q

Q

Travel system does not move (only one side) Upper structure does not swing

To both sides

Swing

In compound operation of work equipment, swing speed or acceleration is low

Fan

Hydraulic drift of work equipment is large in swing operation

8

When parking brake is applied When parking brake is relieved

Q

Fan rotation is abnormal

PC2000-8

Q

Q

PC2000-8 Q

Q

Q Q

Q

Q Q

Q

Q

Q Q

Q

Q

Q

Q

Q Q

Q

Q Q

Q

Q Q

Q

Q Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q Q Q

Q

Q Q

Q

Q Q Q Q

Q Q

Q

Q Q

Q Q

Q Q Q

Q

Q

Q

Q

Diagnostic code

Fan motor

Fan pump

Engine system

Hydraulic cylinder

Final gear

Swing machinery

Main body

Safety valve

Internal oil leakage

Swing motor

Brake

Main body

Suction valve

Safety valve

Solenoid valves

Internal oil leakage

Brake

Swing brake

Bucket Hi cancel

PPC lock

Machine push-up

Straight traveling

Boom throttle valve (R1)

Arm throttle valve (R2)

Arm throttle valve (L1)

2-stage main relief valve

Swing priority valve

Variable back pressure valve

Center swivel joint

Travel junction valve

Variable back pressure valve

Throttle shift valve

PPC cutoff valve

40 Troubleshooting SEN02104-00

Travel motor

H-1

H-3

H-2

H-4

Q H-5

Q H-6

Q H-7

H-8

H-9

H-10

H-12

H-11

H-14

H-13

H-15

Q

Q H-16

H-18

H-17

H-19

H-20

H-21

H-22

H-23

Q

H-24

H-25

H-26

H-27

Q H-28

9

SEN02104-00

40 Troubleshooting

Information in troubleshooting table a

1

The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Related information

Problem that appears on machine Information related to detected trouble or troubleshooting Cause

Standard value in normal state/Remarks on troubleshooting

1

Possible causes and standard value in normal state

2 Possible causes of the current trouble (The order number indicates • Standard value in normal state required to judge possible causes a serial number, not a • Remarks on judgment 3 priority sequence.)

4

10

PC2000-8

40 Troubleshooting

SEN02104-00

H-1 Speed or power of whole work equipment, travel, and swing is low1 Trouble

Related information

• Speed or power of whole work equipment, travel, and swing is low • Measure the work equipment, travel, and swing speed, and make sure that all of their speed (or power) is low. • Make sure that abnormal sound does not come from around the hydraulic pump. (If abnormal sound is heard, troubleshoot the related items.) • Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. • If a failure code relating to the pump control is displayed, carry out the troubleshooting for it first. Cause

Standard value in normal state/Remarks on troubleshooting a Check the engine in Hi idle state. Heavy lift switch and R.H. work Engine speed equipment control lever 1 Defective engine itself When Heavy lift switch is OFF and 1,780 ± 100 rpm Boom raise is relieved When Heavy lift switch is ON and 1,780 ± 100 rpm Boom raise is relieved a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Control lever Control circuit pressure 2 self pressure reducing +0.49 +5 All levers in neutral 3.24 –0.20 MPa {33 –2 kg/cm2} valve If the control circuit pressure is low, adjust the self pressure reducing valve (refer to “Testing and adjusting”). a Stop the machine engine, close valves (1) to (6) of Fig. 1, and troubleshoot with the engine rotating at high idle speed. Internal oil leakage of 3 Control lever Control circuit pressure control system devices All levers in neutral

Possible causes and standard value in normal state

PC2000-8

+0.49

+5

3.24 –0.20 MPa {33 –2 kg/cm2} a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Heavy lift switch and R.H. work Main relief pressure equipment control lever Incorrect adjustment or When Heavy lift switch is OFF and +1.0 +10 29.4 –2.0 MPa {300 –20 kg/cm2} 4 defective operation of Boom raise is relieved main relief valve When Heavy lift switch is ON and +1.0 +10 32.1 –2.0 MPa {327 –20 kg/cm2} Boom raise is relieved If the oil pressure does not become normal after adjustment, the main relief valve may have malfunctioned (at low or high pressure set side). Check the main relief valve directly. a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. (Make sure that failure causes 2 and 4 are normal before troubleshooting.) Defective pump EPC Control lever EPC current of the pump 5 current output (P1/P2) All levers in neutral 220 ± 60 mA When traveled with idle turns 450/675 ± 60 mA (the lever to the stroke end) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. (Make sure that failure cause 5 is normal before troubleshooting.) Defective actuation of Control lever EPC solenoid valve output pressure pump EPC solenoid 6 0.59 MPa valve All levers in neutral (P1/P2) {6 kg/cm2} 1.11/2.04 ± 0.39 MPa When traveled with idle turns (the lever to the stroke end) {11.3/20.8 ± 4.0 kg/cm2}

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Fig. 1 Control System Devices

12

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H-2 Engine speed lowers remarkably or engine stalls Trouble Related information

• Engine speed lowers remarkably or engine stalls • Set the working mode in P-mode when troubleshooting is carried out. • If a failure code relating to the pump control is displayed, carry out the troubleshooting for it first. Cause Defective pump EPC 1 current output (P1/P2)

Possible causes and standard value in normal state

1

Defective actuation of pump EPC solenoid 2 valve (P1/P2)

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Control lever EPC current of the pump All levers in neutral 220 ± 60 mA When traveled with idle turns 450/675 ± 60 mA (the lever to the stroke end) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. (Make sure that failure cause 1 is normal before troubleshooting.) Control lever EPC solenoid valve output pressure All levers in neutral

Max. 0.59 MPa {Max. 6 kg/cm2} 1.11/2.04 ± 0.39 MPa When traveled with idle turns (the lever to the stroke end) {11.3/20.8 ± 4.0 kg/cm2} If causes 1 and 2 are not the cause of the trouble, the engine itself may 3 Defective engine itself have failed. Troubleshoot the engine (in the S-mode).

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H-3 Work equipment, swing, and travel mechanism do not move Trouble Related information

1

• Work equipment, swing, and travel mechanism do not move • Set the working mode in P-mode when troubleshooting is carried out. • If a failure code relating to the pump control is displayed, carry out the troubleshooting for it first. Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine stopped. Internal defect of cou1 pling (Main pump driv- Disconnect the hydraulic pressure measuring coupler of the main pump, ing system) and rotate the crankshaft. If the oil flows out from the coupler hole, it is normal. a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Control lever Control circuit pressure 2 self pressure reducing +0.49 +5 All levers in neutral 3.24 –0.20 MPa {33 –2 kg/cm2} valve If the control circuit pressure is low, adjust the self pressure reducing valve (refer to “Testing and adjusting”). a Stop the machine engine, close valves (1) to (6) of Fig. 1, and troubleshoot with the engine rotating at high idle speed. Internal oil leakage of 3 Control lever Control relief valve pressure control system devices All levers in neutral

+0.49

+5

3.24 –0.20 MPa {33 –2 kg/cm2} a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Lock lever Solenoid valve outlet pressure 4 PPC lock solenoid valve When relieved Min. 2.74 MPa {Min. 28 kg/cm2} When locked

14

0 MPa {0 kg/cm2}

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Fig. 1 Control System Devices

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H-4 Abnormal noise comes from around hydraulic pump Trouble Related information

• Abnormal noise comes from around hydraulic pump

Cause 1 Hydraulic oil low level 2 Loose piping clamps Possible causes and standard value in normal state

Clogging of hydraulic tank strainer Internal defect of 4 hydraulic pump 3

5

16

1

Check for the trouble status change.

Standard value in normal state/Remarks on troubleshooting The hydraulic oil level may be low. Check it directly. The piping clamps may be loose between the hydraulic tank and the oil pump. Check them directly. The hydraulic tank strainer may be clogged. Check it directly. The hydraulic pump may have an internal defect. Check it directly. If the failure cause cannot be identified by troubleshooting, keep the hydraulic system operating for a while and check for the trouble status change.

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H-5 Speed or power of boom is low Trouble

(1) Speed or power of boom is low in the normal operation mode. The normal operation mode is the state when the heavy lift switch is turned OFF and the machine push-up switch is turned OFF. Make sure that the other work equipment, travel and swing speed is normal. (If not, troubleshoot the related items.) Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot the related items.) Set the working mode in P-mode when troubleshooting is carried out. Make sure that the electric circuit related to the boom control are normal before troubleshooting.

• Speed or power of boom is low • •

Related information

• • •

Cause Defective operation of 1 right PPC valve (boom circuit)

Defective operation of 2 boom throttle solenoid valve (R1) Possible causes and standard value in normal state

PC2000-8

1

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. R.H. work equipment control lever PPC valve output pressure When boom is fully raised Min. 2.74 MPa {Min. 28 kg/cm2} or lowered, and to the stroke end. a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. R.H. work equipment control lever Solenoid valve outlet pressure When boom is raised

0 MPa {0 kg/cm2}

Defective operation of The spool of boom control valve (Lo/Hi) may have malfunctioned. Check it 3 boom control valve directly. (spool) The safety-suction valve, mounted on the boom control valve (Lo), may have malfunctioned. Check it directly. (If it is replaced with another workDefective operation of ing circuit for troubleshooting, completely stop the oil feeding through the 4 boom control valve hose at the machine push-up solenoid valve. As the safety-suction valve (safety-suction valve) has the different set pressure and structure, be sure to reset it after the troubleshooting has completed.) Defective boom control The main body of boom control valve (Lo/Hi) may have malfunctioned. 5 valve (main body) Check it directly. a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective seal of boom 6 cylinder R.H. work equipment control lever Leakage from cylinder Boom raise relief Max. 20 cc/min

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Trouble

Related information

40 Troubleshooting

• Speed or power of boom is low (2) Speed or power of boom is low in Heavy lift mode • In Heavy lift mode, the Heavy lift switch is in ON state. • Make sure that the other work equipment, travel and swing speed is normal. (If not, troubleshoot the related items.) • Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. • Make sure that the electric circuit of heavy lift solenoid valve is normal before troubleshooting. Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of R.H. work equipment control lever Solenoid valve outlet pressure 1 2-stage relief solenoid valve At neutral 0 MPa {0 kg/cm2} Possible causes and standard value in normal state

When boom is raised alone

Min. 2.74 MPa {Min. 28 kg/cm2} a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. R.H. work equipment control lever Solenoid valve outlet pressure Incorrect adjustment or At neutral Main relief pressure 2 defective operation of +1.0 +10 main relief valve When boom is raised alone 32.1 MPa {327 kg/cm2} –2.0

–20

If the trouble continues after the adjustment, the main relief valve (at high pressure set side) may have malfunctioned. Check it directly.

Trouble

Related information

• Speed or power of boom is low (3) Speed or power of boom is low in Machine push-up mode. • In Machine push-up mode, the Machine Push-Up switch is in ON state. • Make sure that the other work equipment, travel and swing speed is normal. (If not, troubleshoot the related items.) • Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. • Check the electric circuit of machine push-up solenoid valve first. Cause

Possible causes and standard value in normal state

18

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Machine push-up switch Solenoid valve outlet pressure 1 machine push-up solenoid valve OFF Min. 2.74 MPa {Min. 28 kg/cm2} ON

0 MPa {0 kg/cm2} Defective operation of The safety-suction valve mounted on the boom control valve (Lo) may 2 boom control valve have malfunctioned (at the high pressure set side of the head). Check it (safety-suction valve) directly.

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H-6 Speed or power of arm is low Trouble

Related information

1

• Speed or power of arm is low • Make sure that the other work equipment, travel and swing speed is normal. (If not, troubleshoot the related items.) • Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. • Make sure that the electric circuit of arm control parts is normal before troubleshooting. Cause

1

2

Possible causes and standard value in normal state

3

4

5

6

PC2000-8

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and Defective operation of carry out troubleshooting. left PPC valve (arm cirL.H. work equipment control lever PPC valve output pressure cuit) During arm IN or OUT in full stroke Min. 2.74 MPa {Min. 28 kg/cm2} a Prepare with engine stopped, then run engine at high idle speed and Defective operation of carry out troubleshooting. arm throttle solenoid L.H. work equipment control lever Solenoid valve outlet pressure valve (L1 or R2) During arm IN or OUT operation 0 MPa {0 kg/cm2} Defective operation of The spool of arm control valve (Lo/Hi) may have malfunctioned. Check it arm control valve directly. (spool) Defective operation of The safety-suction valve, mounted on the arm control valve (Lo/Hi), may have malfunctioned. Check it directly. (If it is replaced with another worksafety-suction valve mounted on the arm ing circuit for troubleshooting, be sure to reset the safety-suction valve control valve (Lo) after the troubleshooting because the valve has the different set pressure.) Defective operation of The main body of arm control valve (Lo/Hi) may have malfunctioned. arm control valve Check it directly. (main body) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective seal of arm cylinder L.H. work equipment control lever Leakage from cylinder Arm IN relief Max. 20 cc/min

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H-7 Speed or power of bucket is low Trouble

Related information

1

• Speed or power of bucket is low • Make sure that the other work equipment, travel and swing speed is normal. (If not, troubleshoot the related items.) • Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. • Make sure that the electric circuit of bucket control parts is normal before troubleshooting. Cause

1

2

Possible causes and standard value in normal state

3

4

5

6

20

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of right PPC valve R.H. work equipment control lever PPC valve output pressure (bucket circuit) During bucket curl or dump in full Min. 2.74 MPa {Min. 28 kg/cm2} stroke a Prepare with engine stopped, then run engine at high idle speed and Defective operation of carry out troubleshooting. bucket “Hi” cancel R.H. work equipment control lever Solenoid valve outlet pressure solenoid valve During bucket curl Min. 2.74 MPa {Min. 28 kg/cm2} Defective operation of The spool of bucket control valve (Lo/Hi) may have malfunctioned. Check bucket control valve it directly. (spool) The safety-suction valve, mounted on the bucket control valve (Lo/Hi), Defective operation of may have malfunctioned. Check it directly. (If it is replaced with another safety-suction valve working circuit for troubleshooting, be sure to reset the safety-suction mounted on the bucket valve after the troubleshooting because the valve has the different set control valve pressure.) Defective operation of The main body of bucket control valve (Lo/Hi) may have malfunctioned. bucket control valve Check it directly. (main body) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective seal of bucket cylinder R.H. work equipment control lever Leakage from cylinder Bucket curl relief Max. 20 cc/min

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H-8 Boom does not move Trouble Related information

1

• Boom does not move • Make sure that the other work equipment, travel and swing speed is normal. (If not, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of 1 right PPC valve (boom R.H. work equipment control lever PPC valve output pressure circuit) When boom is fully raised or lowMin. 2.74 MPa {Min. 28 kg/cm2} ered Defective operation of The spool of boom control valve (Lo/Hi) may have malfunctioned. Check it 2 boom control valve directly. (spool)

H-9 Arm does not move Trouble Related information

1

• Arm does not move • Make sure that the other work equipment, travel and swing speed is normal. (If not, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and Defective operation of carry out troubleshooting. 1 left PPC valve (arm cirL.H. work equipment control lever PPC valve output pressure cuit) During arm IN or OUT in full stroke Min. 2.74 MPa {Min. 28 kg/cm2} Defective operation of The spool of arm control valve (Lo/Hi) may have malfunctioned. Check it 2 arm control valve directly. (spool)

H-10 Bucket does not move Trouble Related information

1

• Bucket does not move • Make sure that the other work equipment, travel and swing speed is normal. (If not, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. Cause

Possible causes and standard value in normal state

PC2000-8

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of 1 right PPC valve R.H. work equipment control lever PPC valve output pressure (bucket circuit) During bucket curl or dump in full Min. 2.74 MPa {Min. 28 kg/cm2} stroke Defective operation of The spool of bucket control valve (Lo/Hi) may have malfunctioned. Check 2 bucket control valve it directly. (spool)

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H-11 Hydraulic drift of work equipment is large. Trouble Related information

Possible causes and standard value in normal state

Trouble Related information

• Hydraulic drift of work equipment is large.

1

(1) Hydraulic drift of boom is large

Cause Standard value in normal state/Remarks on troubleshooting Defective seal of boom The spool of boom control valve (Lo) may have a defective seal. Check it 1 control valve (spool) directly. The safety-suction valve (at bottom side), mounted on the boom control Defective operation of valve (Lo), may have malfunctioned. Check it directly. (If it is replaced with 2 boom control valve another working circuit for troubleshooting, be sure to reset the safety-suc(safety-suction valve) tion valve after the troubleshooting because the valve has the different set pressure.) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective seal of boom 3 cylinder R.H. work equipment control lever Leakage from cylinder Boom raise relief Max. 20 cc/min

• Hydraulic drift of work equipment is large.

(2) Hydraulic drift of arm is large

Cause Defective seal of arm 1 control valve (spool)

Possible causes and standard value in normal state

Trouble Related information

Standard value in normal state/Remarks on troubleshooting The spool of arm control valve (Lo) may have a defective seal. Check it directly. The safety-suction valve (at head side), mounted on the arm control valve Defective operation of (Lo), may have malfunctioned. Check it directly. (If it is replaced with 2 arm control valve another working circuit for troubleshooting, be sure to reset the safety-suc(safety-suction valve) tion valve after the troubleshooting because the valve has the different set pressure.) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective seal of arm 3 cylinder L.H. work equipment control lever Leakage from cylinder Arm IN relief Max. 20 cc/min

• Hydraulic drift of work equipment is large.

Cause Defective seal of 1 bucket control valve (spool) Possible causes and standard value in normal state

22

(3) Hydraulic drift of bucket is large

Standard value in normal state/Remarks on troubleshooting The spool of bucket control valve (Lo/Hi) may have a defective seal. Check it directly.

The safety-suction valve (at bottom side), mounted on the bucket control Defective operation of valve (Lo/Hi), may have malfunctioned. Check it directly. (If it is replaced 2 bucket control valve with another working circuit for troubleshooting, be sure to reset the (safety-suction valve) safety-suction valve after the troubleshooting because the valve has the different set pressure.) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective seal of 3 R.H. work equipment control lever Leakage from cylinder bucket cylinder Bucket curl relief Max. 20 cc/min

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H-12 Time lag of work equipment is large Trouble Related information

• Time lag of work equipment is large

1 (1) Time lag of work equipment is large

Cause

Possible causes and standard value in normal state

Trouble Related information Possible causes and standard value in normal state

Trouble Related information

Standard value in normal state/Remarks on troubleshooting The safety-suction valve, mounted on the boom control valve (Lo), may have malfunctioned. Check it directly. (If it is replaced with another workDefective operation of ing circuit for troubleshooting, completely stop the oil feeding through the 1 boom control valve hose at the machine push-up solenoid valve. As the safety-suction valve (safety-suction valve) has the different set pressure and structure, be sure to reset it after the troubleshooting has completed.)

• Time lag of work equipment is large

(2) Time lag of arm operation is large

Cause

Standard value in normal state/Remarks on troubleshooting The safety-suction valve, mounted on the arm control valve (Lo/Hi), may Defective operation of have malfunctioned. Check it directly. (If it is replaced with another work1 arm control valve ing circuit for troubleshooting, be sure to reset the safety-suction valve (safety-suction valve) after the troubleshooting because the valve has the different set pressure.)

• Time lag of work equipment is large

(3) Time lag of bucket operation is large

Cause

Possible causes and standard value in normal state

PC2000-8

Standard value in normal state/Remarks on troubleshooting The safety-suction valve, mounted on the bucket control valve (Lo/Hi), Defective operation of may have malfunctioned. Check it directly. (If it is replaced with another 1 bucket control valve working circuit for troubleshooting, be sure to reset the safety-suction (safety-suction valve) valve after the troubleshooting because the valve has the different set pressure.)

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H-13 Heavy lift function does not work or is not reset. Trouble Related information Possible causes and standard value in normal state

1

• Heavy lift function does not work or is not reset.

Cause 1

Standard value in normal state/Remarks on troubleshooting

Troubleshoot by following Paragraph (2) "H-5 Speed or power of boom is low".

H-14 Machine push-up function does not work or is not reset Trouble Related information Possible causes and standard value in normal state

• Machine push-up function does not work or is not reset

Cause 1

Standard value in normal state/Remarks on troubleshooting

Troubleshoot by following Paragraph (3) "H-5 Speed or power of boom is low".

H-15 Boom shockless function does not work or is not reset Trouble Related information

1

1

• Boom shockless function does not work or is not reset

Cause

Possible causes and standard value in normal state

24

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting Defective operation of 1 boom shockless sole- Remove the solenoid valve from the valve assembly, plug its cable connoid valve nectors into sockets, and make sure that the spool operates normally when the boom shockless control switch is operated. Defective operation of 2 The boom shockless valve may have malfunctioned. Check it directly. boom shockless valve

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H-16 Machine gradually deviates during traveling Trouble Related information

1

• Machine gradually deviates during traveling • Make sure that the travel speed is normal. (If not, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. Cause Defective adjustment 1 of main pump

2

3

4

Possible causes and standard value in normal state

5

6

7

8

9 10

26

Standard value in normal state/Remarks on troubleshooting Refer to “Testing and adjusting the travel deviation” of the Testing and adjusting section. a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Travel lever PPC valve output pressure travel PPC valve During forward or reverse traveling Min. 2.74 MPa {Min. 28 kg/cm2} in full stroke Defective operation of travel control valve The travel control valve (spool) may have malfunctioned. Check it directly. (spool) Defective operation of The travel control valve (main body) may have malfunctioned. Check it travel control valve directly. (main body) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Output pressure of travel PPC shuttravel PPC shuttle Travel lever tle valve valve During forward or reverse traveling Min. 2.74 MPa {Min. 28 kg/cm2} in full stroke Defective operation of The travel junction valve may have malfunctioned. Check it directly. travel junction valve a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective seal of cenTravel lever Leakage from swivel joint ter swivel joint When relieved at one side Max. 100 cc/min If the seal is detective, the machine deviates as in the Figure 2. a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Internal leakage of travel motor Travel lever Leakage from travel motor When relieved at one side Max. 30 l/min Defective travel motor The travel motor may have malfunctioned. Check it directly. (main body) The final drive may have an internal defect. Check it directly. (It may be Internal defect of final checked by abnormal sound, abnormal heating, metal powders in drain oil, drive etc.)

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Fig. 2 Defective sealing position of center swivel joint and machine deviation directions

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Trouble Related information

40 Troubleshooting

(2) Machine deviates to different sides during forward and backward traveling • Make sure that the travel speed is normal. (If not, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out.

• Machine gradually deviates during traveling

Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of 1 Travel lever PPC valve output pressure travel PPC valve During forward or reverse traveling Min. 2.74 MPa {Min. 28 kg/cm2} in full stroke Defective operation of 2 travel control valve The travel control valve (spool) may have malfunctioned. Check it directly. (spool) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective seal of cenTravel lever Leakage from swivel joint 3 ter swivel joint When relieved at one side Max. 100 cc/min If the seal is detective, the machine deviates as in the Figure 2. a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Drop of travel motor Travel lever Travel relief pressure safety valve setting 4 +1.0 pressure 32.9/33.8 –2.0 MPa (P1/P2) When relieved at one side +10 {335/345 –20 kg/cm2}

Fig. 2 Defective sealing position of center swivel joint and machine deviation directions

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H-17 Machine deviates excessively when started to travel Trouble Related information

Possible causes and standard value in normal state

Trouble Related information

1

• Machine deviates excessively when (1) Machine deviates excessively during startup only when started to travel the travel lever is shifted to its full-stroke position. • Make sure that the machine does not deviate during regular traveling. (If it deviates, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. Cause Standard value in normal state/Remarks on troubleshooting Defective operation of The main pump servo valve may have malfunctioned. Check it directly. 1 main pump servo valve (Use the separate unit test or measure the pump stroke for judgment.) Defective operation of 2 travel control valve The travel control valve (spool) may have malfunctioned. Check it directly. (spool) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective seal of cen3 ter swivel joint Travel lever Leakage from swivel joint When relieved at one side Max. 100 cc/min Internal defect of travel The travel motor (main body) may have an internal defect. Check it 4 motor (motor main directly. body)

• Machine deviates excessively when started to (2) Machine deviates excessively regardless of travel the stroke control of travel lever • Make sure that the machine does not deviate during regular traveling. (If it deviates, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. Cause

Possible causes and standard value in normal state

PC2000-8

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. (Make sure that failure cause 3 is normal before troubleshooting.) Defective operation of Output voltage of differential presTravel lever 1 differential pressure sure sensor sensor (jet sensor) At neutral Min. 2.77 V When traveled with idle turns Max. 1.40 V (the lever to the stroke end) Defective operation of The main pump servo valve may have malfunctioned. Check it directly. 2 main pump servo valve (Use the separate unit test or measure the pump stroke for judgment.) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Travel lever Differential pressure of jet sensor Min. 1.28 MPa Defective adjustment At neutral 3 or defective operation {Min. 13.1 kg/cm2} of jet sensor Max. 0.17 MPa During traveling by one side in full stroke (Travel with idle turns) {Max. 1.7 kg/cm2} If oil pressure does not become normal after adjustment, the relief valve may have malfunctioned or the orifice is defective. Check them directly.

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H-18 Machine deviates excessively during multiple operations Trouble Related information

1

• Machine deviates excessively during multiple operations • Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Control lever Solenoid valve outlet pressure 1 straight traveling soleAll levers in neutral 0 MPa {0 kg/cm2} noid valve During traveling and operation or Min. 2.74 MPa {Min. 28 kg/cm2} swing of work equipment Defective operation of The PPC cutoff valve (for straight traveling) may have malfunctioned. 2 PPC cutoff valve (for Check it directly. straight traveling)

H-19 Traveling speed or power is low Trouble Related information

1

• Traveling speed or power is low • Make sure that the work equipment and swing speed is normal. • Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot the related items.) • Set the working mode in P-mode when troubleshooting is carried out. Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of 1 Travel lever PPC valve output pressure travel PPC valve During forward or reverse traveling Min. 2.74 MPa {Min. 28 kg/cm2} in full stroke a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Travel lever Solenoid valve outlet pressure 2 2-stage relief solenoid valve At neutral 0 MPa {0 kg/cm2} Operated

Defective adjustment or defective operation 3 of main relief valve (P1/P2)

30

Min. 2.74 MPa {Min. 28 kg/cm2} a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Travel lever Travel relief pressure +1.0

When relieved at one side

32.9/33.8 –2.0 MPa +10

{335/345 –20 kg/cm2} If the trouble continues after the adjustment, the main relief valve (at high pressure set side) may have malfunctioned. Check it directly.

PC2000-8

40 Troubleshooting

SEN02104-00

H-20 Travel system does not move (only one side) Trouble

• Travel system does not move (only one side)

1

(1) Both the forward and backward travel systems do not operate

Related information

Possible causes and standard value in normal state

Trouble Related information

Cause Standard value in normal state/Remarks on troubleshooting Defective operation of The travel motor (parking brake) may have malfunctioned. Check it 1 travel motor (parking directly. brake) Defective operation of 2 travel motor (motor The main body of travel motor may have malfunctioned. Check it directly. main body) The final drive may have an internal defect. Check it directly. (It may be Internal defect of final 3 checked by abnormal sound, abnormal heating, metal powders in drain oil, drive etc.)

• Travel system does not move (only one side)

(2) Forward or backward traveling system does not operate

• Set the working mode in P-mode when troubleshooting is carried out. Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Travel lever PPC valve output pressure 1 travel PPC valve During forward or reverse traveling Min. 2.74 MPa {Min. 28 kg/cm2} in full stroke Defective operation of 2 travel control valve The travel control valve (spool) may have malfunctioned. Check it directly. (spool) The suction valve mounted on the travel valve may have malfunctioned. Defective travel control 3 Check it directly. (The suspect valve can be replaced with the normal sucvalve (suction valve) tion valve and used for troubleshooting.) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Travel lever Travel relief pressure travel motor (safety 4 +1.0 valve) 32.9/33.8 –2.0 MPa When relieved at one side (in non(P1/P2) moving direction) +10 {335/345 –20 kg/cm2} Defective operation of The counterbalance valve of travel motor may have malfunctioned. Check 5 travel motor (counterit directly. balance valve)

PC2000-8

31

SEN02104-00

40 Troubleshooting

H-21 Upper structure does not swing Trouble Related information

1

(1) Upper structure does not swing in both directions. • Make sure that the work equipment operates normally and the machine travels normally. (If not, troubleshoot the related items.) • Set the working mode in P-mode and the swing lock switch in OFF state when troubleshooting is carried out.

• Upper structure does not swing

Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. L.H. work equipment control lever Solenoid valve outlet pressure Defective operation of 1 swing holding brake When in neutral 0 MPa {0 kg/cm2} solenoid valve (min. 10 sec elapsed) In swing operation Min. 2.74 MPa {Min. 28 kg/cm2} (in the right or left direction) Defective operation of 2 swing motor (swing The swing motor (swing brake) may have malfunctioned. Check it directly. brake) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. L.H. work equipment control lever Swing relief pressure Incorrect adjustment or 3

defective operation of swing motor (safety valve)

Swing relief (in either right or left direction)

+1.0

29.4 –2.0 MPa +10

{300 –20 kg/cm2} If oil pressure does not become normal after adjustment, the safety valve may have malfunctioned. Check it directly.

Internal defect of swing 4 motor (motor main The swing motor may have an internal defect. Check it directly. body) The swing machinery may have an internal defect. Check it directly. (It Internal defect of swing may be checked by abnormal sound, abnormal heating, metal powders in 5 machinery drain oil, etc.)

32

PC2000-8

40 Troubleshooting

Trouble Related information

SEN02104-00

(2) Upper structure does not swing in either direction only. • Make sure that the work equipment operates normally and the machine travels normally. (If not, troubleshoot the related items.) • Set the working mode in P-mode and the swing lock switch in OFF state when troubleshooting is carried out.

• Upper structure does not swing

Cause

1

Possible causes and standard value in normal state

2

3

4

5

PC2000-8

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of L.H. work equipment control lever PPC valve output pressure left PPC valve (swing circuit) During right or left swinging in full Min. 2.74 MPa {Min. 28 kg/cm2} stroke Defective operation of swing control valve The swing control valve (spool) may have malfunctioned. Check it directly. (spool) Defective operation of The swing control valve (suction valve) may have malfunctioned. Check it swing control valve directly. (The right and left valves can be replaced and used for trouble(suction valve) shooting.) Defective operation of The swing motor (suction valve) may have malfunctioned. Check it swing motor (suction directly. (The right and left parts can be replaced and used for troublevalve) shooting.) Defective operation of The swing motor (check valve) may have malfunctioned. Check it directly. swing motor (check (The right and left parts can be replaced and used for troubleshooting.) valve)

33

SEN02104-00

40 Troubleshooting

H-22 Swing speed or acceleration is low Trouble Related information

(1) Swing speed or acceleration is low in both right and left directions • Make sure that the work equipment operates normally and the machine travels normally. (If not, troubleshoot the related items.) • Set the working mode in P-mode and the swing lock switch in OFF state when troubleshooting is carried out.

• Swing speed or acceleration is low

Cause

1

Possible causes and standard value in normal state

1

Internal leakage of swing motor

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. L.H. work equipment control lever Leakage from swing motor Swing relief Max. 10 l/min (in either right or left direction)

Defective operation of 2 swing motor (swing The swing motor (swing brake) may have malfunctioned. Check it directly. brake) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. L.H. work equipment control lever Swing relief pressure Defective adjustment 3

or defective operation of swing motor (safety valve)

Swing relief (in either right or left direction)

+1.0

29.4 –2.0 MPa +10

{300 –20 kg/cm2} If oil pressure does not become normal after adjustment, the safety valve may have malfunctioned. Check it directly.

Internal defect of swing The main body of swing motor may have an internal defect. Check it 4 motor (motor main directly. body) The swing machinery may have an internal defect. Check it directly. (It Internal defect of swing may be checked by abnormal sound, abnormal heating, metal powders in 5 machinery drain oil, etc.)

34

PC2000-8

40 Troubleshooting

Trouble Related information

SEN02104-00

(2) Swing speed or acceleration is low in either direction only. • Make sure that the work equipment operates normally and the machine travels normally. (If not, troubleshoot the related items.) • Set the working mode in P-mode and the swing lock switch in OFF state when troubleshooting is carried out.

• Swing speed or acceleration is low

Cause

1

Possible causes and standard value in normal state

2

3

4

5

PC2000-8

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of L.H. work equipment control lever PPC valve output pressure left PPC valve (swing circuit) During right or left swinging in full Min. 2.74 MPa {Min. 28 kg/cm2} stroke Defective operation of swing control valve The swing control valve (spool) may have malfunctioned. Check it directly. (spool) Defective operation of The swing control valve (suction valve) may have malfunctioned. Check it swing control valve directly. (The right and left valves can be replaced and used for trouble(suction valve) shooting.) Defective operation of The swing motor (suction valve) may have malfunctioned. Check it swing motor (suction directly. (The right and left parts can be replaced and used for troublevalve) shooting.) Defective operation of The swing motor (check valve) may have malfunctioned. Check it directly. swing motor (check (The right and left parts can be replaced and used for troubleshooting.) valve)

35

SEN02104-00

40 Troubleshooting

H-23 In compound operation of work equipment, swing speed or acceleration is low Trouble Related information

• In compound operation of work equipment, swing speed or acceleration is low

1

(1) The swing speed or acceleration is low during multiple operations such as swinging and boom raise operations.

• Set the working mode in P-mode when troubleshooting is carried out. Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Control lever Solenoid valve outlet pressure 1 boom throttle solenoid valve (R1) At neutral 0 MPa {0 kg/cm2} During swinging and boom raising

Possible causes and standard value in normal state

Trouble Related information

Min. 2.74 MPa {Min. 28 kg/cm2} a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Output pressure of boom throttle Control lever 2 boom throttle selector selector valve (R1) valve (R1) At neutral 0 MPa {0 kg/cm2} During swinging and boom raising Same as the main pump pressure Defective operation of throttle valve mounted The throttle valve mounted on the boom control valve (R1) may have mal3 on the boom control functioned. Check it directly. valve (R1)

(2) The swing speed or acceleration is low during multiple operations such as swinging and arm or bucket operation. • Make sure that item (1) is normal first before troubleshooting. • Set the working mode in P-mode when troubleshooting is carried out. • In compound operation of work equipment, swing speed or acceleration is low

Cause

Possible causes and standard value in normal state

36

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of Control lever Solenoid valve outlet pressure 1 swing priority solenoid At neutral 0 MPa {0 kg/cm2} valve During swinging and during excavaMin. 2.74 MPa {Min. 28 kg/cm2} tion or dump by arm or bucket Defective operation of The PPC cutoff valve (for swing priority) may have malfunctioned. Check it 3 PPC cutoff valve (for directly. swing priority valve)

PC2000-8

40 Troubleshooting

SEN02104-00

H-24 Upper structure overruns remarkably when it stops swinging Trouble

• Upper structure overruns remarkably when it stops swinging

1

(1) Upper structure overruns remarkably when it stops swinging in both directions.

Related information Cause

Possible causes and standard value in normal state

Defective adjustment or defective operation 1 of swing motor (safety valve)

2

Trouble

Internal leakage of swing motor

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. L.H. work equipment control lever Swing relief pressure Swing relief (in either right or left direction)

+1.0

29.4 –2.0 MPa +10

{300 –20 kg/cm2} If oil pressure does not become normal after adjustment, the safety valve may have malfunctioned. Check it directly. a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. L.H. work equipment control lever Leakage from swing motor Swing relief Max. 10 l/min (in either right or left direction)

• Upper structure overruns remarkably when it stops swinging

(2) Upper structure overruns remarkably when stopped from swinging in either direction only.

Related information Cause

1

Possible causes and standard value in normal state

2

3

4

5

PC2000-8

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of L.H. work equipment control lever PPC valve output pressure left PPC valve (swing circuit) During right or left swinging in full Min. 2.74 MPa {Min. 28 kg/cm2} stroke Defective operation of swing control valve The swing control valve (spool) may have malfunctioned. Check it directly. (spool) Defective operation of The swing control valve (suction valve) may have malfunctioned. Check it swing control valve directly. (The right and left valves can be replaced and used for trouble(suction valve) shooting.) Defective operation of The swing motor (suction valve) may have malfunctioned. Check it swing motor (suction directly. (The right and left parts can be replaced and used for troublevalve) shooting.) Defective operation of The swing motor (check valve) may have malfunctioned. Check it directly. swing motor (check (The right and left parts can be replaced and used for troubleshooting.) valve)

37

SEN02104-00

40 Troubleshooting

H-25 Large shock is made when upper structure stops swinging Trouble Related information

1

(1) Large shock is made when upper structure stops swinging in both right and left directions. • Set the working mode in P-mode and the swing lock switch in OFF state when troubleshooting is carried out. • Large shock is made when upper structure stops swinging

Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. L.H. work equipment control lever Solenoid valve outlet pressure Defective operation of 1 swing holding brake When in neutral 0 MPa {0 kg/cm2} solenoid valve (min. 12 sec elapsed) In swing operation Min. 2.74 MPa {Min. 28 kg/cm2} (in the right or left direction) Defective operation of 2 swing motor (swing The swing motor (swing brake) may have malfunctioned. Check it directly. brake) a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. L.H. work equipment control lever Swing relief pressure Defective adjustment 3

or defective operation of swing motor (safety valve)

Swing relief (in either right or left direction)

+1.0

29.4 –2.0 MPa +10

{300 –20 kg/cm2} If oil pressure does not become normal after adjustment, the safety valve may have malfunctioned. Check it directly.

Internal defect of swing 4 motor (motor main The swing motor may have an internal defect. Check it directly. body) The swing machinery may have an internal defect. Check it directly. (It Internal defect of swing 5 may be checked by abnormal sound, abnormal heating, metal powders in machinery drain oil, etc.)

Trouble Related information

• Large shock is made when upper structure stops (2) Large shock is made when upper structure swinging stops swinging in either direction only. • Set the working mode in P-mode and the swing lock switch in OFF state when troubleshooting is carried out. Cause

Possible causes and standard value in normal state

38

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. Defective operation of L.H. work equipment control lever PPC valve output pressure 1 left PPC valve (swing At neutral 0 MPa {0 kg/cm2} circuit) During right or left swinging in full Min. 2.74 MPa {Min. 28 kg/cm2} stroke Defective operation of 2 swing control valve The swing control valve (spool) may have malfunctioned. Check it directly. (spool) Defective operation of The swing motor (suction valve) may have malfunctioned. Check it 3 swing motor (suction directly. (The right and left parts can be replaced and used for troublevalve) shooting.)

PC2000-8

40 Troubleshooting

SEN02104-00

H-26 Large abnormal sound comes from when upper structure stops swinging 1 Trouble

• Large abnormal sound comes from when upper structure stops swinging

(1) Large abnormal sound comes from when upper structure is stopped from swinging in both right and left directions.

Related information Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. L.H. work equipment control lever Solenoid valve outlet pressure Defective operation of When in neutral 1 variable back pressure Min. 2.74 MPa {Min. 28 kg/cm2} (min. 12 sec elapsed) solenoid valve In swing operation 0 MPa {0 kg/cm2} When shifted from swing to neutral 0 MPa {0 kg/cm2} position (for 5 sec) Defective operation of The variable back pressure valve may have malfunctioned. Check it 2 variable back pressure directly. solenoid valve a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. L.H. work equipment control lever Swing relief pressure Defective adjustment 3

or defective operation of swing motor (safety valve)

Swing relief (in either right or left direction)

+1.0

29.4 –2.0 MPa +10

{300 –20 kg/cm2} If oil pressure does not become normal after adjustment, the safety valve may have malfunctioned. Check it directly. The swing machinery may have an internal defect. Check it directly. (It Internal defect of swing 4 may be checked by abnormal sound, abnormal heating, metal powders in machinery drain oil, etc.)

Trouble

• Large abnormal sound comes from when upper structure stops swinging

(2) Large abnormal sound comes from when upper structure is stopped from swinging in either direction only.

Related information

Possible causes and standard value in normal state

PC2000-8

Cause Defective operation of 1 swing control valve (spool) Defective operation of 2 swing motor (suction valve)

Standard value in normal state/Remarks on troubleshooting The swing control valve (spool) may have malfunctioned. Check it directly. (The right and left parts can be replaced and used for troubleshooting.) The swing motor (suction valve) may have malfunctioned. Check it directly. (The right and left parts can be replaced and used for troubleshooting.)

39

SEN02104-00

40 Troubleshooting

H-27 Hydraulic drift of work equipment is large in swing operation Trouble Related information

1

• Hydraulic drift of work equipment is large in swing (1) When swing brake is applied operation • Set the working mode in P-mode when troubleshooting is carried out. Cause

Possible causes and standard value in normal state

Trouble

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle speed and carry out troubleshooting. L.H. work equipment control lever Solenoid valve outlet pressure Defective operation of 1 swing holding brake When in neutral 0 MPa {0 kg/cm2} solenoid valve (min. 12 sec elapsed) In swing operation Min. 2.74 MPa {Min. 28 kg/cm2} (in the right or left direction) Defective operation of 2 swing motor (swing The swing motor (swing brake) may have malfunctioned. Check it directly. brake)

• Hydraulic drift of work equipment is large in swing (2) When swing brake is released operation

Related information

1

2 Possible causes and standard value in normal state

3

4

5

40

Cause Defective operation of swing control valve (spool) Defective operation of swing control valve (suction valve) Defective operation of swing motor (safety valve) Defective operation of swing motor (suction valve) Defective operation of swing motor (check valve)

Standard value in normal state/Remarks on troubleshooting The swing control valve (spool) may have malfunctioned. Check it directly. The swing control valve (suction valve) may have malfunctioned. Check it directly. The swing motor (safety valve) may have malfunctioned. Check it directly. The swing motor (suction valve) may have malfunctioned. Check it directly. (The right and left parts can be replaced and used for troubleshooting.) The swing motor (check valve) may have malfunctioned. Check it directly. (The right and left parts can be replaced and used for troubleshooting.)

PC2000-8

40 Troubleshooting

SEN02104-00

H-28 Fan rotation is abnormal (large noise or vibration of fans, or fan overheating) 1 Trouble Related information

• Fan rotation is abnormal (large noise or vibration of fans, or fan overheating) • Measure the fan rotation speed and check for an error from the permissible value. • Set the working mode in P-mode and the fan in 100% speed mode when troubleshooting is carried out. Cause Defective fan pump EPC current output 1 Standard/+55°C specifications

Possible causes and standard value in normal state

Defective operation of EPC solenoid valve of 2 the fan pump Standard/+55°C specifications

3

PC2000-8

Internal defect of fan pump or fan motor

Standard value in normal state/Remarks on troubleshooting a Check the engine in Hi idle state. Control lever EPC current of fan pump Radiator side: 625/555 ± 50 mA (at 840/1,100 rpm) All levers in neutral O/C side: 650/555 ± 50 mA (at 760/1,100 rpm) a Check the engine in Hi idle state. EPC solenoid valve output pressure Control lever of the fan pump Radiator side: 1.69/1.32 ± 0.39 mA {17.2/13.5 ± 4.0 kg/cm2} All levers in neutral O/C side: 1.81/1.32 ± 0.25 mA {18.5/13.5 ± 4.0 kg/cm2} If failure causes 1 and 2 are normal, the fan pump or fan motor may have failed. Check them directly.

41

SEN02104-00

PC2000-8 Hydraulic excavator Form No. SEN02104-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

42

SEN02105-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

40 Troubleshooting

1

Troubleshooting of mechanical system (S-mode) Troubleshooting of mechanical system (S-mode)........................................................................................... 3 Method of using troubleshooting charts ............................................................................................... 3 S-1 Starting performance is poor ......................................................................................................... 6 S-2 Engine does not start..................................................................................................................... 7 S-3 Engine does not pick up smoothly............................................................................................... 10 S-4 Engine stops during operations ....................................................................................................11 S-5 Engine does not rotate smoothly ................................................................................................. 12 S-6 Engine lacks output (or lacks power)........................................................................................... 13 S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 15 S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 16 S-9 Oil becomes contaminated quickly .............................................................................................. 17 S-10 Fuel consumption is excessive.................................................................................................. 18 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 19 S-12 Oil pressure drops ..................................................................................................................... 20

1

SEN02105-00

40 Troubleshooting

S-13 Oil level rises (Entry of coolant or fuel) ...................................................................................... 21 S-14 Coolant temperature becomes too high (overheating) .............................................................. 22 S-15 Abnormal noise is made ............................................................................................................ 23 S-16 Vibration is excessive ................................................................................................................ 24

2

40 Troubleshooting

SEN02105-00

Troubleshooting of mechanical system (S-mode)

1

Method of using troubleshooting charts

1

The troubleshooting chart consists of the “questions”, “check items”, “causes”, and “troubleshooting” blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation according to the troubleshooting procedure. [Questions]: Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their level. [Check items]: Simple check items used by the serviceman to narrow down the causes. They corresponds to C in the chart on the right. [Causes]: Items to be narrowed from the questions and check items. The serviceman narrows down the probable causes from A, B, and C. [Troubleshooting]: Items to finally verify whether the narrowed down causes are undoubtedly the real causes using the troubleshooting tools and direct inspections. Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w. E:Causes to be referred to for questions and check items Q:Causes related to questions and check items w:Causes highly probable among ones marked with Q a When narrowing the “causes”, apply the items marked with w before those marked with Q. When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the causes cannot be narrowed, however, you may apply them.)

3

SEN02105-00

40 Troubleshooting

Exhaust smoke is black Let us assume that [Clogged air cleaner element] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradually], and [Air cleaner clogging caution lamp is flashing].

4

40 Troubleshooting

SEN02105-00

If we look for the linkage of these three phenomena to possible causes, we find that they have causal relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.

5

SEN02105-00

40 Troubleshooting

S-1 Starting performance is poor 1 General causes for poor starting performance are Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel (particularly during winter) q Coolant in exhaust pipe a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however.

Q w w

Q Q

Defective or deteriorated battery

Defective alternator (generator section)

Defective alternator (regulator section)

Defective intake air heater system

Defective injector

Stuck or seized supply pump plunger

Clogged feed pump gauze filter

Clogged fuel filter element

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap

E E

E w

Q Q Q Q w

w w Q Q w w w w

w w w E w Q Q w w w Q

w w

Q Q Q Q Q w

*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]

Q Q Q

w

q q q q q q q q

Replace

Replace

Replace

Replace

Replace

Replace

Clean

Clean

Correct

q Clean

Replace

Correct

Inspect air cleaner directly q When compression pressure is measured, it is found to be low q q When air is bled from fuel system, air comes out Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes engine at low idle? None When specific gravity of electrolyte and voltage of battery are measured, they are low Remedy

6

Worn piston ring and cylinder

Clogged air cleaner element

E

Clean

Questions Check items Troubleshooting

Confirm recent repair history Degree of Operated for long period machine operation Became worse gradually Starting performance Engine starts easily when warm Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed) During operation, charge level monitor indicates abnormal charge (if monitor is installed) Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Starting motor cranks engine slowly Fuel does not flow out if air bleeding plug of fuel filter is While engine is removed cranked with startIf spill hose from injector is disconnected, ing motor, little fuel spills When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive

Defective contact of valve and valve seat

Causes

q

40 Troubleshooting

SEN02105-00

S-2 Engine does not start

1

a) Engine does not turn

Defective starting motor (motor section)

Defective steering circuit wiring

Defective PTO or hydraulic pump Carry out troubleshooting in H-mode

—

—

Defective starting switch

Defective battery relay

Defective connection of battery terminal

E E Q

Q

w w

Battery electrolyte is low Battery terminal is loose When starting switch is turned ON, there is no operating sound from battery relay When starting switch is turned to START, starting pinion does not move out Speed of rotation is low When starting switch is Makes grating noise turned to START, starting Soon disengages pinion moves out, but Makes rattling noise and does not turn

w Q Q w

w Q

w

w w Q

Q

q q

When specific gravity of electrolyte and voltage of battery are measured, they are low There is not voltage (20 – 30 V) between battery relay terminal B and terminal E Turn starting switch OFF, When terminal B and terminal C of starting switch are connected, engine starts connect cord, turn the switch ON and carry out When terminal B and terminal C at safety relay outlet are controubleshooting nected, engine starts When terminal B and terminal C at safety relay outlet are connected, engine does not start

q

Replace

Replace

q

Replace

Remedy

q

Correct

Inspect flywheel ring gear directly Troubleshooting

q

Carry out troubleshooting in E-mode

Confirm recent repair history Degree of machine opera- Operated for long period tion Condition of horn when Horn does not sound starting switch is turned Horn volume is low ON

Replace

Check items

Questions

q

Broken flywheel ring gear

q

Replace

q

Engine seized inside o See “S-4 Engine stops during operations”. Water hammer caused by coolant which entered cylinder Defective electrical system Problem in drive devices on applicable machine side o Troubleshoot the applicable machine side

Replace

q

Defective or deteriorated battery

General causes why engine does not turn

Defective starting motor (safety relay section)

Causes

7

SEN02105-00

40 Troubleshooting

b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out q Fuel is not being supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)

Defective injector

Defective operation of flow damper

Defective operation of overflow valve (Does not close)

Wrong connection of supply pump PCV

Defective supply pump PCV

Stuck or seized supply pump plunger

Broken supply pump shaft spline

w Q w w w w E

E

Q Q

Q Q

E E Q

Q w Q w w w w

Q

q q q q q

q q q Replace

Replace

Replace

Correct

Replace

Replace

Replace

Replace

Clean

Replace

Correct

Correct

Add

q q

*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] in E-mode *2: Failure code [CA271], [CB271] and failure code [CA272], [CB272] in E-mode *3: Failure code [CA273], [CB273] and failure code [CA274], [CB274] in E-mode

8

Seized, abnormally worn feed pump

E

q

When air is bled from fuel system, air comes out Inspect fuel filter directly Inspect feed pump gauze filter directly Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)” in E-mode Carry out troubleshooting according to “Abnormality in PCV1 (*2) or Abnormality in PCV2 (*3)” in E-mode Inspect overflow valve directly Engine can be started in reduced cylinder mode Remedy

Clogged feed pump gauze filter

Clogged fuel filter element

Leaking, clogging and entry of air to fuel piping

Clogged air breather hole of fuel tank cap

Insufficient fuel in tank

Confirm recent repair history Degree of Operated for long period E E machine operation Exhaust smoke suddenly stopped coming out (when starting again) Non-specified fuel is being used w Replacement of filters not carried out according to Operation and Maintenance w 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 When fuel filter is removed, there is no fuel in it w Q w Fuel is leaking from fuel piping w When priming pump is operated, it makes no reaction or it is heavy w Q If air bleeding plug of fuel filter is removed, fuel does not flow While engine is Q Q Q out cranked with starting motor, If spill hose from injector is disconnected, little fuel spills Q

Replace

Troubleshooting

Check items

Questions

Use of improper fuel

Causes

40 Troubleshooting

SEN02105-00

c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel

Defective intake air heater system

Defective coolant temperature sensor and/or wiring harness

Defective or deteriorated battery

Clogged injector and/or defective spray

Stuck and/or seized supply pump plunger

Clogged feed pump gauze filter

Clogged fuel filter and/or strainer

Leaking, clogging of fuel system, and entry of air

Clogged air breather hole of fuel tank cap

Use of improper fuel

Worn piston ring and/or cylinder liner

Worn dynamic valve system (Valve, rocker lever, etc.)

Confirm recent repair history Degree of machine Operated for long period E E E E operation Suddenly failed to start w w Q Non-specified fuel is being used Q Q Q Q Replacement of filters not carried out according to Operation and Maintenance w w w Manual Engine oil replenished more frequently w When engine is preheated or when temperature is low, preheating monitor does not w indicate normally (if monitor is installed) Dust indicator is red (if indicator is installed) w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained w w When fuel filter is removed, there is no fuel in it w Fuel is leaking from fuel piping w When priming pump is operated, it makes no reaction or it is heavy w Q Q Starting motor cranks engine slowly w When engine is cranked, abnormal sound is generated around cylinder head w Fuel does not flow out if air bleeding plug of fuel filter is While engine is Q Q w w cranked with starting removed motor, If spill hose from injector is disconnected, little fuel spills Q Q w When exhaust manifold is touched immediately after starting engine, temperature of w some cylinders is low

q q q q q q q

Replace

Replace

Replace

Clean

Replace

Clean

Clean

Correct

Clean

q Replace

Replace

Remedy

Replace

Inspect air cleaner directly q Inspect dynamic valve system directly q When compression pressure is measured, it is found to be low q When air is bled from fuel system, air comes out Inspect fuel filter, strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)” in E-mode When injector unit is tested, spray condition is bad When specific gravity of electrolyte and voltage of battery are measured, they are low Coolant temperature gauge does not indicate normally (if coolant temperature gauge is installed) When starting switch is turned to HEAT, intake air heater mount does not become warm Clean

Troubleshooting

Check items

Questions

Clogged air cleaner element

Causes

*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] in E-mode

9

SEN02105-00

40 Troubleshooting

S-3 Engine does not pick up smoothly

1

General causes why engine does not pick up smoothly q Insufficient intake of air q Insufficient supply of fuel q Defective spray condition of fuel q Improper selection of fuel q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

w

Clogged injector and/or defective spray

Defective operation of flow damper (Maximum leakage from injector)

Stuck or seized supply pump plunger

Clogged feed pump gauze filter

Clogged fuel filter and/or strainer

Leaking, clogging of or entry of air to fuel piping

Clogged air breather hole of fuel tank cap

E

E E Q Q

Q w

w w w w w

w w w w

w w w w Q Q Q

w

w w Q

w

w

w w Q Q

w w Q w

Q

w

*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] in E-mode

q q q

Correct

Replace

Replace

Clean

Clean

q q Clean

Replace

Replace

Adjusting

Replace

Inspect air cleaner directly q When compression pressure is measured, it is found to be low q q Inspect valve clearance directly q When turbocharger is rotated by hand, it is found to be heavy q When air is bled from fuel system, air comes out Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)” in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Remedy

10

Worn piston ring and/or cylinder liner

Seized turbocharger or interference of turbocharger

Improper valve clearance

Defective contact of valve and valve seat

E E

Correct

Confirm recent repair history Degree of Operated for long period machine operation Engine pick-up suddenly became worse Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Blue under light load Color of exhaust gas is Black When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, interference sound is emitted from around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) Blow-by gas is excessive

Clean

Troubleshooting

Check items

Questions

Clogged air cleaner element

Causes

40 Troubleshooting

SEN02105-00

S-4 Engine stops during operations

1

General causes why engine stops during operations

Q Q Q Q Q Q Q Q Q

Q

w w

w w Q Q w w Q Q

Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Rust and water are found when fuel tank is drained

w w w w

Metal particles are found when oil pan is drained Does not turn at all

w

Turns in opposite direction

w

Moves by amount of gear backlash

w w

Supply pump shaft does not turn

w

Engine turns, but stops when load is applied to machine

q q q q q q q

Replace

Replace

Replace

Replace

Clean

Clean

Correct

Clean

Add

Replace

q

—

q

Replace

Remedy

q

Replace

Inspect dynamic valve system directly Inspect piston and connecting rod directly Inspect crankshaft bearing directly Inspect gear train directly Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)” in E-mode Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed

Replace

Troubleshooting

Defective PTO or hydraulic pump

Broken auxiliary equipment (pump, compressor, etc.)

Stuck or seized supply pump plunger

Broken supply pump shaft spline

Broken or seized feed pump

Clogged feed pump gauze filter

Clogged fuel filter and/or strainer

Q w Q w w

w

Air breather hole of fuel tank cap is clogged

When engine is cranked by hand

EE

w

When fuel tank is inspected, it is found to be empty

Check items

Leaking and/or clogged fuel piping

Clogged air breather hole of fuel tank cap

Insufficient fuel in tank

Broken or seized gear train

Confirm recent repair history Degree of machine Operated for long period operation Abnormal noise was heard and engine stopped sudw w w w denly Condition when engine Engine overheated and stopped w Q stopped Engine stopped slowly w Engine stopped after hunting w Q Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Fuel level monitor indicates low level (if monitor is installed) w

Carry out troubleshooting in H-mode

Questions

q

Broken or seized crankshaft bearing

q

Broken or seized piston and/or connecting rod

q

Causes

Seized parts inside engine Insufficient supply of fuel There is overheating Problem in drive devices on applicable machine side o Troubleshoot the applicable machine side

Broken dynamic valve system (valve, rocker arm, etc.)

q

*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] in E-mode

11

SEN02105-00

40 Troubleshooting

S-5 Engine does not rotate smoothly

1

General causes why engine does not rotate smoothly q Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)

Q w

When priming pump is operated, it makes no reaction or it is heavy

Defective G (Bkup) speed sensor or wiring harness

Defective Ne speed sensor and/or wiring harness

Clogged injector and/or defective spray (dirt in injector)

Defective operation of flow damper (Maximum leakage from injector)

Clogged fuel filter or strainer

Clogged feed pump gauze filter

Q Q Q Q Q Q Q Q Q w Q w w w w Q Q w w Q Q

Q Q Q Q

q

When air is bled from fuel system, air comes out Inspect feed pump gauze filter directly Inspect fuel filter and strainer directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Carry out troubleshooting according to “Abnormality in engine Ne speed sensor (*1)” in Emode Carry out troubleshooting according to “Abnormality in engine Bkup speed sensor (*2)” in Emode

q q q q q

Correct

Correct

Correct

Replace

Replace

Replace

Clean

q

Add

Remedy

Leaking or clogging or entry of air to fuel piping

Clogged air breather hole of fuel tank cap

Insufficient fuel in tank

E E

Replace

Confirm recent repair history Degree of machine Operated for long period operation Occurs at a certain speed range Occurs at low idle Condition of hunting Occurs even when speed is raised Occurs on slopes Replacement of filters not carried out according to Operation and Maintenance Manual When fuel tank is inspected, it is found to be empty Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping

Correct

Troubleshooting

Check items

Questions

Low setting of low idle speed

Causes

*1: Failure code [CA689] and [CB689] *2: Failure code [CA778] and [CB778]

1

12

40 Troubleshooting

SEN02105-00

S-6 Engine lacks output (or lacks power) General causes why engine lacks output q Insufficient intake of air q Insufficient supply of fuel q Defective spray condition of fuel q Improper selection of fuel q Overheat oSee “S-14 Coolant temperature becomes too high (Overheating)” q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

1 Defective fuel temperature sensor and/or wiring harness

Defective boost pressure sensor and/or wiring harness

Defective drive of injector (signal and/or solenoid)

Defective installation of boost pressure sensor (air leakage)

Clogged injector or defective spray (dirt in injector)

Stuck or seized supply pump plunger

Clogged feed pump gauze filter

Clogged fuel filter and/or strainer

Leaking or clogged fuel piping

Clogged air breather hole of fuel tank cap

Worn piston ring and/or cylinder liner

Improper valve clearance

Defective contact of valve and valve seat

Seized turbocharger or interference of turbocharger

Air leakage from air intake piping

Clogged air cleaner element

Causes

Q

Q Q Q Q

Confirm recent repair history

E Q

E E

Q

Q

Q Q Q Q Q

Q Q Q w w w w w w w w w w Q

High idle speed is too high High idle speed under no load is normal, but speed suddenly drops when load is applied Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive

w w Q w

Q Q Q Q Q Q w

w Q

w

q q q q q q

q q q q q q q q q

Replace

Replace

Correct

Replace

Replace

Replace

Clean

Replace

Correct

Clean

Replace

Adjusting

Replace

q Replace

Remedy

E

w

When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around cylinder head

Inspect air cleaner directly Inspect air intake piping directly When boost pressure is measured, it is found to be low When compression pressure is measured, it is found to be low Inspect valve clearance directly Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)” in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Inspect boost pressure sensor mount directly Carry out troubleshooting according to “Abnormality in charge pressure sensor (*2)” in E-mode Carry out troubleshooting according to “Abnormality in fuel temperature sensor (*3)” in E-mode

E Q

Correct

Suddenly Power was lost Gradually Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping Output becomes insufficient after short stop of operation Color of exhaust Black gas Blue under light load When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Clean

Troubleshooting

Check items

Questions

Degree of machine Operated for long period operation

13

SEN02105-00

*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] *2: Failure code [CA122] and failure code[CA123] in E-mode *3: Failure code [CA263], [CB263] and failure code [CA265], [CB265]

14

40 Troubleshooting

40 Troubleshooting

SEN02105-00

S-7 Exhaust smoke is black (incomplete combustion)

E w w

Defective coolant temperature sensor or wiring harness

Improper fuel injection pressure

Improper injection timing

Clogged fuel spill piping (on cylinder head side)

Abnormally worn injector

Clogged or seized injector

Stuck or seized supply pump plunger

Worn piston ring and/or cylinder liner

E

E Q Q Q Q

Q w

Q Q w w Q w

Q Q

Q

Q Q Q

w w Q Q Q Q w w w Q Q Q Q

w Q Q Q

Q Q w w w

q q q

q q

Replace

Adjusting

q

Adjusting

Correct

Replace

Replace

Replace

Replace

q

Correct

Adjusting

Replace

Replace

Inspect air cleaner directly q When turbocharger is rotated by hand, it is fount to be heavy q When compression pressure is measured, it is found to be low q Inspect valve clearance directly q When muffler is removed, exhaust sound improves Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)” in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinder Inspect fuel spill piping (on cylinder head side) directly Carry out troubleshooting according to “Abnormality in coolant temperature sensor error (*2)” in E-mode Remedy

Crushed or clogged muffler

Leakage of air between turbocharger and cylinder head

Improper valve clearance

Defective contact of valve and valve seat

E

Replace

Confirm recent repair history Degree of machine operation Operated for long period Suddenly became black Color of exhaust Gradually became black gas Blue under light load Non-specified fuel is being used Oil replenished more frequently Suddenly Power was lost Gradually Dust indicator is red (if indicator is installed) Muffler is crushed Air leaks between turbocharger and cylinder head, and clamp is loosened Engine is operated in low-temperature mode at normal temperature When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around cylinder head Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal Engine does not pick up smoothly and combustion is irregular Blow-by gas is excessive If spill hose from injector is disconnected, abnormally much fuel spills

Seized turbocharger or interference of turbocharger

Clogged air cleaner element

Causes

Clean

Troubleshooting

Check items

Questions

General causes why exhaust smoke is black q Insufficient intake of air q Excessive injection of fuel q Defective spray condition of fuel q Improper selection of fuel q Overheat o See “S-14 Coolant temperature becomes too high (Overheating)” q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

1

*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] *2: Failure code [CA144] and failure code[CA145] in E-mode

15

SEN02105-00

40 Troubleshooting

S-8 Oil consumption is excessive (or exhaust smoke is blue)

Confirm recent repair history Degree of machine oper- Operated for long period ation Oil consumption suddenly increased Oil replenished more frequently Oil becomes contaminated quickly Outside of engine is contaminated with oil There are loose piping clamps in intake system Inside of turbocharger intake outlet pipe is contaminated with oil Inside of turbocharger exhaust outlet pipe is contaminated with oil There is oil in coolant Oil level in PTO is increasing Exhaust smoke is blue under light load Excessive Amount of blow-by gas None

Oil leakage from oil pan, cylinder head, etc.

Oil leakage from oil drain plug

Oil leakage from oil piping

Oil leakage from oil filter

Oil leakage from oil cooler

Broken oil cooler

Worn or damaged rear oil seal

Worn piston ring and/or cylinder liner

Broken piston ring

Clogged breather or breather hose

Turbocharger 1 Worn seal at blower end

Worn seal at turbocharger end

E E E

E w

Q Q

w Q Q w

w w w w w w w Q w w w Q

w w w w

Q w

q q q q q q q q q q Correct

Correct

Correct

Correct

Replace

Replace

Correct

Replace

Replace

Clean

Replace

Replace

q q q q Replace

When intake manifold is removed, dust is found inside When intake manifold is removed, inside is found contaminated abnormally Excessive play of turbocharger shaft Check breather and breather hose directly When compression pressure is measured, it is found to be low Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage There is external leakage of oil from engine Remedy

16

Worn or damaged valve (stem, guide, seal)

Dust sucked in from intake system

Causes

Correct

Troubleshooting

Check items

Questions

General causes why oil consumption is excessive q Abnormal combustion of oil q Long-time operation of engine at low idle or high idle (Do not run engine continuously at idle without load for more than 20 minutes) q External leakage of oil q Wear of parts in lubrication system

1

40 Troubleshooting

SEN02105-00

S-9 Oil becomes contaminated quickly

1

Exhaust smoke is bad

Clogged turbocharger lubrication drain tube

Defective oil filter safety valve

Clogged oil filter

Clogged oil cooler

Clogged breather and/or breather hose

Worn piston ring and/or cylinder liner

Worn valve and/or valve guide

Defective seal at turbocharger turbine end

Causes

Confirm recent repair history Degree of machine operation Operated for long period E E E Non-specified fuel is being used Q Engine oil replenished more frequently w Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is w Q installed) Metal particles are found when oil filter is drained Q Q w Inside of exhaust pipe is contaminated with oil w Engine oil temperature rises quickly w Blue under light load w Color of exhaust gas Black w Excessive Q Q w Q Amount of blow-by gas None w

q

Excessive play of turbocharger shaft When compression pressure is measured, it is found to be low Inspect breather and breather hose directly Inspect oil cooler directly Inspect oil filter directly Spring of oil filter safety valve is hitched or broken Inspect turbocharger lubrication drain tube directly

q q See S-7

q q q q

—

Clean

Replace

Replace

Clean

Clean

Replace

Remedy

Replace

q Replace

Troubleshooting

Check items

Questions

General causes why oil becomes contaminated q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Operation under excessive load

17

SEN02105-00

40 Troubleshooting

S-10 Fuel consumption is excessive

1

General causes why fuel consumption is excessive

*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] in E-mode *2: Failure code [CA144] and failure code[CA145] in E-mode

Defective coolant temperature sensor or wiring harness

Defective operation of injector

Defective spray by injector

Defective common rail fuel pressure

Defective supply pump plunger

Defective feed pump oil seal

q q q q q q Correct

Replace

Replace

Correct

q Replace

Remove and inspect head cover directly Inspect feed pump oil seal directly Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)” in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change change on some cylinders If spill hose from injector is disconnected and measured, much fuel spills Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” Confirm or with monitoring function on machine monitor Remedy

18

Fuel leakage from fuel filter, piping, etc.

Confirm recent repair history Degree of E E E machine operation Operated for long period Q Q Q More than other machines of same model 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, temperature of some cylinders is w low Low idle speed is high Q Torque converter stall speed or hydraulic pump relief speed is high Q Q Q Q Color of exhaust Black gas White Q

Correct

Troubleshooting

Check items

Questions

Fuel leakage inside head cover

q

Replace

q

Causes

Leakage of fuel Defective condition of fuel injection (fuel pressure, injection timing) Excessive injection of fuel

Correct

q

40 Troubleshooting

SEN02105-00

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1 General causes why oil is mixed in coolant q Internal leakage in lubrication system q Internal leakage in cooling system

Broken oil cooler core and/or O-ring

Insufficient protrusion of cylinder liner

Damaged cylinder liner O-ring and/or hole caused by pitting

Cracks inside cylinder block

Broken cylinder head and/or head gasket

Causes

Oil level

E

Operated for long period

Q

Suddenly increased

Q Q Q

Gradually increased

Q

Q

Q Q

w

Oil level has risen and oil is milky There are excessive air bubbles in radiator, coolant spurts back

w

Pressure-tightness test of cylinder head shows there is leakage

q

w

q q

Inspect cylinder block and liner directly

q

Inspect cylinder liner directly

q Replace

Remedy

Replace

Pressure-tightness test of oil cooler shows there is leakage Replace

Check items

Hard water is being used as coolant

Troubleshooting

E

Replace

Degree of machine operation

Replace

Questions

Confirm recent repair history

19

SEN02105-00

1

General causes why oil pressure drops

*1: Failure code [CA135] and failure code[CA141] in E-mode

Defective oil level sensor and/or wiring harness

Defective oil pressure sensor and/or defective wiring harness

Leaking, crushed, clogged hydraulic piping

Clogged oil filter

Defective oil pump

Clogged and/or broken pipe in oil pan

Clogged strainer in oil pan

Coolant and fuel mixing in oil

Lack of oil in oil pan

Defective oil pump relief valve

E

Q w Q w Q w w w Q

Q w Q w

w

Q Q w

w w w w w w

Q

Metal particles are found in oil filter q Inspect oil pan strainer and pipe directly Oil pump rotation is heavy, there is play in oil pump Valve and spring of oil pump relief valve are fatigued and damaged Inspect oil filter directly Carry out troubleshooting according to “Abnormality in oil pressure sensor (*1)” in E-mode If oil level sensor is replaced, oil level monitor indicates normally

q q q q q q Replace

Correct

Clean

Adjusting

q Replace

Remedy

20

E

Clean

Metal particles are found when oil filter is drained

E

Clean

Confirm recent repair history Degree of Operated for long period machine operation Oil pressure monitor indicates low oil pressure (if monitor is installed) Non-specified oil is being used Replacement of filters not carried according to Operation and Maintenance Manual Indicates pressure drop at low idling time Oil pressure Indicates pressure drop at low and high idling times monitor Indicates pressure drop on slopes (if installed) Indicates pressure drop occasionally Oil level monitor indicates oil level drop (if monitor is installed) Oil level in oil pan is low External hydraulic piping is leaking or crushed Oil is milky or smells of diesel oil Metal particles are found when oil pan is drained

Clean

Troubleshooting

Check items

Questions

Worn journal of bearing

q

See S-13

q

—

q

Causes

Leakage, clogging, and/or wear of lubrication system Defective oil pressure control Improper selection of fuel (improper viscosity) Deterioration of oil due to overheating

Add

q

Replace

S-12 Oil pressure drops

40 Troubleshooting

40 Troubleshooting

SEN02105-00

S-13 Oil level rises (Entry of coolant or fuel)

1

General causes why oil level rises

Confirm recent repair history Degree of machine operation Operated for long period Fuel consumption increasing Coolant replenished more frequently There is oil mixed in coolant Oil smells of diesel fuel Oil is milky When engine is started, drops of water come from muffler When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, or coolant spurts back Exhaust smoke is white Water pump drain hole (breather hole) is clogged When water pump drain hole (breather hole) is cleaned, coolant comes out Oil level in PTO is low

Q Q

E

Defective seal of auxiliary equipment (pump, compressor)

Defects in supply pump

Defective thermostat seat

Clogged water pump drain hole (breather hole) and/or defective seal

Broken oil cooler core and/or O-ring

Worn or damaged rear oil seal

Damaged cylinder liner O-ring and/or hole caused by pitting

Cracks inside cylinder block

Fuel leakage inside head cover

E E

E

w

w w Q Q

w

w

w

Q Q

w

w

Q Q

Q w w w

q

When compression pressure is measured, it is found to be low Remove and inspect head cover directly Inspect cylinder block and/or liner directly Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage Remove and inspect water pump directly Remove and inspect thermostat cover directly Remove and inspect supply pump directly Inspect seal of auxiliary equipment directly

q q q q q q q q Replace

Replace

Correct

Replace

Replace

Correct

Remedy

Replace

q Replace

Troubleshooting

Check items

Questions

Broken cylinder head and/or head gasket

a

Replace

q

Causes

Coolant in oil (milky) Fuel in oil (smells diluted diesel fuel) If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”.

Correct

q

21

SEN02105-00

40 Troubleshooting

S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high

Confirm recent repair history Degree of machine operation Operated for long period Sudden overheated Condition for Persistent overheating Coolant tempera- Rises quickly ture gauge Does not go down from red range (if installed)

Defective radiator fan pump or motor

Defective coolant temperature gauge

Worn or deformed fan pulley

Defective radiator cap (pressure valve)

Clogged radiator core

Clogged or crushed radiator fins

Defective operation of thermostat

Broken water pump

Lack of coolant

E E Q w

Q Q

Q w w w

Q

w w Q w w w w w

w

w w q

q q q q q q Replace

Correct

Replace

Correct

Correct

Replace

q

—

q

Carry out troubleshooting in H-mode

q

Replace

When compression pressure is measured, it is found to be low Inspect cylinder liner directly Inspect oil cooler directly Temperature difference between upper and lower tanks of radiator is large When operation of thermostat is tested, it does not open at cracking temperature Temperature difference between upper and lower tanks of radiator is slight Inspect radiator core directly When operation of radiator cap is carried out, its cracking pressure is low Inspect fan belt and pulley directly When coolant temperature is measured, it is found to be normal

w

Add

Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Engine oil level has risen and oil is milky Fan is deformed or worn Milky oil is floating on coolant There are excessive air bubbles in radiator and coolant spurts back When light bulb is held behind radiator core, no light passes through Radiator shroud, inside of underguard on applicable machine side are clogged with dirt or mud Coolant is leaking because of cracks in hose or loose clamps Coolant flows out from radiator overflow hose

Remedy

22

Clogged or broken oil cooler

E E

Replace

Troubleshooting

Check items

Questions

Broken cylinder head and/or head gasket

q

Damaged cylinder liner O-ring and/or hole caused by pitting

q

Replace

q

Causes

Lack of cooling air (deformation, and/or damages of fan) Drop in heat dissipation efficiency Problem in coolant circulation system Problem in RAD fan pump or motor

Replace

q

1

40 Troubleshooting

SEN02105-00

S-15 Abnormal noise is made

1

General causes why abnormal noise is emitted

Dirt caught in injector

Clogged or seized injector

Deformed or worn cooling fan

Removed or seized gear train bushing

Improper gear train backlash

Excessive wear of piston ring and/or cylinder liner

Improper valve clearance

Defective inside of muffler (dividing board out of position)

Q

Q

Q Q

Q Q w w

w

w w w

w w w Q w

Q w

Q Q

w Q Q

Q w

q

When turbocharger is rotated by hand, it is fount to be heavy Inspect dynamic valve system directly When muffler is removed, abnormal noise disappears Inspect valve clearance directly When compression pressure is measured, it is found to be low Inspect gear train directly Inspect fan directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Abnormal noise is heard only when engine is started

q q q q q q q q q

Correct

Replace

Correct

Replace

Replace

q Replace

Remedy

Broken dynamic valve system (valve and/or rocker lever)

E

Replace

Confirm recent repair history Degree of machine Operated for long period operation Condition of abnor- Gradually increased mal noise Suddenly increased Non-specified fuel is being used Oil replenished more frequently Metal particles are found when oil filter is drained Air leaks between turbocharger and cylinder head When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around EGR gas piping When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, beat noise is emitted around muffler When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Blue under light load Color of exhaust gas Black Engine does not pick up smoothly and combustion is irregular Abnormal noise is loud when engine is accelerated Blow-by gas is excessive

Replace

Troubleshooting

Check items

Questions

a

Correct

a

Interference or seizure of turbocharger

a

Leakage of air between turbocharger and cylinder head

q

Replace

q

Causes

Abnormality due to defective parts Abnormal combustion Air leakage from air intake system Judge if the noise is an internal noise or an external noise before starting troubleshooting. While the engine is not sufficiently warmed up, it is operated in the low-temperature mode. Accordingly, the engine sound rises slightly higher. This is no abnormality, however. When the engine is accelerated, the engine sound rises slightly for approx. 3 seconds maximum. This is no abnormality, however.

Replace

q

23

SEN02105-00

40 Troubleshooting

S-16 Vibration is excessive

1

General causes why vibration occurs

Confirm recent repair history Degree of machine Operated for long period operation Condition of vibra- Suddenly increased tion Gradually increased Non-specified oil is being used Metal particles are found when oil filter is drained Metal particles are found when oil pan is drained Oil pressure is low at low idle Vibration occurs at mid-range speed Vibration follows engine speed

Q Q Q w w Q

Exhaust smoke is black

w

Inspect dynamic valve system directly Inspect main bearing and connecting rod bearing directly Inspect gear train directly Inspect camshaft bushing directly Inspect engine mounting bolts and cushions directly When alignment is checked, radial runout or facial runout is detected Inspect front support spigot joint portion directly Inspect output shaft or inside of damper directly

q

Broken output shaft and/or parts in damper on installed machine side

Worn front support spigot joint portion

Misalignment between engine and devices on installed machine side

Loose engine mounting bolts and/or broken cushions

Worn camshaft bushing

Improper gear train backlash

E E

E

Q Q Q Q w w Q Q Q Q Q Q Q Q

q q q q q q Replace

Adjusting

Replace

Replace

q Remedy

24

Worn main bearing and/or connecting rod bearing

E

Replace

Troubleshooting

Check items

Questions

a

Stuck dynamic valve system (valve, rocker lever, etc.)

q

Replace

q

Causes

Defective parts (abnormal wear, breakage, etc.) Misalignment between installed machine Abnormal combustion If abnormal noise vibration occur, carry out troubleshooting for “S-15 Abnormal noise is emitted”, too.

Replace

q

SEN02105-00

PC2000-8 Hydraulic excavator Form No. SEN02105-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

26

SEN02133-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

50 Disassembly and assembly1 General information on disassembly and assembly General information on disassembly and assembly ....................................................................................... 2 How to read this manual ...................................................................................................................... 2 Coating materials list............................................................................................................................ 4 Special tool list ..................................................................................................................................... 7 Sketches of special tools.................................................................................................................... 10

PC2000-8

1

SEN02133-00

50 Disassembly and assembly

General information on disassembly and assembly How to read this manual 1.

1

Removal and installation of assemblies Special tools q Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1 etc. and their part names, part numbers and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They respectively have a new part number. R: Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank: Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they can not be supplied from Komatsu in Japan (i.e. locally made parts).

* *** ****

a

2

1

General tools that are necessary for removal or installation are described as [1],[2]•••etc. and their part names, part numbers and quantities are not described.

Removal q The [Removal] section contains procedures and precautions for implementing the work, know how and the amount of oil or coolant to be drained. q Various symbols used in the Removal Section are explained and listed below. k : This mark indicates safety-related precautions that must be followed when implementing the work. a : Know-how or precautions for work [*1] : This mark shows that there are instructions or precautions for installing parts. 6 : This mark shows the amount of oil or coolant to be drained. 4 : Weight of part or component

Installation q Except where otherwise instructed, installation of parts is done in the r evers e order of removal. q Instructions and precautions for installing parts are shown with [*1] mark in the Installation Section, identifying which step the instructions are intended for. q Marks shown in the Installation Section stand for the following. k : Precautions related to safety in execution of work. a : This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque 5

: Quantity of oil or coolant to be added

Sketches of special tools q Various special tools are illustrated for the convenience of local manufacture.

PC2000-8

50 Disassembly and assembly

2.

Disassembly and assembly of assemblies

SEN02133-00

Disassembly In Disassembly section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant drained are described. q The meanings of the symbols used in Disassembly section are as follows. k : This mark indicates safety-related precautions that must be followed when implementing the work. a : Know-how or precautions for work q

Special tools q Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1 etc. and their part names, part numbers and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N : Tools newly developed for this model. They respectively have a new part number. R : Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they can not be supplied from Komatsu in Japan (i.e. locally made parts).

* *** ****

a

PC2000-8

6

: Quantity of oil or coolant drained

Assembly q In Assembly section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant added are described. q The meanings of the symbols used in Assembly section are as follows. k : Precautions related to safety in execution of work. a : This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 4 5

: Tightening torque : Quantity of oil or coolant to be added

Sketches of special tools q Various special tools are illustrated for the convenience of local manufacture.

General tools that are necessary for removal or installation are described as [1],[2]•••etc. and their part names, part numbers and quantities are not described.

3

SEN02133-00

50 Disassembly and assembly

Coating materials list a a

The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this manual.

Category

Komatsu code

Part number

Q'ty

Container

Main features and applications

LT-1A

790-129-9030

150 g

Tube

• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.

LT-1B

790-129-9050

20 g (2 pcs.)

• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl Polyethylene chloride), rubber, metal, and non-metal parts container which require immediate and strong adhesion.

LT-2

09940-00030

50 g

Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs.

Adhesive

LT-3

790-129-9040

250 g

Holtz MH 705

790-129-9120

75 g

790-129-9140

• Used to stick and seal metal, glass, and plastics.

Polyethylene • Used to seal plugs. container Tube

• Heat-resistant seal used to repair engines.

50 g

• Quick-setting adhesive. • Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container • Used mainly to stick rubbers, plastics, and metals.

790-129-9130

2g

Loctite 648-50

79A-129-9110

50 cc

LG-1

790-129-9010

200 g

790-129-9080

Can

• Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods.

Aron-alpha 201

LG-5

Gasket sealant

790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener)

LT-4

ThreeBond 1735

1 kg

• Features: Resistance to heat and chemicals. Polyethylene • Used for fitted portions used at high temperacontainer tures. Tube

• Used to stick or seal gaskets and packings of power train case, etc.

• Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.

LG-6

790-129-9020

200 g

Tube

• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.

LG-7

790-129-9070

1 kg

Tube

• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.

ThreeBond 1211

790-129-9090

100 g

Tube

• Gasket sealant used to repair engine.

Tube

• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.

ThreeBond 1207B

4

1

419-15-18131

100 g

PC2000-8

50 Disassembly and assembly

Molybdenum disulfide lubricant

CateKomatsu code gory LM-G

LM-P

G2-LI G0-LI (*) *: For cold district

G2-CA

SEN02133-00

Part number

Q'ty

Container

Main features and applications

09940-00051

60 g

Can

• Used to lubricate sliding portions. (to prevent squeaking) • Used to prevent scuffing and seizure of pressfitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc.

09940-00040

200 g

Tube

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG0-400LI-A (*) SYG0-16CNLI (*)

Various

Various

• General purpose type.

SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

Various

Various

• Used for bearings used at normal temperature under light load in contact with water or steam.

Molybdenum disulfide grease LM-G (G2-M)

SYG2-400M SYG2-400M-A SYGA-16CNM

Hyper White Grease G2-T, G0-T (*) *: For cold district

SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)

Biogrease SYG2-400B G2-B, G2-BT (*) SYGA-16CNB *: For use at high tempera- SYG2-400BT (*) ture and under SYGA-16CNBT (*) high load SUNSTAR PAINT PRIMER 580 SUPER

Primer

SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95

Caution: 400 g x 10 Bellows-type • Do not apply grease to ball bearings like swing 400 g x 20 container circle bearings, etc. 16 kg Can • The grease should be applied to work equipment pins at their assembly only, not applied for greasing afterwards. 400 g 16 kg

400 g 16 kg

• Seizure resistance and heat resistance higher Bellows-type than molybdenum disulfide grease. container • Not conspicuous on machine since color is Can white. Bellows-type • Since this grease is decomposed by natural container bacteria in short period, it has less effects on Can microorganisms, animals, and plants.

20 ml

Glass container

• Used as primer for cab side. (Using limit: 4 months after date of manufacture)

20 ml

Glass container

• Used as primer for glass side. (Using limit: 4 months after date of manufacture)

20 ml

Glass container

417-926-3910

22M-54-27230

SUNSTAR GLASS PRIMER 435-41

22M-54-27240

150 ml

Can

SUNSTAR SASH PRIMER GP-402

22M-54-27250

20 ml

Glass container

PC2000-8

Adhesive for cab glass

Grease

• Used for parts under heavy load.

• Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture) • Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture)

5

SEN02133-00

6

Part number

Q'ty

Container

Main features and applications • “S” is used for high-temperature season and “W” for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture) • Used as adhesive for glass. (Using limit: 6 months after date of manufacture)

SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”

417-926-3910

320 ml

Polyethylene container

Sika Japan, Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene container

SUNSTAR PENGUINE SUPER 560

22M-54-27210

320 ml

Ecocart (Special container)

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920

320 ml

Polyethylene container

SEKISUI SILICONE SEALANT

20Y-54-55130

333 ml

Polyethylene container

• Used to seal front window. (Using limit: 6 months after date of manufacture)

Cartridge

• Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)

GE TOSHIBA SILICONES TOSSEAL 381

22M-54-27220

333 ml

Adhesive for cab glass

Caulking material

Adhesive

Category Komatsu code

50 Disassembly and assembly

• Used as adhesive for glass. (Using limit: 6 months after date of manufacture) • Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture)

PC2000-8

50 Disassembly and assembly

SEN02133-00

Special tool list

1

1 3

Removal, installation of engine front seal

4

A

3

Wrench

5

1

F

J 1

Sketch

New/remodel

1

t

1 1

N

Q

795T-621-1440 Push tool

t

1

N

Q

01050-32240

• Bolt

t

3

01050-32225

• Bolt

t

3

01640-02232

• Washer

t

3

t

1

795-931-1100 Seal puller assembly

t

1

01050-32060

• Bolt

t

5

01640-02032

• Washer

t

5

790-101-5621 Plate

t

1

790-101-5641 Grip

t

1

01010-51240

t

1

Bolt

Nature of work, remarks

Tightening of cylinder head bolt

t

795-931-1100 Seal puller

Extraction of oil seal

Press fitting of oil seal

Extraction of oil seal N

Q Press fitting of oil seal

Press fitting of oil seal

t

1

791-585-1510 Installer

t

1

Installation of floating seal

791-575-1520 Installer

t

1

Installation of floating seal

2 796T-626-1120 Push tool Final drive assembly

q

795T-621-1430 Plate

795T-621-1540 Push tool

Removal, installation of engine rear seal

Swing machinery assembly

790-331-1110

Part name

Q'ty

Removal, installation of cylinder head assembly

Part No.

Necessity

Component

Symbol

a Tool part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured). a Necessity: t ........... Cannot be substituted, must always be installed (used) q ........... Extremely useful if available or can be substituted with commercially available part a New/Remodel: N ........... Tools with new part numbers, newly developed for this model R:........... Tools with upgraded part numbers, remodeled from items already available for other models Blank: ... Tools already available for other models, can be used without any modification a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See Sketches of special tools)

Q Press fitting of bearing

Assembly of carrier roller assembly

2 796T-930-1110 Push tool

t

1

Assembly of idler

3

791-542-1520 Installer

t

1

Installation of floating seal

790-401-1700 Lifting tool

t

1

790-434-1021 Adapter

t

1

Removal, installation of track roller

5

796-675-1510 Installer

t

1

Installation of floating seal

6

791-601-1000 Oil pump

t

1

Filling oil

1

790-434-1502 Remover & installer

t

1

Track shoe assembly R 2

790-101-4300 Cylinder (1,471 kN {150 ton})

t

1

790-101-1102 Hydraulic pump

t

1

Track roller assembly

L

4

Assembly of track roller assembly

3 Installation of hydraulic pump input shaft oil seal

S

796T-867-1810 Push tool

t

1

Hydraulic pump assembly

S1

796-770-1301 Oil stopper

q

2

PC2000-8

N

Q Press fitting of ring

Removal, installation of master pin

N

Q Press fitting of oil seal Removal, installation of hydraulic pump

7

790-101-2501 Push puller

1 2 3

4

Hydraulic cylinder assembly

U 5

1

790-101-2520 • Screw

1

791-112-1180

1

• Nut

790-101-2540 • Washer

1

790-101-2630 • Leg

2

790-101-2570 • Plate

4

790-101-2560 • Nut

2

790-101-2660 • Adapter

2

8

Sketch

790-502-1003 Cylinder repair stand

t

1

790-101-1102 Pump

t

1

790-102-4300 Wrench assembly

t

1

790-102-4310 Pin

t

2

Removal, installation of piston assembly Installation of piston ring

790-720-1000 Expander

t

1

796-720-1690 Ring (for bucket)

t

1

07281-02169

t

1

796-720-1710 Ring (for arm)

t

1

07281-02709

t

1

Clamp Clamp

796-720-1730 Ring (for boom)

t

07281-03209

t

Clamp

790-201-1702 Push tool kit

1

790-201-1881 • Push tool

1

790-101-5021 • Grip

1

01010-50816

• Bolt

1

791-863-1110

Push tool

t

1

790-101-5421 Grip

t

1

01010-51240

t

1

792-630-1300 Push tool

t

1

790-101-5421 Grip

t

1

01010-51240

t

1

t

1

Bolt

Bolt

790-201-1500 Push tool kit

6

Disassembly, assembly of center swivel joint assembly

790-201-1640 • Push tool

1

790-101-5021 • Grip

1

01010-50816

1

• Bolt

792-715-1400 Plate

t

1

790-101-5421 Grip

t

1

01010-51240

Bolt

t

1

790-445-4220

Plate

t

1

790-101-5421

Grip

t

1

01010-51240

Bolt

t

1

Disassembly, assembly of hydraulic cylinder

Compression of piston ring

Bucket cylinder

Arm cylinder

Boom cylinder

Bucket cylinder

Arm cylinder

Press fitting of roll bushing

T

1

Nature of work, remarks

Press fitting of dust seal

Disassembly, assembly of center swivel joint assembly

t

790-101-2510 • Block

New/remodel

Part name

Q'ty

Part No.

Necessity

Component

50 Disassembly and assembly

Symbol

SEN02133-00

Boom

PC2000-8

Arm assembly

V

Operator’s cab glass (stuck glass)

X Air conditioner assembly

PC2000-8

796T-870-1150 Sleeve

t

1

Q

796T-870-1170 Sleeve

t

1

Q

796-870-1180

Part No.

Part name

t

1

796T-870-1190 Plate

t

1

796-900-1230

Screw

t

1

01582-33024

Nut

t

1

01643-33080

Washer

t

1

790-101-4000

Puller (1,471 kN {150 ton})

t

1

790-101-1102

Adapter

Sketch

Q'ty

New/remodel

SEN02133-00

Necessity

Component

Symbol

50 Disassembly and assembly

Nature of work, remarks

Q Extraction of boom top pin

Pump

t

1

1 793-498-1210

Lifter (Suction cup)

t

4

Installation of window glass

2 20Y-54-13180

Adapter

t

2

Fixture of window glass

799-703-1200

Service tool kit

t

1

799-703-1100

Vacuum pump (for 100 V)

t

1

3 799-703-1111

Vacuum pump (for 220 V)

t

1

799-703-1121

Vacuum pump (for 240 V)

t

1

799-703-1401

Gas leak detector

t

1

Filling with refrigerant (air conditioner gas)

9

SEN02133-00

Sketches of special tools

50 Disassembly and assembly

1

NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A4 Plate

A4 Push tool

10

PC2000-8

50 Disassembly and assembly

SEN02133-00

NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A5 Push tool

F2 Push tool

PC2000-8

11

SEN02133-00

50 Disassembly and assembly

NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. L2 Push tool

S Push tool

12

PC2000-8

50 Disassembly and assembly

SEN02133-00

NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. V Sleeve

V Sleeve

PC2000-8

13

SEN02133-00

50 Disassembly and assembly

NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. V Plate

14

PC2000-8

SEN02133-00

PC2000-8 Hydraulic excavator Form No. SEN02133-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 11-06 (01)

16

SEN02134-01

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

50 Disassembly and assembly

1

Engine and cooling system (12V140E-3) Engine and cooling system (12V140E-3)........................................................................................................ 2 Removal and installation of power container assembly ....................................................................... 2 Removal and installation of engine, PTO and hydraulic pump assembly ............................................ 7 Removal and installation of radiator assembly................................................................................... 19 Removal and installation of aftercooler assembly .............................................................................. 20 Removal and installation of hydraulic oil cooler assembly ................................................................. 22 Removal and installation of fuel cooler assembly .............................................................................. 23 Removal and installation of cooling assembly ................................................................................... 24 Removal and installation of fan motor assembly................................................................................ 28 Removal and installation of fuel tank assembly ................................................................................. 29

PC2000-8

1

SEN02134-01

50 Disassembly and assembly

Engine and cooling system (12V140E-3) Removal and installation of power container assembly 1 Removal k k k k k

a a k

Lower the work equipment completely to the ground and stop the engine. Loosen the oil filler cap gradually to release the internal pressure of the hydraulic tank Set the work equipment lock lever to the lock position. Disconnect the cable from the negative (–) terminal of the battery. Collect the refrigerant (R134a) from the air conditioner circuit in advance. Ask professional traders for collecting and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere. Always wear protective glasses when collecting or filling the refrigerant (air conditioner gas: R134a). Refrigerant in your eyes could cause blindness. Only the qualified personnel shall perform collection and filling of the refrigerant.

1.

Remove counterweight assembly, referring to "Removal and installation of counterweight assembly".

2.

Close fuel tank valve.

3.

Remove clamp and drain coolant from the hose (1). 6

2

4.

1

Drain hydraulic oil. 6

Hydraulic tank: 1,300 l

5.

Disconnect hoses (2) to (6). a Prepare a container and oil plug to catch oil leaks.

6.

Disconnect suction hoses (7) to (9). a MIKALOR clamp. [*1] a Apply a marking to the hose end and tube so that their original insertion positions may be identified in later reference. (See the following figure.)

Coolant: 180 l

PC2000-8

50 Disassembly and assembly

SEN02134-01

7.

Disconnect fuel hoses (10).

11. Remove cover A (15).

8.

Disconnect heater hoses (11). [*2] a Disconnect 4 air conditioner hoses AH inside the container. (Refer to next item)

12. Remove bracket (16). 13. Disconnect 4 oil hoses (17) and 2 oil hoses (18). 14. Remove cover (19).

9.

Disconnect clips (12) and 4 air conditioner hoses (13) inside the power container. [*3] a The air conditioner hoses (13) are composed of 2 stages. a Be careful for the air conditioner circuit hoses so that dirt, water may not enter. a The heater hoses HS and fuel hoses FH have been disconnected in the previous step.

15. Disconnect connectors (20). 16. Disconnect clamp (21). a HSTT: Hydraulic tank

17. Open battery cover (22) from the bottom of the ladder R located behind the operator cab. 10. Lift and remove tail pipes (14).

PC2000-8

3

SEN02134-01

50 Disassembly and assembly

18. Disconnect 2 negative terminals (23) and 2 positive terminals (24).

21. Disconnect fuel hose (29) from the bottom rear of the power container.

19. Disconnect connectors (25) and (26) from the rear of the battery.

22. Disconnect hose clamps (30).

20. Pull out harnesses (27) and (28).

23. Lift and remove deck assembly (31). 4

a

4

Deck assembly: Approx. 260 kg

Harnesses (27) and (28) have been pulled out.

PC2000-8

50 Disassembly and assembly

24. Lift and remove deck assembly (32). 4

Deck assembly: Approx. 260 kg

SEN02134-01

26. Lift and remove power container assembly (35). 4

Power container assembly: Approx. 16,300 kg

25. Remove power container M30 mounting bolts (33); 5 bolts each from 4 places. [*4] a The plate (34) can be removed from backside.

PC2000-8

5

SEN02134-01

Installation

Carry out the installation in the reverse order of removal. [*1] Suction hose clamp a Use new MIKALOR clamp. 2 Entire perimeter of hose on the tube side: Adhesive (ThreeBond No.4314) a Apply the adhesive uniformly along the entire perimeter 1) Align the hose to the original position (marked position). (Air hose insertion depth: Min. 80 mm) 2) Place the bridge (BR) under the clamping bolt and adjust the overlapping (b) between the bridge (BR) and band to 5 mm minimum. (b) dimension: Min. 5 mm 3) Tightening of the clamp 2 Threaded portion (BC) of clamping bolt: Lubricant (PANDO 18B from ThreeBond) a Never use an impact wrench. a Displace the tightening positions of the adjacent clamps by 180°.

50 Disassembly and assembly a

q

When the current hose is reused Align the clamp position to the trace of the clamp left on the hose. 3 Clamping bolt: Min. 6 Nm {0.6 kgm}

a

Check that there is no defect or deterioration on the O-ring. When connecting the piping for refrigerant, apply the compressor oil for the new refrigerant to the O-ring (Denso: ND-OIL8 or ZEXEL: ZXL100PG (PAG46 or equivalent)).

3 3 3

Hose clamp: 8.83 – 14.7 Nm {0.9 – 1.5 kgm} Hose thread M16 × 1.5: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} Hose thread M24 × 1.5: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

q

q

When a new hose is used Tighten the bolt until BDG dimension meets the following. Hoses (7) and (9): 12 – 15 mm Hose (8): 17 – 20 mm

[*4]

3

q

Power container mounting bolt: 3,430 – 4,212 Nm {350 – 430 kgm}

Refilling with oil (Hydraulic tank) Fill oil up to the specified level from the oil filler port, start the engine to circulate oil in the pipe and then confirm the oil level again. 5

q

Refilling with coolant Fill coolant up to the specified level from the coolant filler, start the engine to circulate the coolant and then confirm the coolant level again. 5

Filling of refrigerant (R134a) Fill the air conditioner circuit with the refrigerant (R134a). a Filling amount: 950 ± 50 g (per one air compressor) a Two air compressors are used.

q

Bleed air from the main pump, referring to "Bleeding air from each part" in Testing and adjusting.

Heater hose clamp: 5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}

[*3] a When installing the air conditioner circuit hoses, take care so that dirt, water may not enter. a Make sure before the installation that there is O-ring at the piping connector of the air conditioner hose.

6

Coolant: 180 l

q

[*2]

3

Hydraulic tank (Hydraulic tank refill oil capacity): Approx. 1,300 l

PC2000-8

50 Disassembly and assembly

SEN02134-01

Removal and installation of engine, PTO and hydraulic pump assembly 1 Removal 1.

Remove power container assembly, referring to "Removal and installation of power container assembly."

2.

Remove air cleaner upper cover (1).

3.

Remove clamps (2), and then pull out 2 tubes (3). [*1] 9.

4.

Remove hand rails (4).

5.

Remove rear covers (5) and (6). a SWB: Emergency engine stop switch – behind

Disconnect connector A08 (12) and ground TM1 (13) from the inside of emergency engine stop switch – behind (SWB).

10. Disconnect connector L05B (14) from the bottom of SWB. 11. Disconnect connector L08B (15). 12. Remove clip and disconnect harnesses (16).

6.

Disconnect connector A07 (140) from the backside of emergency engine stop switch – front (SWF).

7.

Remove front covers (7) and (8).

8.

Remove upper covers (9) to (11). a SWF: Emergency engine stop switch – front

PC2000-8

7

SEN02134-01

13. Disconnect connector S27B (150) from backside of DSB (door switch - behind).

50 Disassembly and assembly a

In the case of low-grade fuel specification, disconnect connector (141) from priming pump timer (PPT) between brackets (24) and (25).

14. Remove clips (17) and disconnect muffler drain tubes (18). 15. Remove clips (19) and disconnect muffler drain hoses (20). 16. Disconnect heater hoses (21) and (22).

20. Disconnect 4 connectors (151) from the bottom. P41A, P41B, P41C and P41D from the top. 17. Disconnect 2 hoses (23).

21. Disconnect 4 connectors (152). P41A, P41B, P41C and P41D from the top.

18. Disconnect brackets (24) and (25).

22. Remove clip and disconnect harness (153).

19. Remove clip and disconnect harnesses (26).

8

PC2000-8

50 Disassembly and assembly

23. Disconnect connectors L08A (154) and S27A (155).

SEN02134-01

30. Disconnect connector L13 (157) from the front of machine in the pump room.

24. Remove clip and disconnect harness (156).

31. Disconnect 2 air cleaner hoses (33).

[*2]

25. Disconnect connector P24 (27). 26. Disconnect clips (28).

32. Lift and remove hood assembly (34). 4

Hood assembly: 210 kg

27. Disconnect fan connector V18 (29). 28. Disconnect connectors M34 (30) and M35 (31) from the compressor. 29. Disconnect harness (32).

PC2000-8

9

SEN02134-01

33. Remove cover (35).

50 Disassembly and assembly a

In the case of low-grade fuel specification, disconnect fuel filter assembly (145).

34. Lift and remove muffler and bracket assembly (36).

36. Remove bracket (38). a Remove the opposite side at the same procedures. 37. Temporarily lift air inlet duct assembly (39), and lift and remove it. 4

Air inlet duct assembly: 450 kg

35. Remove dividing boards A, B and C (37) between the engine room and pump room.

38. Remove 2 clamps (40). 39. Disconnect 2 tubes (41). 40. Remove clamp (42). 41. Disconnect tube (43). 42. Disconnect hose (44).

10

PC2000-8

50 Disassembly and assembly

SEN02134-01

43. Loosen clamps for hoses (45) to (47). [*3] a Apply a marking to the hose end and tube so that their original insertion positions may be identified in later reference. (See the following figure.)

48. Disconnect 3 radiator lower hoses (51).

[*5]

44. Remove dividing board (D) between the radiator room and engine room. 45. Remove clamp bracket (48). 46. Disconnect 2 tube clamps (49).

[*4]

47. Remove 2 tubes (50). a Remove the opposite side at the same procedures.

49. Remove cover (52). 50. Disconnect 2 radiator upper hoses (53).

[*6]

51. Disconnect hose (54).

52. Temporarily lift cooling (radiator, aftercooler and fan) assembly (55), and lift and remove it. a Holes are provided on the top of the frame for lifting. 4

PC2000-8

Cooling (radiator, aftercooler and fan) assembly: Approx. 1,200 kg

11

SEN02134-01

53. Disconnect 2 tube clamps (56).

50 Disassembly and assembly a 60. and 61. are low-grade fuel specification only 60. Disconnect fuel hoses (142) and (143). 61. Remove water separator assembly (144).

54. Disconnect 3 hoses (57). 55. Disconnect tube clamp (58). 62. Disconnect hoses (64), (65) and (66). 56. Disconnect hose clamp (59). 57. Disconnect hose (60).

63. Disconnect 4 hoses (67). 64. Disconnect hose clamp (68). 65. Disconnect 2 hoses (69) and 2 hoses (70) from the fuel pre-filter. 66. Disconnect rear cover (71).

58. Disconnect 3 hoses (61) and 3 hoses (62) from the filter. 59. Disconnect rear cover (63). 67. Disconnect frame (72) in which rear covers (63) and (71) were attached, from the frame assembly (73).

12

PC2000-8

50 Disassembly and assembly

SEN02134-01

68. Remove bracket (74).

69. Remove mounting bolt, and then lift and remove frame assembly (73). 4

Frame assembly: 270 kg

76. Disconnect fuel hoses (79), (80) and (81) from the rear of the container. 77. Remove brackets (82) and (83). 78. Disconnect engine ground (84). 79. Disconnect radiator pipe (85). q Standard specification

70. Remove bracket (75). 71. Disconnect hose clamps (76). a Do not disconnect air conditioner hoses (AH).

q

Low-grade fuel specification

72. Loosen adjustment nut (170) of the air conditioner compressor. 73. Remove covers (77). 74. Remove air conditioner compressor belts (78). [*7] 75. Remove 2 air conditioner compressors (171).

PC2000-8

13

SEN02134-01

80. Disconnect fuel hose (86). q Standard specification

50 Disassembly and assembly

85. Disconnect connectors V12 (91) and V11 (93) from inside the No.1 main pump. 86. Disconnect harness (94).

q

Low-grade fuel specification 87. Disconnect connectors V15 (161) and V16 (162) from the fan pump (middle lower).

81. Disconnect hose (87) from the No.1 main pump. 82. Disconnect 2 hoses (88). 83. Disconnect hose clamp (89).

88. Disconnect connector P35 (163) from the fan pump (middle lower).

84. Disconnect hose (90).

14

PC2000-8

50 Disassembly and assembly

SEN02134-01

89. Disconnect suction tube (95) from the No.1 main pump.

96. Disconnect connectors V14 (110) and V13 (111) from the No. 2 main pump.

90. Disconnect 3 hoses (96), (97) and (98) from the fan pump (middle lower).

97. Disconnect harnesses (112) and (113). 98. Disconnect 2 hoses (114). 99. Disconnect 2 hoses (115). a Clamps are attached to the hoses.

91. Disconnect hose P34 (100) from the fan pump (middle lower). 92. Disconnect harness (101). 100.Remove engine controller cover (116). 93. Disconnect hoses (102) to (105).

94. Disconnect fan motor connector V17 (106). 95. Disconnect hoses (107) to (109).

PC2000-8

101.Disconnect connectors CE05 (117) and CE08 (118) from the engine controller. [*8] a Remove the opposite side at the same procedures.

15

SEN02134-01

50 Disassembly and assembly

102.Remove cover (119).

110. Disconnect clips (130).

103.Disconnect connectors (120). VH16, VH17, VH18 and VH19 from the left.

111. Disconnect 2 harnesses (131) from the starting motor.

104.Disconnect terminal (121).

112. Disconnect harness (132) from the starting motor.

105. Remove clips and disconnect 2 harnesses (122). 106.Disconnect connectors PIM (123) and TIM (124). 107.Disconnect connectors (125) and E01 (126). 108.Disconnect connector CNRP (127). 109.Remove clips and disconnect 2 harnesses (128) and (129).

113. Disconnect connector P19 (133) from the PTO oil pan. 114. Disconnect clips (134) from the bottom of PTO.

16

PC2000-8

50 Disassembly and assembly

115. Temporarily lift engine, PTO and pump assembly. Rear side fulcrum (right and left of PTO upper area): RP Front side fulcrum: FP

SEN02134-01

Installation q

Carry out the installation in the reverse order of removal.

[*1]

3

Hose clamp of Komaclone tube assembly: 5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}

[*2]

3

Air cleaner hose clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*3] q

a 1) 2) 116. Remove engine, PTO and pump assembly (136) mount bolts. [*9] Pump side mount bolts: (135) Radiator side mount bolt: MB

3)

117. Lift and remove engine, PTO and pump assembly (136). 4

Air hose Use new MIKALOR clamp. Align the hose to the original position (marked position). (Air hose insertion depth: Min. 80 mm) Place the bridge (BR) under the clamping bolt and adjust the overlapping (b) between the bridge (BR) and band to 5 mm minimum. (b) dimension: Min. 5 mm Tightening of the clamp 2 Threaded portion (BC) of clamping bolt: Lubricant (PANDO 18B from ThreeBond) a Never use an impact wrench. When the current hose is reused Align the clamp position to the trace of the clamp left on the hose. 3 Clamping bolt: Min. 6 Nm {0.6 kgm}

q

Engine, PTO and pump assembly: Approx. 6,100 kg

q

When a new hose is used Tighten the bolt until BDG dimension meets the following. BDG: 17 – 20 mm

[*4]

3

Air tube clamp: 21 Nm {2.55 kgm}

[*5]

3

Radiator hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*6]

3

PC2000-8

Radiator hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

17

SEN02134-01

50 Disassembly and assembly

[*7] q

Adjust air conditioner compressor belt tension, referring to "Testing and adjusting: Adjusting air conditioner compressor belt tension."

[*8] q

Make sure inside (particularly the bottom) of the controller connector is free from sands, dusts or water. If such foreign substances are present, clean them completely with the air blow. (Sands, dusts or water can cause defect contact or allow commingling of water.)

[*9] a Note that the washer (U) in upper position is different from the (D) in lower position on the radiator side.

3

18

Engine mount bolt: 824 – 1030 Nm {84 – 105 kgm} Target: 927 Nm {94.5 kgm}

PC2000-8

50 Disassembly and assembly

Removal and installation of radiator assembly

SEN02134-01

1

Removal 1.

Remove clamp and drain coolant from the hose (1). 6

Coolant: 180 l

2.

Disconnect 3 radiator outlet hoses (2). a Three radiators are provided.

3.

Remove hand rail (3).

4.

Remove radiator upper cover (4).

[*1]

Installation q

Carry out installation in the reverse order to removal.

[*1], [*2] 3 Radiator hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} q

5

5.

Disconnect reservoir tank hose (5).

6.

Disconnect radiator inlet hoses (6).

7.

Remove brackets (7) (2 pieces for each radiator).

8.

Raise and remove radiator assembly (8). 4

PC2000-8

Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant and then confirm the coolant level again. Coolant: 180 l

[*2]

Radiator assembly: Approx. 25 kg (each)

19

SEN02134-01

Removal and installation of aftercooler assembly

50 Disassembly and assembly

4.

Remove bracket (4). a Remove the opposite side at the same procedures.

5.

Temporarily lift air inlet duct assembly (5), and lift and remove it.

1

Removal 1.

Remove hand rails (1).

2.

Remove radiator side cover (2). a Remove the opposite side at the same procedures.

3.

Remove radiator upper cover (3).

4

Air inlet duct assembly: 450 kg

6.

Remove lower bracket (6).

7.

Remove air tube clamp (7). [*1] a Loosen tube clamp inside the engine room.

8.

Disconnect aftercooler hoses (8) and (9). [*2] a Apply a marking to the hose end and tube so that their original insertion positions may be identified in later reference. (See the following figure.)

9.

Lift air aftercooler (11) temporarily.

10. Remove upper brackets (10). 11. Lift and remove aftercooler assembly (11) by lifting both sides. 4

20

Aftercooler assembly: 45 kg (one side)

PC2000-8

50 Disassembly and assembly

SEN02134-01

Installation q

Carry out the installation in the reverse order of removal.

[*1]

3

Air tube clamp: 21 Nm {2.55 kgm}

[*2] q

a 1) 2)

3)

Air hose Use new MIKALOR clamp. Align the hose to the original position (marked position). (Air hose insertion depth: Min. 80 mm) Place the bridge (BR) under the clamping bolt and adjust the overlapping (b) between the bridge (BR) and band to 5 mm minimum. (b) dimension: Min. 5 mm Tightening of the clamp 2 Threaded portion (BC) of clamping bolt: Lubricant (PANDO 18B from ThreeBond) a Never use an impact wrench. When the current hose is reused Align the clamp position to the trace of the clamp left on the hose. 3 Clamping bolt: Min. 6 Nm {0.6 kgm}

q

q

PC2000-8

When a new hose is used Tighten the bolt until BDG dimension meets the following. BDG: 17 – 20 mm

21

SEN02134-01

Removal and installation of hydraulic oil cooler assembly

50 Disassembly and assembly

1

Removal k

1.

Loosen the oil filler cap gradually to release the internal pressure of the hydraulic tank Drain hydraulic oil. 6

Hydraulic tank: 1,300 l

2.

Disconnect hoses (1) to (4). a Prepare a container and oil plug to catch oil leaks.

3.

Remove hydraulic oil cooler upper cover (5).

Installation q

Carry out the installation in the reverse order of removal.

q

Refilling with oil (Hydraulic tank) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. 5

4.

Remove cover (6) and disconnect oil cooler upper hose (7).

5.

Remove clamps (8).

6.

Lift and remove hydraulic oil cooler assembly (9). 4

22

Hydraulic tank (Hydraulic tank refill oil capacity): Approx. 1,300 l

Hydraulic oil cooler assembly: 170 kg (each side)

PC2000-8

50 Disassembly and assembly

Removal and installation of fuel cooler assembly

SEN02134-01

Installation 1

Removal 1.

Close fuel tank valve.

2.

Remove hydraulic oil cooler air inlet duct assembly (1).

3.

Disconnect hoses (3) and (4). a Use a double spanner (its reactive force) when removing the fuel hose. (To prevent damaging weld on the fuel cooler.) a Prepare a plug and container to catch fuel.

4.

Remove fuel cooler assembly (5).

PC2000-8

q

Carry out the installation in the reverse order of removal.

23

SEN02134-01

Removal and installation of cooling assembly

50 Disassembly and assembly

1

Radiator side 7. Disconnect 3 radiator lower hoses (9).

[*1]

Removal 1.

Remove power container assembly, referring to "Removal and installation of power container assembly."

2.

Remove hand rails (1).

3.

Remove side covers (2) and (3). a SWB: Emergency engine stop switch – behind

8.

Remove bracket (10). a Remove the opposite side at the same procedures.

9.

Temporarily lift air inlet duct assembly (11), and lift and remove it. 4

4.

Disconnect connector A07 (50) from the backside of emergency engine stop switch – front (SWF).

5.

Remove side covers (4) and (5).

6.

Remove upper covers (6) to (8). a SWF: Emergency engine stop switch – front

Air inlet duct assembly: 450 kg

10. Disconnect fan motor connector V18 (12).

24

PC2000-8

50 Disassembly and assembly

SEN02134-01

11. Remove 2 clamps (13). 12. Disconnect 2 tubes (14). 13. Remove clamp (15). 14. Disconnect tube (16). 15. Disconnect hose (17).

21. Remove cover (24). 22. Disconnect 2 radiator upper hoses (25).

[*4]

23. Disconnect hose (26).

16. Loosen clamps for hoses (18) to (20). [*2] a Apply a marking to the hose end and tube so that their original insertion positions may be identified in later reference. (See the following figure.) 17. Remove dividing board (D) between the radiator room and engine room. 18. Remove clamp bracket (21). 19. Disconnect 2 tube clamps (22).

[*3]

20. Remove 2 tubes (23). a Remove the opposite side at the same procedures.

PC2000-8

24. Temporarily lift cooling (radiator, aftercooler and fan) assembly (27), and lift and remove it. a Holes are provided on the top of the frame for lifting. 4

Cooling (radiator, aftercooler and fan) assembly: Approx. 1,200 kg

25

SEN02134-01

Oil cooler side 25. Temporarily lift air inlet duct assembly (30), and lift and remove it. 4

50 Disassembly and assembly

27. Remove 2 hoses (33). 28. Disconnect 2 tube clamps (34).

Air inlet duct assembly : 450 kg

29. Disconnect 3 hoses (35). 26. Remove cover (31) and disconnect oil cooler upper hose (32). a Disconnect both sides.

30. Disconnect tube clamp (36).

31. Disconnect fan connector V17 (37). 32. Disconnect hoses (38) to (40).

26

PC2000-8

50 Disassembly and assembly

33. Remove fuel tubes (41) from the fuel cooler (FC). a Use a double spanner and avoid applying force to the fuel cooler (aluminum weld portion) when removing the fuel tube. 34. Temporarily lift cooling (oil cooler, fuel cooler and fan) assembly (42), and lift and remove it. a Holes are provided on the top of the frame for lifting. 4

Cooling (oil cooler, fuel cooler and fan) assembly: Approx. 1,200 kg

SEN02134-01

Installation q

Carry out the installation in the reverse order of removal.

[*1]

3

Radiator hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*2] q

a 1) 2)

3)

Air hose Use new MIKALOR clamp. Align the hose to the original position (marked position). (Air hose insertion depth: Min. 80 mm) Place the bridge (BR) under the clamping bolt and adjust the overlapping (b) between the bridge (BR) and band to 5 mm minimum. (b) dimension: Min. 5 mm Tightening of the clamp 2 Threaded portion (BC) of clamping bolt: Lubricant (PANDO 18B from ThreeBond) a Never use an impact wrench. When the current hose is reused Align the clamp position to the trace of the clamp left on the hose. 3 Clamping bolt: Min. 6 Nm {0.6 kgm}

q

q

When a new hose is used Tighten the bolt until BDG dimension meets the following. BDG: 17 – 20 mm

[*3]

3

Air tube clamp: 21 Nm {2.55 kgm}

[*4]

3

PC2000-8

Radiator hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

27

SEN02134-01

Removal and installation of fan motor assembly

50 Disassembly and assembly

1

Removal 1.

Remove cooling assembly, referring to "Removal and installation of cooling assembly."

2.

Remove fan guards (1) and (2).

3.

Remove fan guards (3) and (4). (Radiator side only)

4.

Remove cover (5). (Radiator side only)

5.

Remove oil tubes (6) and (7) for fan motor. (Radiator side only) a Radiator side cooling assembly is shown in the picture.

9.

Remove fan motor assembly (13) from the bracket assembly (12). a Be careful with the key (K).

Installation 6.

Remove fan bracket assembly (8) from the cooling assembly. 4

Fan bracket assembly: Approx. 180 kg

7.

Remove lockplate (9).

8.

Remove bolt (10), and then remove fan assembly (11). [*2] a Use a puller to remove the fan assembly. Do not hit it with a hammer. a Be careful with the key (K).

28

[*1]

q

Carry out the installation in the reverse order of removal.

[*1] When aligning the bolt hole of the lock plate, turn the nut in the retightening direction. [*2] a Degrease the hole and shaft before installing the fan assembly. a Use a bar to fix the fan assembly to tighten the nut. 3 Fan assembly mounting nut: q Initial tightening torque: 932 – 981 Nm {95 – 100 kgm} q Tightening torque median value: 956 Nm {97.5 kgm} a After tightening, use both sides of the lock plate to align the lock plate bolt hole and retighten the nut by the minimum angle. (Allowable retightening angle: Max. 15°)

PC2000-8

50 Disassembly and assembly

Removal and installation of fuel tank assembly

SEN02134-01

Drain fuel. 6

Remove clamp (1).

3.

Remove decks (2) and (3). 4

a

7.

Disconnect clamps (9).

8.

Disconnect connector A24 (10) from the bottom rear (A) of the fuel tank.

9.

Remove 10 mounting bolts (12) from both sides. [*1]

Fuel tank: 3,500 l (at full)

2.

4

Disconnect fuel hoses (8) from the top rear of the fuel tank.

1

Removal 1.

6.

Deck assembly (2): Approx. 240 kg Deck assembly (3): Approx. 400kg

Right side deck of the container has been removed in the picture.

4.

Disconnect fuel supply hose (5) and fuel drain hose (4) from the bottom of the fuel tank.

5.

Disconnect fuel stop cable (6).

PC2000-8

29

SEN02134-01

10. Lift and remove fuel tank assembly (13). 4

Fuel tank assembly: Approx. 2,100 kg

50 Disassembly and assembly

Installation q

Carry out installation in the reverse order to removal.

[*1]

3

30

Fuel tank mounting bolt: 1,520 – 1,910 Nm {155 – 195 kgm}

PC2000-8

50 Disassembly and assembly

PC2000-8

SEN02134-01

31

SEN02134-01

PC2000-8 Hydraulic excavator Form No. SEN02134-01

© 2007 KOMATSU All Rights Reserved Printed in Japan 04-07 (01)

32

SEN02135-01

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

50 Disassembly and assembly

1

Engine (12V140E-3) Engine (12V140E-3) ....................................................................................................................................... 2 Removal and installation of fuel supply pump assembly...................................................................... 2 Removal and installation of cylinder head assembly ........................................................................... 5 Removal and installation of fuel injector............................................................................................. 19 Removal and installation of engine front seal .................................................................................... 30 Removal and installation of engine rear seal ..................................................................................... 33

PC2000-8

1

SEN02135-01

50 Disassembly and assembly

Engine (12V140E-3) Removal and installation of fuel supply pump assembly

1

11. Disconnect fuel hose (13). 1

Removal k k k

Lower the work equipment completely to the ground and stop the engine. Lock the work equipment lock lever. Disconnect the negative terminal (–) of the battery.

1.

Close the fuel valve through the bottom of fuel tank. a The figure shows the left bank side. Repeat the same procedure at the right bank side.

2.

Disconnect connectors PCV1 (1), PCV2 (2) and G (3) in the following procedure. 1) Turn up the cover. 2) Pull the connector housing of the wiring harness with the connector latch pushed. a Excessive force to the connector latch may cause the breakage of the connector housing.

3.

Remove fuel filter (4). a Use a filter wrench or others to remove the filter.

4.

Remove fuel return hose and tube assembly (5) from the common rail system. [*1]

5.

Disconnect fuel return hose (6).

6.

Remove fuel tube (7) and fuel tube and hose assembly (8). [*3]

7.

Disconnect bracket (9).

8.

Remove 4 right and left rubber covers (10).

9.

Remove high-pressure pipe clamp assembly (11).

[*4]

12. Remove lubrication tube (14). 13. Remove bracket (15). q Standard specification

q

Low-grade fuel specification (See standard specification for (9) – (15))

14. Remove mounting bolts (19) and (19-1), and then remove fuel supply pump assembly (16). a Only (19-1) of mounting bolts is reamer bolt and has a spacer. 15. Remove tube (20).

[*2]

10. Remove high-pressure pipe assembly (12).

2

PC2000-8

50 Disassembly and assembly

Installation 1.

Install supply pump assembly (16) in the following procedure. 1) Insert supply pump by aligning unequal spline section (A) at the supply pump drive case to the unequal spline section of supply pump shaft. 2) If it is difficult to insert the supply pump into the port, slightly rotate the crankshaft and change the position of unequal spline section (A). 3) Tighten 3 mounting bolts (19) and mounting bolt (19-1) with the specified torque. a Use a reamer bolt and a spacer only at mounting bolt (19-1) to determine radial direction of the supply pump.

PC2000-8

SEN02135-01

High-pressure piping k When handling the high-pressure piping and clamp, pay attention to the following. q It is strictly prohibited to bend the high-pressure piping to use it again or use it in other locations. q Install the specified clamp securely in the specified position with the specified torque. q Don't apply lubricant and the like to the high-pressure piping sleeve nut and the threaded portion of the mating side. a Axial force in the tightening can be excessive, potentially damaging the high-pressure piping. k Before installing the high-pressure piping, check it for the following defects. If there is any of these defects, it can c a u s e f u e l l e a k a g e . A c c o r di n gl y, replace the high-pressure piping. q Check the taper seal of the connecting part (Part (a): Part of 2 mm from the end) for visible lengthwise slit (b) and dent (c). q Check part (d) (end of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel.

3

SEN02135-01

2.

4

Install the high-pressure pipe in the following procedure. 1) Temporarily install high-pressure pipe assembly (12) and tighten its sleeve nuts with the specified torque. a Use a commercially available (knuckle type) torque wrench to tighten nuts with the correct torque. 3 Sleeve nuts on the high-pressure pipe (fuel supply pump side): 39.2 – 49 Nm {4 – 5 kgm} 3 Sleeve nuts on the high-pressure pipe (common rail system side): 39.2 – 58.8 Nm {4 – 6 kgm} 2) Tighten the fuel supply pump assembly mounting bolts. 3) Tighten bracket (15) and mounting bolts (17) and (18) alternately. 3 Mounting bolt (17): 59 – 74 Nm {6.0 – 7.5 kgm} 3 Mounting bolt (18): 19.6 – 29.4 Nm {2.0 – 3.0 kgm} 4) Install lubrication tube (14). 3 Lubrication tube joint bolts: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} 5) Install high-pressure pipe clamps (11) as follows. 1] Tighten both high-pressure pipe clamps (11) and bracket (9) by hand for temporary installation. 2] Tighten clamps (11) permanently. a Tighten the bolts carefully to prevent excessive force to the highpressure tube. 3 Clamp bolts: 9.8 ± 1 Nm {1 ± 0.1 kgm} 3] Tighten bracket (9) permanently. 6) Install 4 rubber covers (10) onto sleeve nuts of high-pressure pipe. a Direct the slit section as follows during installation. q Fuel supply pump side: Downward q Common rail system side: Inward (in opposite direction)

50 Disassembly and assembly

q

Carry out the following installation in the reverse order of removal.

[*1], [*2], [*3] 3 Joint bolts at fuel supply pump side: 14.8 – 19.6 Nm {1.5 – 2.0 kgm} 3 Face seal nut of fuel tube (7) for low-grade fuel specification: 60 – 68 Nm {6.1 – 6.8 kgm} 3 Face seal nut of fuel hose (8) for low-grade fuel specification: 84 – 132 Nm {8.5 – 13.5 kgm} [*4]

3

Joint bolts at filter (top) side of fuel hoses (13): 24.5 – 34.3 Nm {2.5 – 3.5 kgm} 3 Joint bolts at fuel supply pump side: 14.8 – 19.6 Nm {1.5 – 2.0 kgm} a The fuel tube is used instead of fuel hoses (13) in the right bank section.

k

q

Make sure that a clearance of 10 mm minimum is provided between the high-pressure piping and adjacent wiring harness. If not, secure the clearance by adjusting the wiring harness position. Bleeding air Bleed air from the fuel system, referring to “Bleeding air from fuel system” in Testing and adjusting.

PC2000-8

50 Disassembly and assembly

SEN02135-01

Removal and installation of cylinder head assembly

2. 1

Symbol

Part No.

A 1 790-331-1110

Part name

Wrench

Necessity Q'ty New/Remodel Sketch

Special tool

q 1

Disconnect and remove the following primary components, referring to Steps 1 – 37, 44 – 48, and 54 – 68 of "Removal and installation of engine, PTO and hydraulic pump assembly." q Disconnect cable connectors and wiring harnesses of the container assembly. q Engine hood (1) 4

q q q

Removal k k k

1.

Lower the work equipment completely to the ground and stop the engine. Lock the work equipment lock lever. Disconnect the negative terminal (–) of the battery.

q

Muffler and bracket assembly (2) Disconnect hoses around the oil filter. Air hoses between air aftercooler and engine: Total 4 pieces Frame and air cleaner assembly (3)

4

a

Engine hood assembly: 210 kg

Frame and air cleaner assembly: 270kg

Check whether all hose clamps and others are disconnected.

Remove clamp and drain coolant from the hose (1-1). 6

PC2000-8

Coolant: 180 l

5

SEN02135-01

50 Disassembly and assembly

10. Remove cover (9).

3.

Close the fuel valve through the bottom of fuel tank.

4.

Disconnect the right and left air cleaner hoses (4). [*1]

5.

Remove cover (5).

6.

Disconnect connectors P41A, P41B, P41C and P41D from the left, and then disconnect wiring harness (6).

13. Disconnect wiring harnesses (14).

7.

Remove plate (5-1) from the intake manifold.

14. Remove engine controller, cooler and bracket assembly (15). a E: Ground cable

8.

Disconnect wiring harnesses (7).

9.

Disconnect connectors PIM (8-1) and TIM (82).

11. Disconnect fuel hoses (10). a Fuel hose (10-1) faces downward in the right bank section. 12. Disconnect connectors (11), (12) and (13) from sockets of engine controller (EC). [*2]

q

6

Right bank (back side of machine)

PC2000-8

50 Disassembly and assembly

SEN02135-01

21. Remove clamp (16).

Left bank (standard specification) 15. Remove clamp (16).

q

16. Disconnect fuel tubes (17).

22. Disconnect fuel tubes (17). [*3]

[*3]

23. Remove fuel filter assemblies (18).

17. Remove fuel filter assembly (18). 18. Disconnect fuel hose (19).

[*3]

19. Disconnect and remove fuel tube (20).

Right bank (standard specification) 24. Remove the clamp and then remove fuel tubes (21). [*3]

q

25. Disconnect fuel hose (22). Left bank (low-grade fuel specification) 20. Remove fuel tubes (146) and (147).

q

[*3-1]

[*3]

26. Disconnect and remove fuel tube (23).

Right bank (low-grade fuel specification) 27. Remove fuel tubes (148) and (149). [*3-2]

q

28. Remove the clamp and then remove fuel tubes (21). [*3]

PC2000-8

7

SEN02135-01

50 Disassembly and assembly

38. Remove air intake connector (33). [*5] a Remove the RH: electrical intake air heater, too. a Remove the harness clamp.

29. Disconnect wiring harness (24). 30. Remove fuel filter assembly (25). 31. Remove oil tubes (26). 32. Remove oil filter assembly (27). 33. Remove bracket (28). 34. Remove air tube (29). 35. Remove thermal insulation covers (30). 36. Remove stay (31). a Disconnect the harness clamp.

39. Remove spill tube (34).

37. Remove bracket assembly (32).

[*6]

[*4]

40. Remove brackets (35). 41. Remove clamps (36) and (37). 42. Remove high-pressure pipes (38). 43. Remove bracket (39).

8

PC2000-8

50 Disassembly and assembly

44. Remove clamp (40). 45. Remove brackets (41-1) to (41-7) from the bottom of intake manifold.

SEN02135-01

50. Remove intake manifold (47). 4

Intake manifold: 35 kg

46. Remove clamp (42). 47. Remove brackets (43-1) to (43-3) from the top of intake manifold. a Remove the brackets and clamps similarly from the left bank section.

51. Remove exhaust tube (48). 52. Remove bracket (49). 53. Remove exhaust connector (50). 54. Remove exhaust assembly (51).

connector

and

bracket

48. Remove rubber covers (44) and (45). 49. Remove high-pressure pipes (46).

PC2000-8

9

SEN02135-01

55. Remove the following parts and components from the turbocharger (TC) unit. q Lubrication tube (52) q Lubrication drain tube (53) q Coolant tube (54) [*7] q Coolant hose (55) [*7]

50 Disassembly and assembly

59. Lift and remove turbocharger and exhaust manifold assembly (57). 4

Turbocharger and exhaust manifold assembly: 60 kg

60. Remove the external wiring harness of injector. 1) Remove cover plate (58). 2) Disconnect harness connector (59) from each cylinder head, and then remove wiring harness (60). 61. Remove air vent tubes (61) and (62).

[*9]

62. Remove spill tube (63). 63. Remove head cover (64).

56. Remove thermal insulation cover (56). 57. Remove 2 exhaust temperature sensors (57-2) from each exhaust mainfold (57-1).

58. Temporarily lift turbocharger and exhaust manifold assembly (57), and remove the mounting bolts. [*8]

10

PC2000-8

50 Disassembly and assembly

SEN02135-01

64. Removal of rocker arm assembly 1) Loosen locknut (65), and fully loosen adjustment screws (66). a Check that the rocker arm has no valve tension and it is in free status. 2) Remove rocker arm assembly (67). a Record the assembly installation position (cylinder No.) using luggage tag for identification, and place the assembly in storage.

6)

Insert a small L-shaped bar [B] to the bottom of the fuel connector, and then pull out the fuel injector (75) using the leverage. a Do not pull out the solenoid valve section at the top of the fuel injector, using a tool such as pliers.

65. Remove pushrods (68). 66. Remove crosshead (69). 67. Removal of fuel injector 1) Remove injector terminal mounting nuts (70). 2) Remove clamp mounting bolt (71). 3) Remove bolt (71-1) and connector stay (71-2). 4) Push harness connector (72) into the cylinder head, and remove injector harness (73). 5) Remove holder mounting bolt (74).

68. Lift and remove cylinder head assembly (76). 4

a

Cylinder head assembly: 30 kg

When removing the cylinder head assembly with the fuel injector being installed, the top end of injector extends from the cylinder head bottom section. Thus, install appropriate blocks on the floor to prevent interference to the floor surface.

69. Remove the cylinder head gasket. PC2000-8

11

SEN02135-01

Installation

50 Disassembly and assembly a

For retightening, use tool A1 (see Special tools). When not using tool A1, apply a marking to the cylinder head and bolt with a felt pen and then retighten the bolt by 90 – 120° (target is 120°).

a

After tightening the main bolt, apply a punch mark (a) on its head (this mark shall not be applied to a new bolt).

Cylinder head assembly 1.

Install the cylinder head gasket.

2.

Lift and install cylinder head assembly (93). 4

Cylinder head assembly: 30 kg

a

Check the punch mark on the mounting bolt head. If 5 marks are punched, replace it with a new one without using it. a Length of mounting bolts: (1), (2), (4): 166 mm (3), (5), (6): 201 mm a Tighten the mounting bolts in the following order. 2 Cylinder head assembly mounting bolt: Molybdenum disulfide grease (LM-P) 3 Cylinder head assembly mounting bolts (1 – 6): 1st time: 137 – 157 Nm {14 – 16 kgm} 2nd time: 284 – 294 Nm {29 – 30 kgm} 3rd time: 90 – 120° retightening 3 Cylinder head assembly mounting bolts (7): 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

12

PC2000-8

50 Disassembly and assembly

Fuel injector a Check that the inside of the injector sleeve is free from dirt. 2 O-ring: Engine oil (EO30-DH) 3.

Assemble O-rings (77) and (78) to fuel injector (75). a Take care not to install O-rings (78) in groove (A) at the center.

4.

Assemble gasket (79) to fuel injector (75).

5.

Insert fuel injector (75) to cylinder head with injector holder (80).

SEN02135-01

Crosshead 7. Install crosshead (69). 2 Crosshead sliding surface: Engine oil (EO30-DH)

8.

6.

Attach spherical washer (81) to bolt (74) and then tighten injector holder (80) temporarily. 2 Ball washer: Engine oil (EO30-DH) a Tightening of injector holder (80) is done permanently after installing the intake manifold and tightening the high-pressure piping temporarily.

PC2000-8

Adjust the crosshead in the following procedure. 1) Loosen locknut (102) and then loosen adjustment screw (103) to a position where it does not touch valve stem (104). 2) Maintain the contact with valve stem (105) on the push rod side by pressing the contact face against the rocker arm using a finger. 3) Tighten adjustment screw (103) to confirm the position where adjustment screw (103) is contacted against valve stem (104). 4) Drive in adjustment screw (103) further by 20 – 30° from the contacting position against valve stem (104). 5) Tighten locknut (102) while suppressing move of adjustment screw (103). 3 Locknut: 58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}

13

SEN02135-01

9.

Injector harness 1) Push out harness connector (72) from inside to outside of cylinder head, and install injector harness (73) inside of the cylinder head. 2) Tighten injector terminal mounting nuts (70) and clamp mounting bolt (71). a Confirm that there is no dirt on both contact faces. a Tighten injector terminal mounting nuts (70) alternately. 3 Injector terminal mounting nuts: 2 ± 0.2 Nm {0.2 ± 0.02 kgm} a After having tightened the injector terminal mounting nuts, eliminate sag on the wiring harness and secure it to the injector main unit. After installing rocker arm assembly, check the clearance between rocker arm, valve spring and injector harness taking into account that rocker arm lifts.

50 Disassembly and assembly a

Adjust the valve clearance, referring to "Checking and adjusting valve clearance" of Testing and adjusting.

3

a

Locknuts: 52.9 – 64.7 Nm {5.4 – 6.6 kgm} After having tightened the locknut, check the valve clearance again.

10. Install pushrod (68). a Check that the end of pushrod is securely engaged with the holder section of cam follower. 2 Both ends of pushrod: Engine oil (EO30-DH)

12. Install spill tube (63). 3 Joint bolts: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

11. Install the rocker arm assembly. 2 Rocker arm shaft: Engine oil (EO30-DH) 2 Rocker arm assembly mounting bolt threads and washer: Engine oil (EO30-DH) a Check that the ball section of adjustment screw (66) is securely placed in the socket of pushrod. a When tightening the bolt, check that adjustment screw (66) does not press the pushrod. 2 Rocker arm assembly mounting bolts: 93 – 103 Nm {9.5 – 10.5 kgm} a Adjust the valve clearance, and then tighten locknut (65).

14

13. Install head cover (64). (This is necessary to prevent dust insertion into cylinders. Remove the cylinder head cover later.)

PC2000-8

50 Disassembly and assembly

14. Fuel injector and high-pressure piping (Between common rail and fuel injector) k When handling the high-pressure piping and clamp, pay attention to the following. q It is strictly prohibited to bend the high-pressure piping to use it again or use it in other locations. q Install the specified clamp securely in the specified position with the specified torque. q Don't apply lubricant and the like to the high-pressure piping sleeve nut and the threaded portion of the mating side. a Axial force in the tightening can be excessive, potentially damaging the high-pressure piping. k Before installing the high-pressure piping, check it for the following defects. If there is any of these defects, it can c a u s e f u e l l e a k a g e . A c c o r d i n g l y, replace the high-pressure piping. q Check the taper seal of the connecting part (Part (a): Part of 2 mm from the end) for visible lengthwise slit (b) and dent (c). q Check part (d) (end of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel.

PC2000-8

SEN02135-01

1) 2)

3) 4)

5)

Install O-ring (83) on sleeve nut (82). 2 O-ring: Engine oil (EO30-DH) Tighten sleeve nut (82) on fuel injector (75) temporarily. a If it is difficult to mount sleeve nut (82) onto the threads of mount, push the end of sleeve nut (82) toward the injector using the rod. Then rotate the nut using a wrench. Temporarily tighten sleeve nut (84) at the common rail section, too. Tighten and secure injector holder (80) permanently. 3 Injector holder mounting bolt (74): 58.9 – 73.5 Nm {6.0 – 7.5 kgm} Tighten the sleeve nut with the specified torque. a Use a commercially available (knuckle type) torque wrench to tighten nuts with the correct torque. 3 Sleeve nuts on high-pressure pipe (46) at injector side: 39.2 – 49 Nm {4 – 5 kgm} 3 Sleeve nuts on high-pressure pipe (46) at common rail system side: 39.2 – 49 Nm {4 – 5 kgm} a After having tightened the nuts, check that O-rings (77) and (83) do not protrude from sleeve nut (82).

15

SEN02135-01

6)

7)

Install the cylinder head cover. 3 Cylinder head cover mounting bolts: 14.7 – 34.3 Nm {1.5 – 3.5 kgm} Install rubber covers (44) and (45) on the sleeve nuts of high-pressure pipes (46). a Direct the slit section as follows during installation. q Injector side (44): Downward q Common rail system side (45): Toward the cylinder block

50 Disassembly and assembly

16. Install the high-pressure pipe clamp (between the common rail system and fuel injector) in the following procedure. 1) Manually tighten brackets (41-1) to (41-7) and clamp (42) from the bottom of intake manifold for temporary installation. 2) Also, manually tighten brackets (43-1) to (43-3) and clamp from the top of intake manifold for temporary installation. 3) Tighten the top and bottom clamps permanently. 3 Top and bottom clamp bolts: 9.8 ± 1.0 Nm (1.0 ± 0.1 kgm} 4) Tighten brackets (41-1) to (41-7) and (431) to (43-3) permanently. 5) Temporarily tighten clamp (40) and bracket (39), and then tighten them permanently. a Bracket (39): See the figure next page. 3 Mounting bolts for bracket (39): 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} a Install the brackets and clamps similarly in the left bank section.

15. Intake manifold assembly 1) Install the gasket. a Face the side with "UP" mark upward, and install the gasket so that the UP side directs to the intake manifold. a Tighten the mounting bolts in the procedure shown in the figure. 3 Intake manifold mounting bolts: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}

16

PC2000-8

50 Disassembly and assembly

17. High-pressure pipe (between the common rail system and fuel supply pump) a For precaution for installation, refer to "High-pressure pipe (between the common rail system and fuel supply pump)." a Use a commercially available (knuckle type) torque wrench to tighten nuts with the correct torque. 1) Temporarily tighten high-pressure pipes (38), and then tighten it permanently. 3 Sleeve nuts on the high-pressure pipe (common rail system side): 39.2 – 58.8 Nm {4 – 6 kgm} 3 Sleeve nuts on the high-pressure pipe (fuel supply pump side): 39.2 – 49 Nm {4 – 5 kgm} 2) Manually tighten brackets (35) and clamps (36) and (37) for temporary installation. 3) Tighten high-pressure pipe clamps (36) and (37) permanently. 3 High-pressure pipe clamp bolts: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} 4) Tighten high-pressure pipe bracket (35) permanently.

SEN02135-01

q

Carry out the following installation in the reverse order of removal.

[*1]

3

Air cleaner hose clamps: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*2] q

Make sure inside (particularly the bottom) of the controller connector is free from sands, dusts or water. If such foreign substances are present, clean them completely with the air blow. (Sands, dusts or water can cause defect contact or allow commingling of water.)

[*3]

3 3

Fuel tube joint bolts: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Fuel hose joint bolts: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

[*3-1]

3

3

Fuel tube (146) joint bolt and fuel tube (147) upper side joint bolt: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} Fuel tube (147) lower side joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

[*3-2]

3

3

Fuel tube (148) joint bolt and fuel tube (149) upper side joint bolt: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} Fuel tube (149) lower side joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

[*4]

3

Bracket assembly mounting bolts: 49 – 68.6 Nm {5.0 – 7.0 kgm}

[*5]

3

Air intake connector mounting bolts: 49 – 68.6 Nm {5.0 – 7.0 kgm}

[*6]

3

Spill tube joint bolts Cylinder head side: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} Intake manifold side: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}

[*7]

3 3 3

PC2000-8

Turbocharger coolant tube joint bolts (upper side): 24.5 – 34.3 Nm {2.3 – 2.5 kgm} Turbocharger coolant tube sleeve nuts (lower side): 24.5 – 59 Nm {2.3 – 6.0 kgm} Turbocharger coolant hose: 29.4 – 39.2 Nm {3.0 – 4.0 kgm}

17

SEN02135-01

[*8] Exhaust manifold assembly 1) Install the gasket. a Face the side with "OUT" mark to the exhaust manifold during installation. a Tighten the mounting bolts in the procedure shown in the figure. a After having tightened all bolts, retighten them with the same torque. 2 Mounting bolt threads and washer: Seizure prevention compound (LC-G) (NEVER-SEEZ (Bostik, Inc.) or equivalent) 3 Exhaust manifold mounting bolts: 58.8 – 73.6 Nm {6 – 7.5 kgm}

50 Disassembly and assembly

Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant and then confirm the coolant level again.

q

5 k

q

Coolant: 180 l

Make sure that a clearance of 10 mm minimum is provided between the high-pressure piping and adjacent wiring harness. If not, secure the clearance by adjusting the wiring harness position. Bleeding air Bleed air from the fuel system, referring to “Bleeding air from fuel system” in Testing and adjusting.

Reference Turbocharger assembly 2 Turbocharger assembly mounting bolts and nuts: Seizure prevention compound (LC-G) (NEVER-SEEZ (Bostik, Inc.) or equivalent) 3 Turbocharger assembly mounting bolts: 44.1 – 53.9 Nm {4.5 – 5.5 kgm} [*9]

3

18

Air vent tube mounting bolts: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

PC2000-8

50 Disassembly and assembly

Removal and installation of fuel injector

SEN02135-01

5.

Remove rear covers (4). a SWB: Rear side of emergency engine stop switch

6.

Disconnect connector A07 (100) at the rear of front side of emergency engine stop switch (SWF).

7.

Remove front covers (5). a SWF: Front side of emergency engine stop switch

8.

Remove top covers (6) and (7).

9.

Disconnect connector (8) and ground connector TM1 (9) from the inside of rear side of emergency engine stop switch (SWB).

1

Removal k k k

a

1.

Lower the work equipment completely to the ground and stop the engine. Lock the work equipment lock lever. Disconnect the negative terminal (–) of the battery. Clean around cylinder head covers and remove dust completely using air blow, brake cleaner and so on. Remove clamp and drain coolant from the hose (1-1). (Because of disconnecting turbocharger coolant hose, see item 40.) 6

Coolant: 180 l

2.

Close the fuel valve through the bottom of fuel tank.

3.

Remove air cleaner top cover (1).

4.

Remove clamps (2), and disconnect 2 tubes (3). [*1]

PC2000-8

19

SEN02135-01

10. Disconnect connector L05B (10) from the bottom of SWB.

11. Lift and remove engine hood assembly (12). 4

Engine hood assembly: 210 kg

50 Disassembly and assembly

13. Disconnect air cleaner hose (22).

[*2]

14. Loosen hose clamps (23). [*3] a Apply a marking to the hose end and tube so that their original insertion positions may be identified in later reference. (See the following figure.) 15. Loosen clamps from clamp bracket (24). 16. Loosen 2 tube clamps (25).

[*4]

17. Disconnect 2 tubes (26). a Disconnect the tubes from the opposite side, too.

12. Remove clip (19) and disconnect muffler drain hoses (20). a Remove the stay from rear side, too.

20

PC2000-8

50 Disassembly and assembly

SEN02135-01

18. Remove stay (27). a Disconnect the harness clamp.

Left bank (low-grade fuel specification) 25. Remove fuel tubes (146) and (147).

q

[*5-1]

19. Remove thermal insulation covers (28).

Left bank (standard specification) 20. Remove clamp (29).

q

21. Disconnect fuel tubes (30).

[*5]

22. Remove fuel filter assembly (31). 23. Disconnect fuel hose (32).

[*5]

24. Disconnect fuel tube (33). 26. Remove clamp (29). 27. Disconnect fuel tubes (30).

[*5]

28. Remove fuel filter assemblies (31).

PC2000-8

21

SEN02135-01

50 Disassembly and assembly

Right bank 29. Remove clamps and disconnect fuel tube (34). [*5] 30. Disconnect fuel hose (35). (Standard specification only) [*5]

q

39. Remove bracket assembly (43).

[*6]

31. Disconnect fuel tube (36). (Standard specification only) 32. Remove fuel tubes (148) and (149). (Low-grade fuel specification only)

[*5-2]

33. Disconnect wiring harness (37). 34. Remove fuel filter assembly (38). 35. Remove oil tubes (39). 36. Remove oil filter assembly (40). 4

40. Disconnect turbocharger coolant hose (150) connection and remove bracket bolt (151). (Both banks) [*8]

Oil filter assembly: 50 kg

37. Remove brackets (41). 38. Disconnect air tube (42).

41. Remove air intake connector (44). [*7] a Remove the RH: electrical intake air heater with together. a Remove the harness clamp. a

Low-grade fuel specification around filter assembly (38).

42. Remove brackets (45). 43. Remove clamp (47). 44. Disconnect high-pressure pipes (48). 45. Remove bracket (49).

22

PC2000-8

50 Disassembly and assembly

SEN02135-01

50. Remove rubber covers (54) and (55). 51. Remove high-pressure pipes (56).

46. Remove clamp (50). 47. Remove bolts of brackets (51-1) to (51-7) from the bottom of intake manifold. 48. Remove clamps (52). 49. Remove brackets (53-1) to (53-3) from the top of intake manifold. a Remove the brackets and clamps similarly from the left bank section.

PC2000-8

52. Disconnect the external wiring harness of injector. 1) Remove cover plate (58). 2) Disconnect harness connector (59) from each cylinder head, and then remove wiring harness (60). 53. Remove head cover (61).

23

SEN02135-01

54. Removal of rocker arm assembly 1) Loosen locknut (65), and fully loosen adjustment screws (66). a Check that the rocker arm has no valve tension and it is in free status. 2) Remove rocker arm assembly (67). a Record the assembly installation position using luggage tag for identification, and place the assembly in storage.

50 Disassembly and assembly

4)

Insert a small L-shaped bar [B] to the bottom of the fuel connector, and then pull out the fuel injector (75) using the leverage. a Do not pull out the solenoid valve section at the top of the fuel injector, using a tool such as pliers.

55. Removal of fuel injector 1) Remove injector terminal mounting nuts (70). 2) Remove clamp mounting bolt (71). 3) Remove holder mounting bolt (74).

24

PC2000-8

50 Disassembly and assembly

Installation Fuel injector a Check that the inside of the injector sleeve is free from dirt. 2 O-ring: Engine oil (EO30-DH) 1.

Assemble O-rings (77) and (78) to fuel injector (75). a Take care not to install O-rings (78) in groove (A) at the center.

2.

Assemble gasket (79) to fuel injector (75).

3.

Insert fuel injector (75) to cylinder head with injector holder (80).

4.

Attach spherical washer (81) to bolt (74) and then tighten injector holder (80) temporarily. 2 Ball washer: Engine oil (EO30-DH) a Tightening of injector holder (80) is done permanently after installing the intake manifold and tightening the high-pressure piping temporarily.

SEN02135-01

5.

Injector harness 1) Push out harness connector (72) from inside to outside of cylinder head, and install injector harness (73) inside of the cylinder head. 2) Tighten injector terminal mounting nuts (70) and clamp mounting bolt (71). a Clean the contact face of the terminal. a Tighten injector terminal mounting nuts (70) alternately. 3 Injector terminal mounting nuts: 2 ± 0.2 Nm {0.2 ± 0.02 kgm} a After having tightened the injector terminal mounting nuts, eliminate sag on the wiring harness and secure it to the injector main unit.

a

PC2000-8

After installing rocker arm assembly, check the clearance between rocker arm, valve spring and injector harness taking into account that rocker arm lifts.

25

SEN02135-01

6.

Install the rocker arm assembly. a Check that the ball section of adjustment screws (66) is securely placed in the socket of pushrod. a When tightening the bolt, check that adjustment screws (66) do not press the pushrod. 2 Rocker arm shaft: Engine oil (EO30-DH) 2 Rocker arm assembly mounting bolt threads and washer: Engine oil (EO30-DH) 2 Rocker arm assembly mounting bolts: 93 – 103 Nm {9.5 – 10.5 kgm} a Adjust the valve clearance, and then tighten locknut (65). a Adjust the valve clearance, referring to "Checking and adjusting valve clearance" of Testing and adjusting.

50 Disassembly and assembly

8.

Fuel injector and high-pressure piping (Between common rail and fuel injector) k When handling the high-pressure piping and clamp, pay attention to the following. q It is strictly prohibited to bend the high-pressure piping to use it again or use it in other locations. q Install the specified clamp securely in the specified position with the specified torque. q Don't apply lubricant and the like to the high-pressure piping sleeve nut and the threaded portion of the mating side. a Axial force in the tightening can be excessive, potentially damaging the high-pressure piping. k Before installing the high-pressure piping, check it for the following defects. If there is any of these defects, it can c a u s e f u e l l e a k a g e . A c c o r d i n g l y, replace the high-pressure piping. q Check the taper seal of the connecting part (Part (a): Part of 2 mm from the end) for visible lengthwise slit (b) and dent (c). q Check part (d) (end of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel.

3

a

7.

26

Locknuts: 52.9 – 64.7 Nm {5.4 – 6.6 kgm} After having tightened the locknut, check the valve clearance again.

Install cylinder head cover. (This is necessary to prevent dust insertion into cylinders. Remove the cylinder head cover later.)

PC2000-8

50 Disassembly and assembly

1) 2)

3) 4)

5)

Install O-ring (83) on high-pressure pipe sleeve (82). 2 O-ring: Engine oil (EO30-DH) Tighten sleeve nut (82) on fuel injector (75) temporarily. a If it is difficult to mount sleeve nut (82) onto the threads of mount, push the end of sleeve nut (82) toward the injector using the rod. Then rotate the nut using a wrench. Temporarily tighten sleeve nut (84) at the common rail section, too. Tighten and secure injector holder (80) permanently. 3 Injector holder mounting bolt (74): 58.9 – 73.5 Nm {6.0 – 7.5 kgm} Tighten the sleeve nut with the specified torque. a Use a commercially available (knuckle type) torque wrench to tighten nuts with the correct torque. 3 Sleeve nuts on high-pressure pipe (46) at injector side: 39.2 – 49 Nm {4 – 5 kgm} 3 Sleeve nuts on high-pressure pipe (46) at common rail system side: 39.2 – 49 Nm {4 – 5 kgm} a After having tightened the nuts, check that O-rings (77) and (83) do not protrude from sleeve nut (82).

PC2000-8

SEN02135-01

6)

7)

9.

Install the cylinder head cover. 3 Cylinder head cover mounting bolts: 14.7 – 34.3 Nm {1.5 – 3.5 kgm} Install rubber covers (54) and (55) on the sleeve nuts of high-pressure pipes (56). a Direct the slit section as follows during installation. q Injector side (54): Downward q Common rail system side (55): Toward the cylinder block

Install the high-pressure pipe clamp (between the common rail system and fuel injector) in the following procedure. 1) Manually tighten brackets (51-1) to (51-7) and clamps (52) from the bottom of intake manifold for temporary installation. 2) Also, manually tighten brackets (53-1) to (53-3) and clamp from the top of intake manifold for temporary installation. 3) Tighten the top and bottom clamps permanently. 3 Top and bottom clamp bolts: 9.8 ± 1.0 Nm (1.0 ± 0.1 kgm} 4) Tighten brackets (51-1) to (51-7) and (531) to (53-3) permanently. 5) Temporarily tighten clamp (50) and bracket (49), and then tighten them permanently. a Bracket (49): See the figure below. 3 Mounting bolts for bracket (49): 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} a Install the brackets and clamps similarly in the left bank section.

27

SEN02135-01

50 Disassembly and assembly

4)

Tighten high-pressure pipe bracket (45) permanently.

10. High-pressure pipe (between the common rail system and fuel supply pump) a For precaution for installation, refer to "High-pressure pipe (between the common rail system and fuel supply pump)." a Use a commercially available (knuckle type) torque wrench to tighten nuts with the correct torque. 1) Temporarily tighten high-pressure pipes (48), and then tighten them permanently. 3 Sleeve nuts on the high-pressure pipe: 39.2 – 49 Nm {4 – 5 kgm} 2) Manually tighten brackets (45) and clamps (46) and (47) for temporary installation. 3) Tighten high-pressure pipe clamps (46) and (47) permanently. 3 High-pressure pipe clamp bolts: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}

28

PC2000-8

50 Disassembly and assembly

q

Carry out the following installation in the reverse order of removal.

[*5]

3 3

[*1]

3

SEN02135-01

Komaclone tube assembly hose clamps: 5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}

Fuel tube joint bolts: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Fuel hose joint bolts: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

[*5-1]

3

[*2]

3

Air cleaner hose clamps: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*3] Suction hose clamp a Use new MIKALOR clamp. 1) Align the hose to the original position (marked position). (Air hose insertion depth: Min. 80 mm) 2) Place the bridge (BR) under the clamping bolt and adjust the overlapping (b) between the bridge (BR) and band to 5 mm minimum. (b) dimension: Min. 5 mm 3) Tightening of the clamp 2 Threaded portion (BC) of clamping bolt: Lubricant (PANDO 18B from ThreeBond) a Never use an impact wrench. a Displace the tightening positions of the adjacent clamps by 180°. When the current hose is reused Align the clamp position to the trace of the clamp left on the hose. 3 Clamping bolt: Min. 6 Nm {0.6 kgm}

3

Fuel tube (146) joint bolt and fuel tube (147) upper side joint bolt: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} Fuel tube (147) lower side joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

[*5-2]

3

3

Fuel tube (148) joint bolt and fuel tube (149) upper side joint bolt: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} Fuel tube (149) lower side joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

[*6]

3

Bracket assembly mounting bolts: 49 – 68.6 Nm {5.0 – 7.0 kgm}

[*7]

3

Air intake connector mounting bolts: 49 – 68.6 Nm {5.0 – 7.0 kgm}

q

q

When a new hose is used Tighten the bolt until BDG dimension meets the following. BDG: 17 – 20 mm

[*8]

3

Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant and then confirm the coolant level again.

q

5 k

q

Turbocharger coolant hose: 29.4 – 39.2 Nm {3.0 – 4.0 kgm}

Coolant: 180 l

Make sure that a clearance of 10 mm minimum is provided between the high-pressure piping and adjacent wiring harness. If not, secure the clearance by adjusting the wiring harness position. Bleeding air Bleed air from the fuel system, referring to “Bleeding air from fuel system” in Testing and adjusting.

[*4]

3

Air tube clamp: 21 Nm {2.55 kgm}

PC2000-8

29

SEN02135-01

50 Disassembly and assembly

Removal and installation of engine front seal

7.

Apply counter mark (E) on the damper and on the front cover assembly. a Be sure to apply the counter mark as the pointer is shown on the damper.

8.

Lift and remove damper and clamp pulley assembly (7). [*2]

1

Symbol

Part No.

3 790-331-1100

A

Part name

Seal puller assembly

Necessity Q'ty New/Remodel Sketch

Special tools

t 1

795T-621-1430 Plate

t 1 N Q

795T-621-1440 Push tool

t 1 N Q

4 01050-32240

• Bolt

t 3

01050-32225

• Bolt

t 3

01640-02232

• Washer

t 3

4

9.

Damper and clamp pulley assembly (7): 75 kg

Remove front seal (8) in the following procedure.

Removal k k k

1.

2.

Lower the work equipment completely to the ground and stop the engine. Lock the work equipment lock lever. Disconnect the negative terminal (–) of the battery. Remove the radiator cooling assembly, referring to "Removal and installation of cooling assembly." Loosen adjustment nut (2) of air conditioner compressor (1). a Repeat this step for both of air conditioner compressors.

3.

Remove cover (3).

4.

Loosen the mounting bolts of air conditioner compressor bracket (4).

5.

Remove air conditioner compressor belts (5). [*1]

6.

Remove bracket (6).

30

1) 2) 3)

q

Replace the tip of tool A3 with the hook type one. Hitch the hook to the hoop of front seal (8). Remove front seal with impact of slide hammer (SH). Tool A3

PC2000-8

50 Disassembly and assembly a

CS: Crankshaft

PC2000-8

SEN02135-01

Installation 1.

Clean, degrease and then dry the contact surface between the front cover and front seal.

2.

Using a clean cloth, remove foreign matter deposited on the crankshaft flange. a Clean foreign matter deposited on the seal lip surface (surface around the crankshaft) and then degrease and dry the surface. a Check the crankshaft end face corner and lip siding surface for scratches due to the housing, burrs or rusts.

3.

Install front oil seal (8) according to the following procedure. a Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing. a When installing the seal, do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. 1)

The surface having the parts number (PN) marking must face to the outside of engine.

2)

Tighten bolts using the tool A4 (plate), and press oil seal (8) to the shaft end.

31

SEN02135-01

3)

q

Using the A4 (push tool), press oil seal (8) in the front case until it becomes the dimension (a) as shown in the figure. a Oil seal press fit dimensions (a): 17 mm (from shaft end surface) (b): 25.1 mm (from front cover end surface)

50 Disassembly and assembly

[*2] Installation of damper and crankshaft pulley assembly 1) Install the damper and crankshaft pulley assembly by aligning it to the crankshaft dowel pin. 2) Tighten each mounting bolt 3 times in the procedure shown in the figure. 2 Damper and crankshaft pulley a s s e mb l y mo u n t i n g b o l ts a n d washers: Engine oil (EO30-DH) 3 Damper and crankshaft pulley assembly mounting bolts 1st time: 73.5 ± 19.6 Nm {7.5 ± 2.0 kgm} 2nd time: 245 ± 19.6 Nm {25 ± 2.0 kgm} 3rd time: 744.8 ± 19.6 Nm {76 ± 2.0 kgm}

Carry out the following installation in the reverse order of removal.

[*1] q

Adjust the tension of the air conditioner compressor belt tension, referring to "Adjusting air conditioner compressor belt tension" in Testing and adjusting. a

When the damper and crankshaft pulley have been disassembled, reassemble them by tightening their mounting bolts in the procedure shown in the figure. 2 Damper mounting bolts and washers: Engine oil (EO30-DH) 3 Damper mounting bolts: 98 – 122 Nm {10.0 – 12.5 kgm}

32

PC2000-8

50 Disassembly and assembly

SEN02135-01

Removal and installation of engine rear seal

1

Symbol

Part No.

3 790-331-1110

Part name

Seal puller assembly

795T-621-1540 Push tool

A

5 01050-32060 01640-02032

Necessity Q'ty New/Remodel Sketch

Special tools

t 1 t 1 N Q

• Bolt

t 5

• Washer

t 5

7.

Removal k k

k k

1.

Lower the work equipment completely to the ground and stop the engine. Loosen the hydraulic tank cap gradually to release the inside pressure of the hydraulic tank. Lock the work equipment lock lever. Disconnect the negative terminal (–) of the battery. Drain the hydraulic oil. 6

Hydraulic tank: 1,300 l

2.

Remove engine, PTO and hydraulic pump assembly referring to "Removal and installation of engine, PTO and hydraulic pump assembly".

3.

Remove PTO assembly referring to "Removal and installation of PTO assembly".

4.

Disconnect wiring harness (1-1) of rotation sensor (1-2) from its connector.

5.

Remove rotation sensor (1-2).

6.

Flywheel assembly 1) Lift and hold flywheel assembly (1). 2) Remove the mounting bolts. 3) Using forcing screws [1], separate the flywheel from the crankshaft. 4) Lift and remove flywheel assembly (1) . [*2] 4

PC2000-8

Remove rear seal (2). a Take care in the removal not to damage the seal installation position on the flywheel housing and the seal contact face on the crankshaft. a Before removing, slightly drive the seal in once to free it from fixation. a When rear seal (2) is fixed too hard to the flywheel housing (FWH), carry out the following procedure. 1) Replace the tip of tool A3 with the drill type one. 2) Drill through a hole of approx. 3 mm dia. on rear seal (2). 3) Insert the top end of tool A3 into the drilled hole, and remove the rear seal by the impact of slide hammer (SH). (Apply the slide hammer evenly not to tilt the rear seal.) a Remove the metal powders completely. a When the sleeve is attached, cut sleeve (5) using a gad and hammer to remove it. a Take care not to damage crankshaft (4).

[*1]

Flywheel assembly: 130 kg

33

SEN02135-01

q

Tool A3

50 Disassembly and assembly

Installation 1.

Rear seal (2) a Check the Teflon seal (Laydown lip seal) by checking the wear of the shaft and replace it with the “Standard seal” or “Sleeved seal”. a When wear on the shaft is not serious and only makes it look lustrous (depth of wear is 10 mm or less when checked with finger cushion) and no scratch is recognized, assemble the standard seal (A). When the above is not applicable, assemble sleeved seal (B). a (5): Shows the sleeve. a Handle rear seal (2) and sleeve (5) as an integral part. Don't try to separate them.

a a a

34

Clean, degrease and then dry the contact surface between the flywheel housing and rear seal. Clean foreign matter deposited on the seal lip surface (surface around the crankshaft) and then degrease and dry the surface. Check the crankshaft end face corner and lip siding surface for scratches due to the housing, burrs or rusts.

PC2000-8

50 Disassembly and assembly

2.

Installation procedure of standard seal a Do not apply any grease, oil and others to the seal lip surface. 1) Apply rear seal (2) on the end of crankshaft (4). a Install the rear seal in the correct direction. 2) Manually push the metal ring of rear seal (2) evenly, and insert in its position. 3) Using the tool A5, further press and insert rear seal (2) evenly.

4)

Using the tool A5, press rear seal (2) by tightening bolts equally. a Press rear seal (2) until tool A5 reaches crankshaft (4). q Press fit method of oil seal (from flywheel housing end surface) (a): 13.5 mm q Press fit method of oil seal (from crankshaft end surface) (b): 25.7 mm a After having pressed the rear seal, remove the red sealant form outer edge.

PC2000-8

SEN02135-01

3.

Installation procedure of seal having sleeve a Do not apply any grease, oil and others to the seal lip surface. 1) Apply sleeve (5) of rear seal (2) on the end of crankshaft (4). a Install the rear seal in the correct direction. 2) Manually push the sleeve (5) of rear seal (2) evenly, and insert in its position. 3) Using the tool A5, further press and insert rear seal (2) evenly.

4)

Using the tool A5, press rear seal (2) by tightening bolts equally. a Tool A5 presses both the metal ring and sleeve (5) of rear seal (2) simultaneously. a Press rear seal (2) until tool A5 reaches crankshaft (4). q Press fit method of oil seal (from flywheel housing end surface) (a): 13.5 mm q Press fit method of oil seal (from crankshaft end surface) (b): 25.7 mm a After having pressed the rear seal, remove the red sealant form outer edge.

35

SEN02135-01

q

50 Disassembly and assembly

5)

Carry out the following installation in the reverse order of removal.

[*1] Engine speed sensor a Tighten the mounting bolt until the sensor end contacts the ring gear teeth of flywheel. Then, return the bolt for 3/4 to 1 turn, and tighten the locknut. 3 Engine speed sensor locknut: 49.0 – 68.6 Nm {5 – 7 kgm}

After having installed the flywheel assembly, check for its facial runout and radial runout using dial gauge [2]. Standard value for facial runout: Max. 0.25 mm Standard value for radial runout: Max. 0.25 mm

[*2] Flywheel assembly a Install the flywheel assembly by aligning it to the crankshaft dowel pin. a After having tightened the mounting bolts, mount plate [1] between the flywheel and the flywheel housing so that the crankshaft does not rotate. 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. 5

Hydraulic tank (Hydraulic tank refill oil capacity): Approx. 1,300 l

a

Tighten the mounting bolts in the procedure shown in the figure. 2 Flywheel assembly mounting bolts: Engine oil (EO30-DH) 3 Flywheel assembly mounting bolts 1st time: 98 ± 19.6 Nm {10 ± 2 kgm} 2nd time: 294 ± 19.6 Nm {30 ± 2 kgm} 3rd time: 539 ± 19.6 Nm {55 ± 2 kgm}

36

PC2000-8

50 Disassembly and assembly

PC2000-8

SEN02135-01

37

SEN02135-01

PC2000-8 Hydraulic excavator Form No. SEN02135-01

© 2007 KOMATSU All Rights Reserved Printed in Japan 04-07 (01)

38

SEN02136-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

50 Disassembly and assembly

1

Power train Power train...................................................................................................................................................... 2 Removal and installation of PTO assembly.......................................................................................... 2 Disassembly and assembly of PTO assembly ..................................................................................... 3 Removal and installation of swing motor and swing machinery assembly........................................... 7 Disassembly and assembly of swing machinery assembly.................................................................. 9 Removal and installation of swing circle assembly ............................................................................ 19 Removal and installation of final drive assembly ............................................................................... 20 Disassembly and assembly of final drive assembly ........................................................................... 22

PC2000-8

1

SEN02136-00

50 Disassembly and assembly

Power train Removal and installation of PTO assembly

1

1

Removal 1.

Remove engine, PTO and hydraulic pump assembly, referring to "Removal and installation of engine, PTO and hydraulic pump assembly."

2.

Remove hydraulic pump assembly, referring to "Removal and installation of hydraulic pump assembly."

3.

Drain oil in the PTO case (lubricating oil). 6

7.

Lift PTO assembly (1) temporarily.

8.

Remove 32 mounting bolts (2).

9.

Lift and remove PTO assembly (1). 4

[*1]

PTO assembly: 1,100 kg

Amount of lubricating oil: 36 l

4.

Disconnect connector (11).

5.

Disconnect clips (12).

6.

Disconnect hose (13).

10. Lift and remove output shaft (3). 11. Remove coupling (4).

[*2]

12. Remove plate (5).

[*3]

Installation q

Carry out installation in the reverse order to removal.

[*1]

3

Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

[*2], [*3] 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}

2

PC2000-8

50 Disassembly and assembly

Disassembly and assembly of PTO assembly

SEN02136-00 a 1

1.

Remove engine output shaft (1) if it is installed to the PTO assembly (2) side instead of the engine side.

2.

Lay down PTO assembly (2) on the block [1] with the pump side up. 4

3.

The gear and bearing assemblies (5) and (15) may be either remain on the case side or removed with the covers. In the latter case, take care not to let the gear and bearing assembly (15) drops during removal.

PTO assembly: 1,100 kg

Using forcing screws, lift and remove cage assemblies (3) and (4).

PC2000-8

4.

Using bar [2], lift and remove gear and bearing assembly (5).

5.

Using forcing screws [3], lift and remove cage assembly (6).

3

SEN02136-00

6.

Turn over PTO case assembly (7).

50 Disassembly and assembly

10. Using puller [4], remove gear and bearing assembly (11) from the cage assembly (8). 11. Remove snap ring (12) from the gear and bearing assembly (11), and then remove bearing inner race (13).

7.

Remove mounting bolts of the cage assembly (8). Using forcing screws on (B), remove cage assembly. 12. Using puller [4], remove gear and bearing assembly (14) from the cage assembly (6). Remove gear and bearing assembly (15) from the cage assembly (4) in the same manner.

8.

Lift and remove cage assembly (8).

9.

Remove snap ring (9) and remove bearing (10).

4

PC2000-8

50 Disassembly and assembly

13. Using puller [5], remove bearings (16) from gear and bearing assemblies (5), (14) and (15) respectively. a Bearings are installed in both sides of the gear. 14. Remove bearing assembly (17) from the gear and bearing assembly (11) in the same manner.

PC2000-8

SEN02136-00

Assembly 1. Using push tool [6], press bearing assemblies (16) on both sides of the gears (5), (14) and (15) respectively. 2.

Press bearing assembly (17) to the gear (11) in the same manner.

3.

Install bearing inner race (13) and snap ring (12) to the gear and bearing assembly (11).

4.

Install gear and bearing assembly (11) to the cage (8). a Insert push tool [7] to the hole (A), and fit bearing outer races by tapping in.

5

SEN02136-00

5.

Install gear and bearing assembly (14) to the cage (6). a Insert push tool [8] to the hole (AA), and fit bearing outer races by tapping in.

50 Disassembly and assembly

9.

Turn over PTO assembly (7).

10. Install cage assembly (6) using guide bolt [9]. 6.

Install gear and bearing assembly (5) to the cage (3). a Insert push tool [8] to the hole (AAA), and fit bearing outer races by tapping in.

7.

Fit gear and bearing assembly (15) by tapping in to the cage (4) in the same manner.

11. Install cage assemblies (3) and (4) using guide bolt [9].

8.

6

Install cage assembly (8). 2 Mounting bolt: Liquid adhesive (LT-2) 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}

PC2000-8

50 Disassembly and assembly

SEN02136-00

Removal and installation of swing motor and swing machinery assembly 1

6.

Removal k k

k

a

Lift and remove swing motor and swing machinery assembly (8). a When removing the assembly, take care that they will not interfere with adjacent hoses. 4

Lower the work equipment completely to the ground. Release remaining pressure in hydraulic circuit, referring to "Releasing remaining pressure in hydraulic circuit" in Testing and adjusting. Set steering lock lever to lock position.

Swing motor and swing machinery assembly: 1,200 kg

Two swing motor and swing machinery assemblies are used (front and rear).

Front side 1. Remove 6 work equipment hoses (1).

Rear side 7. Disconnect connector BV1 (9) (mating part: V19).

2.

Disconnect hoses (2) to (4). a Fasten tags to hoses to identify them for reinstallation.

3.

Disconnect drain hose (5) from the bracket.

4.

Remove step (6).

5.

Remove 14 mounting bolts (7).

8.

Disconnect 2 hoses (10). a Fasten tags to hoses to identify them for reinstallation.

9.

Remove filter and bracket assembly (11).

10. Disconnect hose (12). a SM: Swing motor and swing machinery assembly - behind

[*1]

q

PC2000-8

For further removal steps, refer to Step 2 to 6 in the front side.

7

SEN02136-00

50 Disassembly and assembly

Installation q

Carry out installation in the reverse order to removal.

[*1]

3

Mounting bolt: 1,520 – 1,910 Nm {155 – 195 kgm}

q

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.

q

Bleeding air Bleed air referring to the section Testing and adjusting, "Bleeding air from each part".

8

PC2000-8

50 Disassembly and assembly

SEN02136-00

Disassembly and assembly of swing machinery assembly

3.

Cover Lift cover (4) and remove it using forcing screws [1].

4.

No. 1 sun gear 1) Remove thrust washer (5). 2) Remove No. 1 sun gear (6).

5.

No. 1 carrier assembly 1) Pass wires over the carrier case, and then lift and remove carrier assembly (7).

1

Symbol

Part No.

790-101-5621 F

1 790-101-5641 01010-51240

Part name

Necessity Q'ty New/Remodel Sketch

Special tools

Plate

t 1

Grip

t 1

Bolt

t 1

2 796T-626-1120 Push tool

t 1

Q

Disassembly 1.

Remove swing motor assembly (100) from swing machinery assembly (101). 4

2.

Swing motor assembly: 210 kg

Oil filler port Remove bracket (1), and then remove oil filler port (2) and breather tube (3). a Breather tube is provided only for front machinery.

PC2000-8

9

SEN02136-00

2)

Disassemble No. 1 carrier assembly by the following procedure. 1] Drive pin (8) into the shaft (9). 2] Drive out shaft (9) upward to remove it. 3] Pull out pin (8) from the shaft (9).

50 Disassembly and assembly

7.

No. 2 sun gear 1) Remove No. 2 sun gear (15).

2)

4]

Pull out gear (10) from the carrier (11), and remove thrust washer (12) and bearing (13).

8.

6.

10

Remove thrust washer (16), ball (17) and holder (18) from the No. 2 sun gear (15).

No. 2 carrier assembly 1) Pass wires over the carrier case, and then lift and remove carrier assembly (19).

No. 1 ring gear Remove No. 1 ring gear (14).

PC2000-8

50 Disassembly and assembly

2)

Disassemble No. 2 carrier assembly by the following steps. 1] Drive pin (20) into the shaft (21). 2] Drive out shaft (21) downward to remove it. 3] Pull out pin (20) from the shaft (21).

SEN02136-00

9.

Cover Remove 28 bolts (102), and then lift and remove cover (27).

10. No. 2 ring gear Remove No. 2 ring gear (28). 4]

Pull out gear (22) from the carrier (23), and remove thrust washer (24) and bearing (25).

11. Hub 1) Remove bolt (29). 2) Remove plate (30). 3) Remove hub (31). 5]

PC2000-8

Remove thrust washer (26).

11

SEN02136-00

12. Pinion shaft assembly When pulling out from the outer race side, observe the following procedure. 1) Remove mounting bolts of the cover assembly (32).

50 Disassembly and assembly

5)

6)

7)

2)

3)

4)

Apply case body (33) to the block [2] and set it on the press. a Adjust the block height so that the pinion-to-press clearance is approx. 150 mm. Drive out pinion shaft (34) by pressing it down. a The outer race comes off from the lower bearing (35) and the inner race comes off from the upper bearing (36). a Since the spherical bearing is used here, do not hold the press down constantly but release it occasionally. Remove spacer (37).

8)

Place the bolt hole of the cover assembly (32) to the block [3] and set it on the press. a Adjust the block height so that the pinion-to-press clearance is approx. 150 mm. Drive out the bearing (35) by pressing pinion shaft (34). a Press the pinion shaft straight to prevent the shaft from tilting. Remove cover assembly (32) from the pinion shaft (34).

Remove oil seal (39) from the cover (38).

13. Bearing 1) Remove bearing (36) from the case body (33).

12

PC2000-8

50 Disassembly and assembly

2)

When pulling out from the inner race side, observe the following procedure. 1] Apply cover assembly (32) to the block [4] and set it on the press. a Adjust the block height so that the pinion-to-press clearance is approx. 150 mm. 2] Drive out pinion shaft (34) by pressing it down. a The inner races come off from both the bearings (35) and (36). 3] Remove spacer (37).

4] 5]

PC2000-8

Remove cover assembly (32). Remove bearings (35) and (36) from the case body (33).

SEN02136-00

Assembly a a

a 1.

Before assembly, clean the parts, check for dust or defect, and apply engine oil on the sliding parts. Do not reuse the bearing because the track surface of the bearing can be damaged when excessive thrust load is applied during disassembly. Do not reuse the oil seal, too. It can be deformed during disassembly. Bearing 1) Perform expansion fit or use the press for bearing (35) to install the case body (33).

2)

Using tool F1, press oil seal (39) to the cover (38). 2 Oil seal outside perimeter: Gasket sealant (LG-6) 2 Oil seal lip: Grease (G2-LI)

13

SEN02136-00

3)

2.

14

Install cover assembly (32) by aligning its oil groove with the drill hole (drain port) of the case body (33). a Be careful not to let the gasket sealant run over the drain port when applying it. 2 Cover mounting face: Gasket sealant (LG-6) 3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}

50 Disassembly and assembly

3.

Wheel hub 1) Using tool F2, press bearing (36). Dimension (b) shall be 1 to 2 mm. a Press bearing by pressing both the inner and outer races simultaneously. Do not press the inner race only. a After press fitting, check that the case rotates smoothly.

4.

Hub 1) Install hub (31). 2) Install plate (30). 3) Tighten bolt (29). 2 Mounting bolt: Liquid adhesive (LT-2) 3 Mounting bolt: 343 – 427 Nm {35 – 43.5 kgm}

5.

No. 2 carrier assembly 1) Assemble No. 2 carrier assembly by the following steps. 1] Install thrust washer (26).

Pinion shaft assembly 1) Place spacer (37) on the push tool [5], and set case body (33). a Adjust the case-to-press clearance (a) for 1 to 2 mm. 2) Make sure the spacer (37) is correctly positioned. Set pinion shaft (34) and press bearing (35) using the press. a Make sure that the seal lip contact surface of the shaft comes to the center to prevent it from tilting.

PC2000-8

50 Disassembly and assembly

SEN02136-00

a a

However the thinner areas vary depending on individual carrier. Always check the area before installation. Caulk the pin area (arrow mark) of the carrier after having installed the pin. After having assembled the carrier assembly, check that the gear (22) rotates smoothly.

a

2]

3]

4]

PC2000-8

The trace of caulking is left on the end surface of the side hole (h) when the pin was installed previously. Correct the shape (protrusion) of the inner diameter before installation. Assemble bearing (25) on the gear (22), attach thrust washers (24) on both sides, and place gear assembly to the carrier (23).

Align the pin holes of the shaft (21) to that of carrier (23), and then drive in the shaft by lightly tapping with a plastic hammer. a Install shaft as rotating the planetary gear. Use care not to damage the thrust washers. Insert pin (20). a Check the pin for deformation on the pin groove or protrusion, and replace if defective. a Do not locate the pin at the same position where it was caulked previously. a When installing the pin, be careful that the claws (b) at 3 locations on the circumference do not overlap with the areas (c) where the carrier is thinner than other areas.

2)

Pass wires over the carrier case, and then lift and install the carrier assembly (19) by aligning with the gear of the hub.

15

SEN02136-00

6.

50 Disassembly and assembly

2)

No. 2 ring gear Install No. 2 ring gear (28). 2 Mounting face with case: Gasket sealant (LG-6)

9. 7.

Cover 1) Install cover (27) by aligning the oil groove of the oil filler port with the protrusion of the case body. 2 Mounting face with No. 2 ring gear: Gasket sealant (LG-6) 2) Tighten 28 bolts (102).

8.

No. 2 sun gear 1) Install thrust washer (16), ball (17) and holder (18) to the No. 2 sun gear (15).

No. 1 carrier assembly Assemble No. 1 carrier assembly in the following procedure. a The trace of caulking is left on the end surface of the side hole (h) when the pin was installed previously. Correct the shape (protrusion) of the inner diameter before installation. 1) Assemble bearing (13) on the gear (10), attach thrust washers (12) on both sides, and place gear assembly to the carrier (11).

2)

3)

16

Install No. 2 sun gear (15).

Align the pin holes of the shaft (9) to that of carrier (11), and then drive in the shaft by lightly tapping with a plastic hammer. a Install shaft as rotating the planetary gear. Use care not to damage the thrust washers. Insert pin (8). a Check the pin for deformation on the pin groove or protrusion, and replace if defective. a Do not locate the pin at the same position where it was caulked previously. a Caulk the pin area (arrow mark) of the carrier after having installed the pin. [Refer to section 5., 1), 4].]

PC2000-8

50 Disassembly and assembly a

4)

After having assembled the carrier assembly, check that the gear (10) rotates smoothly.

Pass wires over the carrier case, and then lift and install the carrier assembly (7) by aligning with the No. 2 sun gear (15).

SEN02136-00

11. No. 1 sun gear 1) Install thrust washer (5). 2) Install No. 1 sun gear (6).

12. Cover Lift and install cover (4) by aligning the oil filler port. 2 Cover mounting face: Gasket sealant (LG-6) 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}

10. No. 1 ring gear 1) Install No. 1 ring gear (14) by aligning the drill hole of the oil filler port. 2 Mounting face: Gasket sealant (LG-6)

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17

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50 Disassembly and assembly

13. Oil filler port Install bracket (1), and then install oil filler port (2) and breather tube (3). 2 Oil filler port mounting part: Gasket sealant (LG-6) 3 Oil filler port: 42.1 – 70.6 Nm {4.3 – 7.2 kgm} 3 Mounting bolt: 98 – 123 Nm {105 – 12.5 kgm}

14. Install swing motor assembly (100) to swing machinery assembly (101).

18

PC2000-8

50 Disassembly and assembly

SEN02136-00

Removal and installation of swing circle assembly 1

Installation q

Removal 1.

Remove revolving frame assembly, referring to "Removal and installation of revolving frame assembly."

2.

Remove 38 mounting bolts (1).

3.

Install 3 eyebolts (M36) on top of the swing circle.

4.

[*1]

Lift and remove swing circle assembly (2). [*2] 4

Swing circle assembly: 3,330 kg

Carry out the installation in the reverse order of removal.

[*1]

2 3

Threaded portion of swing circle mounting bolt: Liquid adhesive (LT-2) Swing circle mounting bolt: 2,746 ± 294 Nm {280 ± 30 kgm}

[*2]

2

Swing circle mounting face: Gasket sealant (LG-6) 2 Amount of grease in oil bath: Grease (G2-LI) Approx. 80 l a Note that the capacity up to the top of the internal gear is 500 l. a

Apply grease to the internal gear. Internal gear: Grease (G2-LI)

a

Fill grease to the seal groove. Seal groove: Grease (G2-LI) When install the assembly, align the inner race soft zone (a) (S-mark) and the outer race soft zone (b) (S-mark) to the positions as shown in the figure below. (Arrow mark points to the front of the machine.)

2

2

a

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19

SEN02136-00

Removal and installation of final drive assembly

50 Disassembly and assembly

1

Removal 1. k

Spread the track shoe assembly, referring to "Removal of track shoe assembly." Lower the work equipment completely to the ground and stop the engine. Then, gradually loosen the oil filler cap of the hydraulic tank to release the pressure inside the hydraulic tank.

2.

Remove travel motor assembly, referring to "Removal of travel motor assembly."

3.

Remove sprocket assembly (1) from the final drive assembly (2). [*1] 2 Sprocket assembly: 260 kg a

20

4.

Temporarily lift final drive assembly (2).

5.

Remove 23 mounting bolts and then lift and remove final drive assembly (2). [*2] a Take care not to damage the nipple seal face of the hose installing portion. 2 Final drive assembly: 2,830 kg

If it is difficult to remove the sprocket (1), burrs (B) may have been formed. In this case, remove the burrs (B) with a grinder before removing the sprocket (1). (Do this only when burrs are found.)

PC2000-8

50 Disassembly and assembly

SEN02136-00

Installation q

Carry out the installation in the reverse order of removal.

[*1]

2

3

Mounting bolt: Liquid adhesive (LT-2) Mounting bolt: 2,110 – 2,450 Nm {215 – 250 kgm}

[*2]

3

Mounting bolt: 1,960 – 2,450 Nm {200 – 250 kgm}

q

Add oil Add power train oil (TO30) up to the specified level from the oil filler port. Run the engine and travel for a while. Then check the oil level again.

q

Bleeding air Bleed air from the travel motor, referring to "Bleeding air from each part" in Testing and adjusting.

PC2000-8

21

SEN02136-00

50 Disassembly and assembly

Disassembly and assembly of final drive assembly

2. 1

Symbol J

Part No.

791-585-1510

Part name

Installer

Necessity Q'ty New/Remodel Sketch

Special tools

Case and gear assembly 1) Using eyebolt, lift and remove case and gear assembly (5).

t 1

Disassembly 1.

Case assembly 1) Using eyebolt (M16 mm, P = 2.0), lift and remove case assembly (1). 2)

2)

Disassemble case and gear assembly in the following procedure. 1] Remove bolt (6) and holder (7), and then remove shaft (8) and spacer (9).

Remove bearing outer races (3) and (4) from the case (2).

2]

22

Remove gears (10) and (11). a To avoid the bearing (12) interfere with the gear (10), pull up both gears simultaneously.

PC2000-8

50 Disassembly and assembly

3]

SEN02136-00

7]

Remove 2 bearing inner races (13) from the gear (10).

8]

4]

5] 6]

PC2000-8

Remove 2 bearing inner races (12) from the gear (11).

Remove bearing outer races (15) and (16) from the case (14). Remove oil lubrication tube (17).

3.

Remove thrust washer (18) from the case (14). Remove oil lubrication plate (18-1).

Carrier assembly (small) 1) Using eyebolt, lift and remove carrier assembly (19).

2)

Disassemble carrier assembly in the following procedure. 1] Remove lockplate (20).

23

SEN02136-00

2] 3]

4]

4.

Using the press to push out shaft (21). Remove gear (22) and bearing (23). a The outer race is coupled with the bearing. Apply counter marks on them. Remove spacers (24) and (25) from the gear (22), and then remove snap ring (26).

50 Disassembly and assembly

2)

Using eyebolt (24 mm, P=3.0), screw in forcing screws, and then lift and remove carrier assembly (29).

3)

Disassemble carrier assembly in the following procedure. 1] Remove lockplate (30).

Ring gear (small) Lift and remove ring gear (27).

2] 3] 4] 5.

24

Using the press to pull out shaft (31). Remove 2 thrust washers (32). Remove gear (33) and remove bearing (34) and spacer (35).

Carrier assembly (large) 1) Reverse final drive assembly (28).

PC2000-8

50 Disassembly and assembly

5]

6.

7.

Remove button (37) from the carrier case (36).

Shaft Lift and remove shaft (38).

Ring gear assembly (large) 1) Remove retainer (39).

PC2000-8

SEN02136-00

2)

Remove shim (40). Check the thickness and quantity of the shims in advance.

3)

Lift and remove ring gear assembly (41).

4)

Remove 6 lockplates (42), and then remove case (44) from the ring gear (43). a Apply counter marks on them before removal.

25

SEN02136-00

8.

50 Disassembly and assembly

4)

Case assembly 1) Using the press, remove case assembly (45) from the housing assembly (46).

9. 2)

Lift and remove case assembly (45).

3)

Remove bearing inner race (47).

Housing assembly 1) Remove floating seal (49) and 2 bearing inner races (47) from the housing (51).

2)

26

Remove floating seal (49) and 2 bearing outer races (50) from the case (48).

Remove spacer (52) from the housing (51).

PC2000-8

50 Disassembly and assembly

Assembly a a a k

1.

Before assembly, clean the parts and check for dust or defect. Apply engine oil on the sliding parts and assemble them. Using engine oil, remove dust completely from the O-ring surface of the floating seal. Be careful not to apply impact or drop the parts during installation. Even the slightest damage on the floating seal can cause oil leaks.

SEN02136-00

2.

Case assembly 1) Assemble following parts to the case (48). 1] Perform expansion fit to install 2 bearing outer races (50). 2] Using tool J1, install floating seal (49). a Thoroughly degrease the floating seal and O-ring contact surface of the housing. a Use tool J1 and apply force evenly on the O-ring of the floating seal for tightening so as not to let it twist.

Housing assembly Assemble following parts to the housing (51). 1) Install spacer (52).

2) 2) 3)

Lift and install case assembly (45) by aligning the seal.

Perform shrink fit, install bearing inner race (47). Using tool J1, install floating seal (49). a Thoroughly degrease the floating seal and O-ring contact surface of the housing. a Use tool J1 and apply force evenly on the O-ring of the floating seal for tightening so as not to let it twist.

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27

SEN02136-00

3.

Bearing Install bearing inner race (47).

4.

Ring gear 1) Install ring gear (43) to the case (44) and fix with 6 lockplates (42). a Install by aligning the counter marks. 3 Mounting bolt: 98.5 – 123 Nm {10 – 12.5 kgm} 2 Mounting bolt: Adhesive (LT-2)

50 Disassembly and assembly

5.

Preload adjustment and retainer Adjust the preload in the following procedure. 1) Install retainer (39) by tightening with 4 mounting bolts evenly. 2) Remove 4 mounting bolts and rotate the case (48). Then check that it rotates smoothly together with the bearing.

3) 4)

2)

28

Tighten with 4 mounting bolts evenly again. 3 Mounting bolt: 34.3 Nm {3.5 kgm} Measure the retainer-to-housing clearance (a) either by using a depth micrometer [1] through the mounting bolt hole, or by using a clearance gauge from inside of the case.

Lift and install ring gear assembly (41) to case (48).

PC2000-8

50 Disassembly and assembly

5)

Select shim(s) (40) so that its thickness equals the measured value plus 0 to 0.1 mm, and install.

6)

Install retainer (39). 3 Mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} 2 Mounting bolt: Adhesive (LT-2)

7)

Set dial gauge [2] on the ring gear (43), pry out the case (48) and measure the end play. a End play: 0 – 0.1 mm a If the end play does not meet the standard value, add or remove the number of shim, and repeat Step 5) and 6).

PC2000-8

SEN02136-00

6.

Shaft 1) Lift and install shaft (38).

7.

Carrier assembly (large) 1) Disassemble carrier assembly (29) in the following procedure. 1] Install button (37) to the carrier case (36).

29

SEN02136-00

2]

3]

4]

50 Disassembly and assembly

Assemble bearing (34) and spacer (35) to the gear (33). a The bearing is coupled with the spacer. Always reassemble with original pairs. Apply thrust washers (32) on both side of the gear (33), and install them to the carrier. a Align the inner diameter of the spacer to that of the bearing. Perform expansion fit to Install shaft (31). a If it is difficult to install the shaft, press it using the press.

2)

8.

5]

30

Install lockplate (30). a Install lockplate (30) to the shaft, and use guide bolt to match the bolt hole. 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm} 2 Mounting bolt: Adhesive (LT-2)

Apply gasket sealant to the mounting face of the case assembly of the carrier, and then install the carrier assembly (29) by aligning with the shaft. 2 Mounting face of carrier: Gasket sealant (LG-6) 3 Mounting bolt: 1,520 – 1,910 Nm {155 – 195 kgm} 2 Mounting bolt: Adhesive (LT-2)

Carrier assembly (small) 1) Assemble carrier assembly (19) in the following procedure. 1] Install snap ring (26) to the gear (22). 2] Install spacer (24), and then install outer race of the bearing (23). a The outer race is coupled with the bearing. Always check the counter marks for reassembly. 3] Assemble inner race of the bearing (23) and spacer (25) to the gear, and set them to the carrier. a Align the inner diameter of the spacer (25) to that of the bearing. 4] Perform expansion fit to install shaft (21). a If it is difficult to install the shaft, press it using the press.

PC2000-8

50 Disassembly and assembly

5]

2)

Install lockplate (20). a Install lockplate (20) to the shaft, and use guide bolt to match the bolt hole. 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} 2 Mounting bolt: Adhesive (LT-2)

Lift and install carrier assembly (19) by aligning the shaft.

PC2000-8

SEN02136-00

9.

Ring gear assembly (small) Apply gasket sealant to the ring gear (27), and lift and install it. 2 Mounting face: Gasket sealant (LG-6)

10. Case and gear assembly 1) Assemble case and gear assembly in the following procedure. 1] Install bearing inner race (12) to the gear (11).

31

SEN02136-00

2]

3]

32

Install oil lubrication plate (18-1) to the case (14). a Note the assembly direction (right to left or up and down). DH: Drain hole 2 Mating face: Gasket sealant (LG-6) a Thoroughly remove excessive gasket that runs into the hole. 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm} 2 Mounting bolt: Adhesive (LT-2)

50 Disassembly and assembly

4]

5]

Tighten oil lubrication tube (17). 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm} 2 Mounting bolt: Adhesive (LT-2) Install bearing outer races (15) and (16) to the case (14).

6]

Install 2 bearing inner races (13) to the gear (10).

7]

Install gears (10) and (11). a To avoid the bearing (12) interfere with the gear (10), pull up both gears simultaneously.

Install thrust washer (18) by aligning with the dowel pin.

PC2000-8

50 Disassembly and assembly

8] 9]

2)

Install spacer (9) to the shaft (8). Install shaft (8) to the gear, install holder (7) and tighten with bolt (6). 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm} 2 Mounting bolt: Adhesive (LT-2)

SEN02136-00

2)

Apply gasket sealant to the mounting face, and then lift and install case assembly (1). 2 Mounting face: Gasket sealant (LG-6)

Apply gasket sealant to the mounting face, and then lift and install case and gear assembly (5). 2 Mounting face: Gasket sealant (LG-6)

11. Case assembly 1) Install bearing outer races (3) and (4) to the case (2).

PC2000-8

33

SEN02136-00

PC2000-8 Hydraulic excavator Form No. SEN02136-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 11-06 (01)

34

SEN02137-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

50 Disassembly and assembly

1

Undercarriage and frame Undercarriage and frame ................................................................................................................................ 2 Removal and installation of track shoe assembly ................................................................................ 2 Removal and installation of idler assembly .......................................................................................... 4 Disassembly and assembly of idler assembly...................................................................................... 5 Disassembly and assembly of idler adjust cylinder assembly.............................................................. 7 Removal and installation of idler cushion cylinder assembly ............................................................... 8 Disassembly and assembly of idler cushion cylinder assembly........................................................... 9 Removal and installation of track roller assembly .............................................................................. 10 Disassembly and assembly of track roller assembly...........................................................................11 Removal and installation of carrier roller assembly............................................................................ 13 Disassembly and assembly of carrier roller assembly ....................................................................... 14 Removal and installation of revolving frame assembly ...................................................................... 18 Removal and installation of counterweight assembly ........................................................................ 21

PC2000-8

1

SEN02137-00

50 Disassembly and assembly

Undercarriage and frame

1

Removal and installation of track shoe assembly 1

Symbol

Part No.

Part name

Necessity Q'ty New/Remodel Sketch

Special tools

790-434-1502

Remover & installer t 1

R 1 790-101-4300

Cylinder t 1 (1,471 kN {150 ton})

790-101-1102

Hydraulic pump

t 1

Removal 1.

Master pin positioning a Move the master pin to the middle of the front idler and carrier roller. As the track shoe is extended backward, retain the space for it.

2.

Loosen the track shoe tension. [*1] k When loosening lubricator (1), don't turn it more than 360°. a If the track shoe tension does not slacken after loosening the lubricator, move the machine body forward/reverse.

3.

2

4.

Apply a block or jack [1] (10-ton) to under the shoe (3) on the idler side and pull out the guide pin [2]. [*2]

5.

Lift the end of the track shoe with a crane. Slowly move the machine backward and extend the track shoe assembly (3).

Remove the snap ring and pull out the master pin using tool R1.

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50 Disassembly and assembly

SEN02137-00

Installation q

Carry out the installation in the reverse order of removal.

[*1] a Before pressing grease, check the thrusting dimension (A) of the plunger (P) of hydraulic cushion cylinder (S). Thrusting dimension (A): 135 ± 5 mm k Always adjust the thrusting dimension (A) of the plunger (P) of the hydraulic cushion cylinder (S) to a specified value, or a major accident may occur when adjusting the track shoe tension.

a

For the tension of track shoe assembly, refer to the "Adjusting track shoe tension" in Testing and adjusting. 3 Lubricator: 74.5 – 88 Nm {7.6 – 9 kgm} 2 Grease (G2-LI): 4,600 ml (standard position)

[*2] a Install spacer (4) and washer (5) to the link, joint it to the lower link and install the guide pin.

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3

SEN02137-00

Removal and installation of idler assembly

50 Disassembly and assembly

Installation 1

q

Removal k k

k k

Lower the work equipment completely to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the pressure inside the hydraulic tank. Set the work equipment lock lever to the lock position. Release residual pressure in the circuit, referring to the "Releasing residual pressure in HIC circuit" in Testing and adjusting.

1.

Remove the track shoe assembly, referring to "Removal and installation of track shoe assembly."

2.

Lift and remove idler adjust cylinder assembly (2). [*1] a Lift the assembly horizontally using the lever block on the adjust cylinder side. a Pull out and remove idler adjust cylinder assembly (2). 4 Idler adjust cylinder assembly: 1,700 kg

3.

Remove mounting bolt (4) and remove the yoke (3). [*2] 4

4

Carry out the installation in the reverse order of removal.

[*1]

3

Mounting bolt (4): 1,720 ± 196 Nm {175 ± 20 kgm}

[*2]

3

Idler adjust cylinder assembly mounting bolt: 927 ± 98 Nm {94.5 ± 10 kgm}

Yoke (3): 460 kg

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50 Disassembly and assembly

SEN02137-00

Disassembly and assembly of idler assembly

1

Symbol

Part No.

L 3 791-542-1520

Part name

Installer

Set idler to block [1].

7.

Pull out shaft (4) from the idler.

8.

Remove bushings (10) and (11) from the idler.

Necessity Q'ty New/Remodel Sketch

Special tools

6.

t 1

Disassembly 1.

Remove plug (1) and drain oil. 6

Idler assembly: 1.4 l

2.

Pull out mounting bolt (3) of support (2) and remove the support.

3.

Remove O-ring (5) from shaft (4).

4.

Remove spacer (6) and remove dowel pin (7).

5.

Remove floating seal assembly (9) from support and idler (8).

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5

SEN02137-00

Assembly 1.

Press bushings (2) and (3) to the idler (1).

50 Disassembly and assembly

q

a

Refilling with oil Add engine oil to the specified amount from the oil filler port.

5

2.

Using tool L3 (see the tool table), install floating seal (4) to the idler.

3.

Using tool L3 (see the tool table), install floating seal (5) to the support. q Carry out the installation of the shaft, spacer and support in the reverse order of removal.

6

Amount of oil: 1.4 l (GO140)

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50 Disassembly and assembly

Disassembly and assembly of idler adjust cylinder assembly

SEN02137-00

5.

Remove dust seal (10) from yoke (5).

1

Disassembly 1.

Remove guard (1), plates (2) and (3) from the idler assembly.

2.

Remove cylinder assembly (4) from the idler assembly.

Assembly a 1.

3.

4.

Refer to a figure included in the Disassembly section. Install wear ring (9) and packing (8), and then install snap ring (7) to plunger (6).

2.

Fill the inside of plunger (6) with grease (G2LI). a Standard capacity: 4,600 cc a Always apply grease to the plunger in advance because the air cannot completely purged once plunger (6) is installed to yoke (5).

3.

Apply grease, lift and lower yoke (5) on the side of plunger (6) and install.

4.

Install dust seal (10) to yoke (5).

Remove plunger assembly (6) from yoke (5). k Remove the lubricator and inject the air to push out the plunger. Care must be paid for jumping plunger.

Remove snap ring (7), and then remove packing (8) and wear ring (9) from the plunger (6).

PC2000-8

7

SEN02137-00

Removal and installation of idler cushion cylinder assembly

50 Disassembly and assembly

1

Removal k k

k k

4.

Remove air bleeding bolt (3).

5.

Disconnect hose (4). a (6): Idler adjust cylinder assembly mounting bolt

6.

Temporarily lift the idler cushion cylinder assembly (5).

7.

Remove mounting bolts (6), and then lift and remove idler cushion cylinder assembly (5).

Lower the work equipment completely to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the pressure inside the hydraulic tank. Set the work equipment lock lever to the lock position. Release residual pressure in the circuit, referring to "Releasing residual pressure in HIC circuit" in Testing and adjusting.

1.

Remove the track shoe assembly, referring to "Removal and installation of track shoe assembly."

2.

Remove step (1).

4

3.

Idler cushion cylinder assembly: 480 kg

Lift and remove idler adjust cylinder assembly (2). a Pull out and remove idler adjust cylinder assembly (2). 4

Idler adjust cylinder assembly: 1,700 kg

Installation q

Carry out the installation in the reverse order of removal.

q

Bleeding air Bleed air from inside the idler cushion and press-in pressurized oil, referring to "Bleeding air from HIC circuit and pressing-in pressurized oil" in Testing and adjusting.

a

8

PC2000-8

50 Disassembly and assembly

Disassembly and assembly of idler cushion cylinder assembly

SEN02137-00

Assembly 1

1.

Install bushing (10) (outside diameter: 144 mm) to the cylinder.

2.

Press dust seal (9) (outside diameter: 160 mm) and Install snap ring (8).

a

For the rest of procedures, refer to a figure in the Disassembly section.

3.

Install wear ring (6) and packing (5) to plunger (7), and then install snap ring (4).

4.

Apply grease (G2-LI) and install plunger assembly (2) to cylinder (3).

5.

Install O-ring and install gland (1). a If the end of the bolt protrudes from the gland, grind it flush to the gland plane. a Install the gland so that the tube mounting hole will be parallel to the bracket mounting plate of the cylinder.

Disassembly 1.

Remove gland (1).

2.

Remove plunger assembly (2) from cylinder (3).

3.

Remove snap ring (4), and then remove packing (5) and wear ring (6) from plunger (7).

4.

Remove snap ring (8) from cylinder (3) and remove dust seal (9).

5.

Remove bushing (10).

PC2000-8

9

SEN02137-00

50 Disassembly and assembly

4.

Set tool L4, remove mounting bolt (3) and remove track roller assembly (4). [*1]

Special tools

5.

Using tool L4, remove track roller assembly (4) by maintaining balance.

Symbol

L 4

Part No.

Part name

Necessity Q'ty New/Remodel Sketch

Removal and installation of track roller assembly 1

790-401-1700

Lifting tool

t 1

790-431-1021

Adapter

t 1

4

Track roller assembly: 345 kg

Removal k k

k

Lower the work equipment completely to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the pressure inside the hydraulic tank. Set the work equipment lock lever to the lock position.

1.

Loosen the track shoe tension, referring to "Removal of track shoe assembly."

2.

Remove track roller guards (1) and (2).

Installation q

Carry out the installation in the reverse order of removal.

[*1]

3

3.

10

Roller mounting bolt: 1,520 – 1,910 Nm {155 – 195 kgm}

Using the work equipment, push up the track frame on the removal side. k After lifting the machine, set the block on the track shoe.

PC2000-8

50 Disassembly and assembly

SEN02137-00

Disassembly and assembly of track roller assembly

4.

Pull out floating seals (7) and (8) from roller (5) and collar (3),

5.

Remove bushings (9), (10) from roller (5).

1

Symbol

L

Part No.

Part name

Necessity Q'ty New/Remodel Sketch

Special tools

5 796-675-1510

Installer

t 1

6 791-601-1000

Oil pump

t 1

Disassembly 1.

Remove plug (1) and drain oil. 6

Track roller assembly: 1.3 – 1.45 l

2.

Remove bolt (2), and remove collar (3).

3.

Remove shaft (4) from roller (5), and remove O-ring (6).

PC2000-8

11

SEN02137-00

50 Disassembly and assembly

Assembly 1.

Press bushings (9) to track roller (5).

2.

Reverse the roller and press bushings (10).

3.

Using tool L5 (see the tool table), install floating seals (7) to track roller (5).

4.

Using tool L5 (see the tool table), install floating seals (8) to collar (3).

7.

Apply the reference pressure to the roller oil filling port and check the seal for the air leakage. a Reference pressure: 0.1 MPa {1 kg/cm2}

8.

Using tool L6 (see the tool table), fill the track roller assembly with oil. 5

5.

Install O-ring (6) to shaft (4) and assemble shaft (4) to track roller (5).

6.

Install collar (3) to shaft (4) and install bolt (2). 3 Bolt (2): 245 – 309 Nm {25 – 31.5 kgm} a Track roller play in axial direction: 0.29 – 0.68 mm a (1): Plug (Install after filling oil)

9.

12

Amount of oil: 1.3 – 1.45 l (GO140)

Install the plug (1) (stated in the preceding paragraph).

PC2000-8

50 Disassembly and assembly

Removal and installation of carrier roller assembly

SEN02137-00

1

Removal k k

k

5.

Remove bolt (3).

6.

Open bracket (4) using a driver, and remove the carrier roller from the bracket.

Lower the work equipment completely to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the pressure inside the hydraulic tank. Set the work equipment lock lever to the lock position.

1.

Loosen the track shoe tension slightly, referring to "Adjusting track shoe tension" in Testing and adjusting.

2.

Using a hydraulic jack [1], push up the track shoe.

4

Carrier roller assembly: 175 kg

Installation q

Carry out the installation in the reverse order of removal.

[*1]

3

3.

Remove 4 mounting bolts (1).

4.

Lift and remove carrier roller bracket assembly (2). a Pull the carrier roller assembly to outside but within the safe range from falling. 4

PC2000-8

Roller mounting bolt: 1,520 – 1,910 Nm {155 – 195 kgm}

[*1]

Carrier roller bracket assembly: 130 kg

13

SEN02137-00

50 Disassembly and assembly

Disassembly and assembly of carrier roller assembly

Disassembly 1

1.

Special tools

L q

a

14

Part No.

1 791-575-1520

6

Part name

Installer

2 796T-930-1110 Push tool

Carrier roller assembly: 0.86 – 0.94 l

Necessity Q'ty New/Remodel Sketch

Symbol

Remove plug (14) and drain oil from the carrier roller assembly.

t 1 t 1 N Q

Sectional view The numbers represent those in the texts.

2.

Remove cover (10) from roller (1). a O-ring (11) is installed to cover (10).

3.

Remove dowel pin (12) and spacer (13).

4.

Remove plate (9) from roller (1).

5.

Remove shaft (7) from roller (1).

PC2000-8

50 Disassembly and assembly

6.

Remove floating seal (5) from shaft (7). a Take care so that the seal face will not be damaged.

7.

Remove ring (4) from shaft (7).

8.

Remove floating seal (6) from roller (1). a Take care so that the seal face will not be damaged.

9.

Using the push tool, remove bushings (2) and (3) from roller (1). q Press fitting force (Reference): Bushing (2): 0.2 – 6.9 kN {200 – 6,900 kg} Bushing (3): 1.6 – 11.3 kN {1,600 – 11,300kg}

PC2000-8

SEN02137-00

15

SEN02137-00

50 Disassembly and assembly

Assembly 1.

Bushing 1) Using the push tool, press bushing (2) to roller (1). 2) Reverse the roller (1) and press bushing (3) to roller (1) using push tool. q Press fitting force (Reference): Bushing (2): 0.2 – 6.9 kN {200 – 6,900 kg} Bushing (3): 1.6 – 11.3 kN {1,600 – 11,300kg}

2.

Floating seal 1) Using tool L1, install floating seal (5) to ring (4). 2) Using tool L1, install floating seal (6) to roller (1). a When installing the floating seal, wash the contact faces of the O-ring and floating seal (shaded area), degrease completely and dry. The contact surface of floating seal must be clean without dirt. a Using tool L1, push and insert the Oring to floating seal (4). a After inserting the floating seal, check that the seal slants by 1 mm or under and the seal thrust capacity (a) is within the range of 8 to 10 mm.

16

3.

Insert shaft (7) to roller (1) and install plate (9). a Apply oil to the sliding surfaces of floating seal so that no dirt will be stuck. a Roller (1) play in axial direction: 0.4 – 0.68 mm

PC2000-8

50 Disassembly and assembly

4.

Using the push tool L2, press the ring (4) to shaft (7) so that the step between roller (1) and ring (4) shall be 18.5 ± 0.2 mm. a Support shaft (7) from under with push tool [1]. q Press fitting force (reference): 60 – 160 kN {6,000 – 16,000 kg} a Take care not to give large impact to the bushing until c over ( 10) is installed because pressed ring (4) may be misaligned.

SEN02137-00

8.

Apply the reference pressure to the roller oil filling port and check the seal for the air leakage. a Reference pressure: 0.1 MPa {1 kg/cm2}

9.

Tighten plug (14) after having filled the carrier roller assembly with oil. 5

5.

Install spacer (13) and dowel pin (12).

6.

Install O-ring (11) to cover (10).

7.

Install cover (10) to roller (1).

PC2000-8

Carrier roller: 0.86 – 0.94 l (GO140)

17

SEN02137-00

Removal and installation of revolving frame assembly

50 Disassembly and assembly

Remove the work equipment assembly from the machine body, referring to "Removal and Installation of boom assembly."

2.

Remove the counterweight, referring to "Removal and Installation of counterweight assembly."

3.

Remove the mounting bolts by leaving about 5 bolts in front and rear. [*1] a Start the engine and remove mounting bolts while swinging the machine. a If the engine cannot be started, remove the swing motors (total 2 motors in front and rear). Then using the crane, swing and remove the mounting bolts.

4.

Remove the power container assembly, referring to "Removal and Installation of power container assembly."

5.

Remove the operator cab assembly, referring to "Removal and Installation of operator cab assembly."

18

Remove clamps (2) and disconnect grease tubes (3).

7.

Remove covers (4).

8.

Remove nipple (5).

1

Removal 1.

6.

PC2000-8

50 Disassembly and assembly

9.

SEN02137-00

Disconnect hoses (6) to (14) from the center swivel joint (SJ). a Fasten tags to hoses to identify them for reinstallation.

10. Remove bar (15).

12. Remove the remaining mounting bolts, and then lift and remove revolving frame assembly (16). [*2] a Provide a stopper to the slings on the back using eyebolts to prevent them from moving away. k Remove the revolving frame assembly carefully by avoiding contact with the center swivel joint assembly. a Fuel tank deck and front swing machinery have been removed in the picture. a Because the swing machinery gear (SMG) protrudes downward from the revolving frame (portion marked with A, place the revolving frame on top of the block of 350 mm high. 4

Revolving frame assembly: Approx. 31,500 kg

11. Temporarily lift the revolving frame assembly. a Two cranes are required.

a

Apply protective plates, to where the slings on the back make contact.

PC2000-8

19

SEN02137-00

50 Disassembly and assembly

Installation q

Carry out the installation in the reverse order of removal.

[*1], [*2] 2 Swing circle mating face: Gasket sealant (LG-6) 2 Threaded portion of revolving frame mounting bolt: Liquid adhesive (LT-2) 3 Revolving frame mounting bolt: 2,452 – 3,040 Nm {240 – 310 kgm} q

a

q

a

20

Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Bleeding air Bleed air, referring to "Bleeding air from each part" in Testing and adjusting.

PC2000-8

50 Disassembly and assembly

Removal and installation of counterweight assembly

SEN02137-00

5. 1

Lift and remove counterweight assembly (2). [*2] 4

Removal 1.

Remove hand rail (1).

2.

Remove cover (4) from the top of counterweight assembly (2).

3.

Temporarily lift counterweight assembly (2) using shackles [1].

Counterweight assembly: 24,000 kg

Installation q

Carry out the installation in the reverse order of removal.

[*1]

3

Mounting bolt: 3,430 – 4,212 Nm {350 – 430 kgm}

[*2] a Install so that clearance to the power container assembly shall be uniform to the left and right.

4.

Remove 12 mounting bolts (3). a M42 x 3 (Width across flats: 65 mm)

PC2000-8

[*1]

21

SEN02137-00

PC2000-8 Hydraulic excavator Form No. SEN02137-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 11-06 (01)

22

SEN02138-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

50 Disassembly and assembly

1

Hydraulic system Hydraulic system............................................................................................................................................. 2 Removal and installation of hydraulic tank assembly........................................................................... 2 Removal and installation of hydraulic pump assembly ........................................................................ 5 Removal and installation of hydraulic pump input shaft oil seal ......................................................... 10 Removal and installation of control valve assembly............................................................................11 Disassembly and assembly of control valve assembly ...................................................................... 18 Removal and installation of center swivel joint assembly .................................................................. 22 Disassembly and assembly of center swivel joint assembly .............................................................. 23 Removal and installation of swing motor assembly ........................................................................... 24 Removal and installation of travel motor assembly ............................................................................ 25 Disassembly and assembly of work equipment PPC valve assembly ............................................... 26 Disassembly and assembly of travel PPC valve assembly................................................................ 28 Disassembly and assembly of hydraulic cylinder assembly............................................................... 29

PC2000-8

1

SEN02138-00

50 Disassembly and assembly

Hydraulic system

1

Removal and installation of hydraulic tank assembly

1

Part number

Part name

799-703-1200

Service tool kit

Necessity Q’ty N/R Sketch

Symbol

Special tools

t 1

799-703-1100

Vacuum pump (100 V) t 1

X 3 799-703-1111

Vacuum pump (220 V) t 1

799-703-1121

Vacuum pump (240 V) t 1

799-703-1401

Gas leak detector

t 1

3.

Lift and remove hand rail (2) and floor (3).

4.

Disconnect clamps (4) and (5) and disconnect 4 air conditioner hoses (6) from the right side of the fuel tank assembly.

5.

Disconnect hoses (7) to (16). a Fasten tags to hoses to identify them for reinstallation. a Clamp is provided to the hose (14).

6.

Remove cover (17).

Removal k k k k k k

Lower the work equipment completely to the ground and stop the engine. Loosen the hydraulic tank cap gradually to release the internal pressure. Lock the work equipment lock lever. Disconnect the negative terminal (–) of the battery before starting with the work. Collect air conditioner gas (R134a) before disconnecting the hose. If the air conditioner gas (R134a) gets inside one's eyes, it may cause blindness. Therefore, make sure to wear protective glasses when collecting or filling the gas. Collecting and filling work must be conducted by a qualified person.

a

Fasten tags to pipes to identify them and show their installation position. This helps prevent any mistakes when re-installing.

1.

Drain hydraulic tank. 6

2.

2

Hydraulic tank: 1,300 l

Disconnect 4 air conditioner hoses (1) from under floor at the entrance of the operator cab. [*1] a Fasten tags to hoses to identify them for reinstallation.

PC2000-8

50 Disassembly and assembly

7.

Disconnect connectors P39 (18), P22 (19) and P38 (20) from the bottom of the cover (17).

8.

Disconnect clamp (21).

9.

Disconnect suction tubes (22) and (23).

SEN02138-00

10. Disconnect connector P40 (24) and harness (25) from the rear of the hydraulic tank assembly (29).

11. Disconnect connectors S23A (26) and S23B (27) and disconnect harness (28).

12. Temporarily lift hydraulic tank assembly (29). 13. Remove 12 mounting bolts (M30) (30) and remove hydraulic tank assembly (29). [*2] 4

PC2000-8

Hydraulic tank assembly: Approx. 1,700 kg

3

SEN02138-00

Installation

50 Disassembly and assembly

q

Bleeding air Bleed air from the travel motor, referring to "Bleeding air from each part" in Testing and adjusting.

q

Filling of refrigerant Using tool X3, fill the air conditioner circuit with the refrigerant (air conditioner gas: R134a). a Filling amount: 950 ± 50 g (per one air compressor) a Two air compressors are used.

Carry out the installation in the reverse order of removal.

q

[*1] a When installing the air conditioner circuit hoses, use care so that dirt, water, may not enter. a Make sure before the installation that there is O-ring at the piping connector of the air conditioner hose. a Check that there is no defect or deterioration on the O-ring. a When connecting the piping for refrigerant, apply the compressor oil for the new refrigerant to the O-ring (Denso: ND-OIL8 or ZEXEL: ZXL100PG (PAG46 or equivalent)). 3 3 3 3

Hose thread M16 × 1.5 (Width across flats 19): 12 – 15 Nm {1.2 – 1.5 kgm} Hose thread M22 × 1.5 (Width across flats 24): 20 – 25 Nm {2.0 – 2.5 kgm} Hose thread M24 × 1.5 (Width across flats 27): 30 – 35 Nm {3.0 – 3.5 kgm} M6 bolt for piping (Width across flats 10): 8 – 12 Nm {0.8 – 1.2 kgm}

[*2]

2

3

q

Refilling with oil (Hydraulic tank) 3 Hydraulic tank drain plug: 127.4 – 176.4 Nm {13 – 18 kgm} Fill oil up to the specified level from the oil filler port, start the engine to circulate oil in the pipe and then confirm the oil level again. 5

4

Mounting bolt: Liquid adhesive (LT-2) Hydraulic tank mounting bolt: 1,520 – 1,910 Nm {155 – 195 kgm}

Hydraulic tank: Approx. 1,300 l

PC2000-8

50 Disassembly and assembly

Removal and installation of hydraulic pump assembly

SEN02138-00

5.

Disconnect connector A07 (100) from the backside of emergency engine stop switch front (SWF).

6.

Remove front covers (5).

7.

Remove upper covers (6) and (7). a SWF: Emergency engine stop switch front

8.

Disconnect connector A08 (8) and ground TM1 (9) from the inside of emergency engine stop switch - behind (SWB).

9.

Disconnect connector L05B (10) from the bottom of SWB.

1

Removal k k k k

1.

Lower the work equipment completely to the ground and stop the engine. Loosen the hydraulic tank cap gradually to release the internal pressure. Lock the work equipment lock lever. Disconnect the negative terminal (–) of the battery before starting with the work. When the oil stopper is not used, drain the hydraulic oil. 6

Hydraulic tank: 1,300 l

2.

Remove air cleaner upper cover (1).

3.

Remove clamps (2), and then pull out 2 tubes (3). [*1]

4.

Remove hand rail (4). a SWB: Emergency engine stop switch behind

PC2000-8

5

SEN02138-00

10. Disconnect air cleaner hose (11).

11. Sling and remove hood assembly (12). 4

Hood assembly: 210 kg

12. Remove air cleaner (13).

50 Disassembly and assembly

[*1]

14. Remove cover (A) area.

a

Pump locations q (17): No. 1 main pump assembly q (25): No. 2 main pump assembly q (35): Fan pump assembly (middle lower)

13. Remove frame (14).

6

PC2000-8

50 Disassembly and assembly

SEN02138-00

No. 1 main pump assembly (17) 15. Disconnect connectors V12 (13) and V11 (15) from inside the No.1 main pump assembly (17). 16. Disconnect harness (16).

17. Disconnect hoses (18) of both sides from the No.1 main pump assembly (17). 18. Disconnect hose (19). 19. Disconnect delivery hoses (20). 20. Disconnect hose (21). 21. Disconnect suction tube (22). 22. Remove drain branch hose (23). 23. Remove fan guard (24). 24. Lift and remove No.1 main pump assembly (17) described below. [*2] 1) Move the pump toward the fan, and disconnect the spline. 2) Rotate the main pump assembly 90°. 3) Lift the main pump assembly. 4

PC2000-8

No. 1 main pump assembly: 500 kg

7

SEN02138-00

50 Disassembly and assembly

No. 2 main pump assembly (25) 25. Disconnect connectors V14 (26) and V13 (27) from the No. 2 main pump assembly. 26. Disconnect harness (28). 27. Disconnect 2 hoses (29). 28. Disconnect 2 delivery hoses (30). 29. Disconnect hoses (31) and (32). 30. Remove drain branch hose (33). 31. Disconnect suction tube. 32. Remove fan guard (34). 33. Lift and remove No.2 main pump assembly (25) described below. [*2] 1) Move the pump toward the fan, and disconnect the spline. 2) Rotate the main pump assembly 90°. 3) Lift the main pump assembly. 4

No. 2 main pump assembly: 500 kg Fan pump assembly (middle lower) (35) 34. Disconnect connector P35 (36) from the fan pump assembly (35).

8

PC2000-8

50 Disassembly and assembly

SEN02138-00

35. Disconnect connector P34 (38) from the fan pump assembly (35).

Installation q

Carry out the installation in the reverse order of removal.

36. Disconnect harness (39). [*1]

3

37. Disconnect hoses (40) to (45).

Air cleaner hose clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*2]

3

Main pump mounting bolt: 824 – 1,030 Nm {84 – 105 kgm}

[*3]

3

Fan pump mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}

38. Disconnect connectors V15 (46) and V16 (47) from the fan pump assembly (35). 39. Disconnect suction tube (48).

40. Lift and remove fan pump assembly (35). 6

PC2000-8

[*3]

Fan pump assembly: 220 kg

9

SEN02138-00

50 Disassembly and assembly

Removal and installation of hydraulic pump input shaft oil seal

Installation q

1

Part number

[*1] Part name

S 796T-867-1810 Push tool

Necessity Q’ty N/R Sketch

Symbol

Special tools

Carry out the installation in the reverse order of removal.

2

a a

Oil seal lip: Grease (G2-LI) Apply a thin coat of grease (G2-LI) on the outside perimeter of the oil seal, and press it. Using tool S and [1], press the oil seal (3).

t 1 N

Removal 1.

Remove main pump assembly, referring to "Removal of hydraulic pump assembly." a This step is common for both No. 1 main pump assembly and No. 2 main pump assembly.

2.

Remove snap ring (1).

3.

Remove spacer (2).

4.

Remove oil seal (3).

10

[*1]

PC2000-8

50 Disassembly and assembly

Removal and installation of control valve assembly

SEN02138-00

Rear overview 1

Removal k k

k

k k

a

Lower the work equipment completely to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the pressure inside the hydraulic tank. Release remaining pressure in hydraulic circuit, referring to "Releasing remaining pressure in hydraulic circuit" in Testing and adjusting. Set the work equipment lock lever to the lock position. Disconnect the negative (–) terminal of the battery beforehand. Fasten tags to pipes to identify them and show their installation position. This helps prevent any mistakes when re-installing.

Front overview

1.

Drain hydraulic tank. 6

PC2000-8

Hydraulic tank: 1,300 l

11

SEN02138-00

Right side 2. Disconnect left PPC cutoff valve (1) from the mounting bracket as follows. a The mounting bracket straddles on both right-and-left control valves. When you remove the bracket from the left side, it will remain connected to the right control valve and the right PPC cutoff valve. 1) Disconnect hose clamps (2) from the top of the control valve. 2) Disconnect hoses (3) to (5). q (3): Without collar band q (4): Brown/black q (5): Brown/yellow 3) Disconnect hose (6) and other hoses underneath of it. q (6): White/black q Underneath of (6): White/yellow 4) Disconnect hoses (7) to (10). 5) Disconnect hose clamp (11) from the bracket (12). 6) Remove PPC cutoff valve (1). 3.

12

Remove the left mounting bolt of the bracket (12), and disconnect the bracket (12) from the left control valve.

50 Disassembly and assembly

4.

Disconnect following hoses from the right PPC cutoff valve (13). 1) Disconnect hose (14) and other hoses underneath of it. From the top: q Brown/brown q Green/red q Blue q Red/red q Black 2) Disconnect hose (15) and other hoses underneath of it. From the top: q Brown q Green/brown q Blue/white q Red/brown q White/black 3) Disconnect hose (16) (yellow). 4) Disconnect hose (17) and other hoses underneath of it. From the top: q Brown q Green q Blue q Red q Black 5) Disconnect hose clamp (18).

PC2000-8

50 Disassembly and assembly

Front right side 5. Disconnect connectors P32 (19) and P33 (20) from the filter on top of the control valve. 6.

Disconnect hoses (21) to (23).

7.

Disconnect hose (24) and other hoses underneath of it. From the top: q Blue q Green q White q Without collar band q Black Disconnect hoses (25) (brown) and (26) (None).

8. 9.

SEN02138-00

Control valve rear right side 14. Disconnect hoses (32) to (35). q (32): White q (33): Without collar band q (34): White/red q (35): Without collar band

Remove bracket (27).

10. Remove 5 tubes (28). From the top: q Arm cylinder (head side) q Boom cylinder (head side) q Bucket cylinder (head side) q Swing motor (left) q Travel motor (right forward) 11. Disconnect tube (29). q Swing motor (S) 12. Disconnect hose (30) and other hoses underneath of it. From the top: q White/blue q Without collar band q White/white q Without collar band q Black/white 13. Disconnect hose clamp (31).

PC2000-8

13

SEN02138-00

15. Disconnect hoses (36) and (37). 16. Disconnect hoses (38) to (40). q (38): Without collar band q (39): Red q (40): Without collar band

50 Disassembly and assembly

26. Disconnect valve and bracket assembly (50) from the bottom of the filter and bracket assembly (47). 27. Disconnect hose (51) that connects to the hydraulic tank.

17. Disconnect 4 hoses (41). From the top: q Yellow q Brown q Black q Blue

28. Disconnect connector P36 (52).

18. Remove bracket (42).

30. Remove 8 mounting bolts (53), and then lift and remove control valve assembly (54). [*1]

19. Remove 5 tubes (43). From the top: q Arm cylinder (bottom side) q Boom cylinder (bottom side) q Bucket cylinder (bottom side) q Swing motor (right) q Travel motor (right reverse)

29. Disconnect the hose clamp and harness clamp which connect to the control valve assembly (54).

4

Control valve assembly: 1,750 kg

20. Disconnect connector P37 (44) from the bottom. 21. Disconnect hose (45). 22. Disconnect connector BV1 (46) (mating part: V19) from the filter and bracket. 23. Disconnect filter and bracket assembly (47). 24. Disconnect 5 hoses (48). From the top: q White/yellow q Without collar band q White/black q Red q White/blue 25. Disconnect hose (49).

14

PC2000-8

50 Disassembly and assembly

Left side 1. Disconnect hose (61). 2.

Disconnect hose (63) and other hoses underneath of it, from the PPC cutoff valve (62). From the top: q Brown q Green q Blue q Red q Black

3.

Disconnect hose (64) and other hoses underneath of it. From the top: q Brown/black q Yellow/brown q Blue/brown q White/brown q Green/brown

4.

Disconnect hose (65).

5.

Disconnect hose (66) and other hoses underneath of it. From the top: q Black q Yellow q Blue q White q Green

6.

Disconnect hoses (67) to (69).

7.

Disconnect hose clamp (70).

PC2000-8

SEN02138-00

8.

Disconnect hose (71).

9.

Disconnect hose clamp (72).

10. Remove the mounting bolt of the right PPC cutoff valve (62) and disconnect the right PPC cutoff valve (62) from the bracket (73). a Put aside right PPC cutoff valve. 11. Remove the right mounting bolt of the bracket (73), and disconnect the bracket (73) from the right control valve. a The mounting bracket straddles on both right-and-left control valves. When you remove the bracket from the left side, it will remain connected to the right control valve and the right PPC cutoff valve.

15

SEN02138-00

Front left side 12. Disconnect hoses (74) and (75).

50 Disassembly and assembly

21. Disconnect connectors P25 (85) and P26 (86) from the filter on top of the control valve.

13. Disconnect hose (76) and other hoses underneath of it. From the top: q Brown/blue q Green/brown q White/brown q Without collar band q Red/brown 14. Disconnect hose (77). 15. Disconnect hose clamp (78). 16. Remove bracket (79). 17. Disconnect hoses (80) and (81). 18. Disconnect hose (82) and other hoses underneath of it. From the top: q Blue/red q Green/red q White/red q Without collar band q Red/red 19. Remove 4 tubes (83). From the top: q Arm cylinder (head side) q Boom cylinder (head side) q Bucket cylinder (head side) q Travel motor (left forward) 20. Remove mounting bolt and disconnect valve (84).

22. Disconnect hoses (87) to (90). 23. Disconnect hoses (91) to (96). From the top: q (91): Without collar band q (92): Red/yellow q (93): Without collar band (both lines) q (94): Black/red q (95): Without collar band q (96): Green/red 24. Disconnect hose clamp (97). 25. Disconnect connector P28 (98) from the bottom of the control valve. 26. Disconnect hoses (99) (Without collar band) and (100) (Blue). 27. Disconnect valve and bracket assembly (101). 28. Remove bracket (102). 29. Remove 4 tubes (103). From the top: q Arm cylinder (bottom side) q Boom cylinder (bottom side) q Bucket cylinder (bottom side) q Travel motor (left reverse) 30. Disconnect hose (104) and other hoses underneath of it. From the top: q Brown/yellow q Brown/brown q Black/brown q Without collar band q Green/brown 31. Disconnect connector P27 (105) from the bottom of the control valve. 32. Disconnect hose (106).

16

PC2000-8

50 Disassembly and assembly

33. Remove 8 mounting bolts (107), and then lift and remove control valve assembly (108). [*2] 4

SEN02138-00

Installation q

Control valve assembly: 1,750 kg

Carry out installation in reverse order of removal.

[*1], [*2] 3 Control valve bracket mounting bolt: 245 – 309 Nm {25 – 31.5 kgm} q

Refilling with oil (Hydraulic tank) Hydraulic tank drain plug: 127.4 – 176.4 Nm {13 – 18 kgm} 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.

3

5 q

PC2000-8

Hydraulic tank: Approx. 1,300 l

Bleeding air Bleed air from the parts, refer to “Bleeding air from various system” in Testing and adjusting.

17

SEN02138-00

Disassembly and assembly of control valve assembly a a

50 Disassembly and assembly

1

This section describes precautions only for assembly of control valve. For information on the tightening torque, refer to "Structure, function and maintenance standard."

2

q

Mating face (F1, F2, F3, F4): Seal end 242 or equivalent L1: L1 valve L2: L2 valve

q

Left 10-spool valve

q

L1 valve Care should be taken for that spool, arm Lo (AML), Boom Lo (BML) and bucket Hi (BH) are directional.

q

1.

2.

18

Degrease and dry the threaded portions of the valve and plug (PL).

PC2000-8

50 Disassembly and assembly

3.

4.

q

5.

6.

SEN02138-00

Apply two drops (approx. 0.04 g) of Loctite (No. 638) to the threaded portion of the plug (PL). 2 Threaded portion of the plug (PL): 2 drops (approx. 0.04 g) of Loctite (No. 638) After tightening the plug (PL), keep it in stationary standing for 2 hours or longer.

L2 valve Core should be taken for that spool, arm Hi (AMH), boom Hi (BMH) and bucket Lo (BL) are directional. For installation of plug (PL), refer to the "L1 valve".

PC2000-8

19

SEN02138-00

q

q q

q

7.

8.

20

50 Disassembly and assembly

Right 10-spool valve 2 Mating face (F3, F4): Sealend 242 or equivalent R1: R1 valve R2: R2 valve

R1 valve Care should be taken for that spool, arm Lo (AML), boom Hi (BMH) and bucket Lo (BL) are directional. For installation of plug (PL), refer to the "L1 valve".

PC2000-8

50 Disassembly and assembly

q

9.

SEN02138-00

R2 valve Care should be taken for that spool, Arm Hi (AMH), boom Lo (BML) and bucket Hi (BH) are directional.

10. For installation of plug (PL), refer to the "L1 valve".

PC2000-8

21

SEN02138-00

Removal and installation of center swivel joint assembly 1 Removal k k

k

k

a 1.

2. 3. 4.

50 Disassembly and assembly

5. 6. 7.

Lower the work equipment completely to the ground and stop the engine. Loosen the cap of the hydraulic tank gradually to release the pressure inside the hydraulic tank. Release remaining pressure in hydraulic circuit, referring to "Releasing remaining pressure in hydraulic circuit" in Testing and adjusting. Set the work equipment lock lever to the lock position. Fasten tags to pipes to identify them and show their installation position. This helps prevent any mistakes when re-installing. To remove the center swivel joint assembly (24), remove the swing motor and swing machinery assembly - front (SMF), referring to "Removal and installation of swing motor and swing machinery assembly." (SMB: Swing motor and swing machinery assembly - behind) Disconnect hoses (1) to (10). a Fasten tags to hoses to identify them for reinstallation. Remove pin (11) and move bar (12). Remove nipple (13).

4

Center swivel joint assembly: 150 kg

Installation q

Carry out installation in reverse order of removal.

[*1] a A: Right travel (forward) B: Right travel (reverse) C: Left travel (forward) D: Left travel (reverse) P: Drain T: Drain q Top view

q

a

q

a

22

Disconnect hoses (14) to (22). Remove 4 mounting bolts (23). Lift and remove center swivel joint assembly (24).

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. Bleeding air Bleed air from the parts, refer to “Bleeding air from various system” in Testing and adjusting.

PC2000-8

50 Disassembly and assembly

SEN02138-00

Disassembly and assembly of center swivel joint assembly

1

Symbol

T

Part No.

Part name

Necessity Q'ty New/Remodel Sketch

Special tools

t 1

790-101-2501

Push puller

790-101-2510

• Block

1

790-101-2520

• Screw

1

791-112-1180

• Nut

1

790-101-2540

• Washer

1

790-101-2630

• Leg

2

790-101-2570

• Plate

4

790-101-2560

• Nut

2

790-101-2660

• Adapter

2

Assembly a

See the left figure.

1.

Assemble 6 slipper seals (8) to the swivel rotor (4). Using push tool [2], install oil seal (7) to the swivel rotor (4).

2.

Disassembly 1. 2. 3.

4. 5.

Remove cover (1). Remove snap ring (2). Using tool T1, pull out the swivel rotor (4) and ring (3) from the swivel shaft (5). Remove snap ring (6) and oil seal (7) from the swivel rotor (4). Remove 6 slipper seals (8) from the swivel rotor (4).

4

3. 4.

Oil seal lip: Grease (G2-LI)

Install snap ring (6). Set swivel shaft (5) to the block. Using push tool [3], install the swivel rotor (4) by hitting with a plastic hammer. 2 Rotor-to-shaft contact surface: Grease (G2-LI) a Be extremely careful not to damage the dust seal or O-ring when installing the rotor.

5. 6.

Install ring (3) and fix with snap ring (2). Install O-ring and install cover (1). 3 Mounting bolt: 58.8 – 73.6 Nm {6 – 7.5 kgm}

PC2000-8

23

SEN02138-00

Removal and installation of swing motor assembly 1 Removal k k k

k k

a a

Lower the work equipment completely to the ground. Stop the engine. Release remaining pressure in hydraulic circuit, referring to "Releasing remaining pressure in hydraulic circuit" in Testing and adjusting. Set the work equipment lock lever to the lock position. Loosen the oil filler cap of the hydraulic tank to release the internal pressure of the hydraulic tank.

50 Disassembly and assembly

Rear side 6. Disconnect connector BV1 (9) (mating part: V19). 7. Disconnect 2 hoses (10). a Fasten tags to hoses to identify them for reinstallation. 8. Remove filter and bracket assembly (11). 9. Disconnect hose (12). a SM: Swing motor and swing machinery assembly - behind

Fasten tags to pipes to identify them and show their installation position. This helps prevent any mistakes when re-installing. Two swing motor assemblies are used (front and rear).

Front side 1. Remove 6 work equipment hoses (1).

q

For further removal steps, refer to Step 2 to 5 in the front side.

Installation q

Carry out the installation in the reverse order of removal.

[*1] 4

q

a 2. 3. 4. 5.

24

Disconnect hoses (2) to (4). Remove step (5). Temporarily lift swing motor assembly (6). Remove mounting bolt (7), and then lift and remove swing motor assembly (6). [*1] 4 Swing motor assembly: 115 kg

q

Swing motor assembly mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Bleeding air Bleed air from the swing motor, referring to "Bleeding air from each part" in Testing and adjusting.

PC2000-8

50 Disassembly and assembly

Removal and installation of travel motor assembly 1

SEN02138-00

2.

Disconnect hoses (2) to (4).

3.

Temporarily lift travel motor assembly (5).

4.

Remove mounting bolt, and then lift and remove travel motor assembly (5).

Removal k k k

k k

a

Swing the work equipment by 90° and lower it completely to the ground. Stop the engine. Release remaining pressure in hydraulic circuit, referring to "Releasing remaining pressure in hydraulic circuit" in Testing and adjusting. Set the work equipment lock lever to the lock position. Loosen the oil filler cap of the hydraulic tank to release the internal pressure of the hydraulic tank. For the "Disassembly and assembly of travel motor", refer to the "PPM Disassembly and Assembly Procedures, Centralized Maintenance Manual." English book No. : EEA00041-0* * denotes a revision number.

a

Fasten tags to pipes to identify them and show their installation position. This helps prevent any mistakes when re-installing.

1.

Remove cover (1). 4

4

Travel motor assembly: 150 kg

Cover: 135 kg

Installation q

Carry out the installation in the reverse order of removal.

[*1]

3

Mounting bolt: 385 ± 42 Nm {39 ± 4 kgm}

q

a

q

PC2000-8

Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Bleeding air Bleed air from the travel motor, referring to "Bleeding air from each part" in Testing and adjusting.

25

SEN02138-00

Disassembly and assembly of work equipment PPC valve assembly a

50 Disassembly and assembly

Assembly q

1

a a

In this section, only precautions for assembling the work equipment PPC valve assembly are explained.

a

Work equipment PPC valve assembly Install spring (8) with its small (inside) diameter end on the shim (10) side. Springs (11) having different numbers of turns are used for the following hydraulic ports. Take care when installing them. Installed height (34 mm), Spring constant: 0.98 Nm {0.1 kg/mm} (Common to P1, P2, P3, and P4) Port

Installed load

P1, P2

3.92 N {0.4 kg}

P3, P4

11.76 N {1.2 kg}

a

The location of each port is stamped at the lower part of the valve body. 2 Piston (7): Grease (G2-LI)

a

When installing piston (7), apply grease to the outside of the piston and inside of the body hole. 3 Mounting bolt (3) of plates (5) and (6): 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 2 Sliding part of joint (4): Grease of 2 – 4 cc (G2-LI)

a

Degrease the male threads of joint (4) and female threads of body (12) thoroughly, and then dry them. 2 Female threads of body: Adhesive (THREEBOND No. 648)

a

Apply 1 drop (about 0.02 g) of LOCTITE each to 2 places of the female threads of the body as shown in the figure. 3 Joint (4): 39 – 49 Nm {4 – 5 kgm}

a

26

Observe the tightening torque for the joint.

PC2000-8

50 Disassembly and assembly 2 3

SEN02138-00

Contacting surfaces of piston and disc (2): Grease of 0.3 – 0.8 cc (G2-LI) Nut (1): 69 – 78 Nm {7 – 8 kgm}

a

After installing the disc, see Testing and adjusting, “Adjusting work equipment, swing PPC valve”. a Take care of the direction of piston (11). 3 Mounting bolt (14) of cover (13): 19.6 – 27.5 Nm {2.0 – 2.8 kgm}

PC2000-8

27

SEN02138-00

Disassembly and assembly of travel PPC valve assembly a

50 Disassembly and assembly

7. 1

In this section, only precautions for assembling the travel PPC valve assembly are explained.

Assembly a

Clean and check the parts so that dirt, rust, flaws, etc. will not cause a trouble and then assemble them with extreme care.

1.

When assembling piston (1), apply grease (G2-LI) to the outside of the piston and inside of the body hole.

2.

Install spring (2) with its small diameter end on the shim (3) side. q Diameter of (Inside diameter) of spring Small diameter end: ø4.9 mm Large diameter end: ø5.54 mm

3.

Do not insert bushing (4) by hitting it with a hammer directly.

4.

Do not insert pin (5) by hitting it with a hammer directly.

5.

Apply grease (G2-LI) to the rocking parts of shaft (6), contacting parts of lever (7) and piston (1), and contacting parts of the lever of damper (9) and pin (8). 2 Quantity of grease (G2-LI) to be applied Rocking parts of shaft (6): 4 – 8 cc/periphery Contacting parts of lever (7) and piston (1): 0.3 – 0.8 cc/part Contacting parts of lever of damper (9) and pin (8): 0.3 – 0.8 cc/part

6.

Install washer (10) 1.6 mm thick first. If the difference of the lever stroke angle between the right and left exceeds 0.7°, replace the washer with one of different thickness to reduce the difference below 0.7°. (If the washer thickness is reduced by 0.3 mm, the stroke angle is increased by 0.39°.) a Install one of washers (10). q Thicknesses of washers: 1.0, 1.3, 1.6, 1.9, 2.2 mm

28

Tighten each part to the following torque. Plug (11): 34 – 44 Nm {3.5 – 4.5 kgm} q Plug (12): 9.8 – 14.7 Nm {1 – 1.5 kgm} q Screw (15): 0.441 – 0.588 Nm {0.045 – 0.06 kgm} q Bolt (16): 25 – 31 Nm {2.5 – 3.2 kgm} q Bolt (17): 27 – 34 Nm {2.8 – 3.5 kgm} q Plug (18): 6 – 11 Nm {0.6 – 1.1 kgm} q Plug (19): 4 – 9 Nm {0.4 – 0.9 kgm} q

PC2000-8

50 Disassembly and assembly

SEN02138-00

Disassembly and assembly of hydraulic cylinder assembly

3)

Pull out piston rod assembly (2). a Place a container under the cylinder to catch the oil.

4)

Disassemble piston rod assembly as follows. 1] Set piston rod assembly (2) to tool U1.

1

1

2

U

5

790-502-1003

Cylinder repair stand

t 1

790-101-1102

Pump

t 1

790-102-4300

Wrench assembly t 1

790-102-4310

Pin

t 2

Expander

t 1

796-720-1690

Ring (for bucket)

t 1

07281-02169

Clamp

t 1

796-720-1710

Ring (for arm)

t 1

07281-02709

Clamp

t 1

796-720-1730

Ring (for boom)

t

07281-03209

Clamp

t

790-201-1702

Push tool kit

t 1

790-201-1881

• Push tool (for bucket)

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

791-863-1110

Push tool (for arm)

t 1

790-101-5421

Grip

t 1

01010-51240

Bolt

t 1

792-630-1300

Push tool (for boom)

t 1

790-101-5421

Grip

t 1

01010-51240

Bolt

t 1

790-201-1500

Push tool kit (for bucket)

t 1

790-201-1640

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

Plate (for boom)

t 1

Grip

t 1

01010-51240

Bolt

t 1

790-445-4220

Plate (for arm)

t 1

790-101-5421

Grip

t 1

01010-51240

Bolt

t 1

6 792-715-1400 790-101-5421

Sketch

Part name

N/R

Q’ty

Part number

3 790-720-1000

4

Necessity

Symbol

Special tools

2]

Remove piston assembly stopper screw (3). Screw size: M12 × pitch 1.75: Arm, Bucket M16 × pitch 2 : Boom

Disassembly 1.

Piston rod assembly 1) Remove piping from cylinder assembly. 2) Remove mounting bolts, and disconnect head assembly (1).

PC2000-8

29

SEN02138-00 a

50 Disassembly and assembly

If screw (3) has been caulked strongly and cannot be removed, screw it in fully, then fit a tap to the thread and pull it out.

7]

3]

Using tool U2, remove piston assembly (4). q When not using tool U2, use the drill holes (H) (2 places) and loosen the piston assembly. a Drill holes ø10 mm (Bucket, Arm) ø16 mm (Boom)

2.

4] 5] 6]

30

Remove plunger (5). (Boom, bucket only) Remove collar (6). (Boom, bucket only) Remove head assembly (7).

Remove cap (8), and pull out balls (9), then remove cushion plunger (10). q Balls (9): 10 balls (Arm cylinder) 11 balls (Bucket cylinder) a Except boom cylinder

Disassembly of piston assembly 1) Remove ring (11). 2) Remove wear ring (12). a 2 pieces are installed to each of the boom cylinder, and 4 pieces to the bucket cylinder and arm cylinder. 3) Remove piston ring (13). 4) Remove O-ring and backup ring (14). q Boom cylinder

PC2000-8

50 Disassembly and assembly

q

Arm cylinder, bucket cylinder

SEN02138-00

Assembly a a

1.

3.

Be careful not to damage the packings, dust seals, and O-rings. Do not try to force the backup ring into position. Warm it in warm water (50 – 60°C) before fitting it. Assembly of cylinder head assembly 1) Using tool U5, press fit bushing (20). 2) Assemble buffer ring (19). 3) Assemble rod packing (18). 4) Using tool U6, install dust seal (17), and secure with snap ring (16). 5) Install backup ring and O-ring (15).

Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (15). 2) Remove snap ring (16), then remove dust seal (17). 3) Remove rod packing (18). 4) Remove buffer ring (19). 5) Remove bushing (20).

PC2000-8

31

SEN02138-00

2.

Assembly of piston assembly 1) Using tool U3, expand piston ring (13). a Set the piston ring on tool U3, and t ur n th e h an d le 8 – 1 0 t im e s t o expand the ring. 2) Set tool U4 in position, and compress piston ring (13).

50 Disassembly and assembly

3.

Piston rod assembly 1) Set piston rod assembly (2) to tool U1.

2) 3)

3) 4) 5)

Install backup ring and O-ring (14). Assemble wear rings (12). Assemble rings (11). a Be careful not to open the end gap of the ring too wide. 2 Ring groove: Grease (G2-LI) q Boom cylinder

q

32

4)

Assemble head assembly (7). Fit O-ring and backup ring to collar (6), then assemble. q Boom cylinder and bucket cylinder only Assemble plunger (5). q Boom cylinder and bucket cylinder only

Arm cylinder, bucket cylinder

PC2000-8

50 Disassembly and assembly

5)

Set cushion plunger (10) to piston rod, then assemble balls (9), and secure with cap (8). q Balls (9):10 balls (Arm cylinder) 11 balls (Bucket cylinder) a Except boom cylinder a Put a mark on the end surface of the rod so that the machined hole position on the cap (8) can be identified from outside. a After installing, check that the cushion plunger end has a little play.

6)

Assemble piston assembly (4) as follows. q When using rod assembly (2) and piston assembly (4) again a Wash thoroughly and remove all metal particles and dirt. 1] Screw in piston assembly (4), then use tool U2 to tighten piston assembly so that position of screw thread hole matches. a Remove all burrs and flashes with a file.

SEN02138-00

2]

Tighten screw (3). Threaded part: Thread tightener (Locktite No. 262 or equivalent) 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm} (arm and bucket) 98 – 123 Nm {10 – 12.5 kgm} (boom) 3] Caulk thread at 4 places (a) of screw (3) with punch.

q

PC2000-8

2

When using a new part for either or both of rod assembly (2) or piston assembly (4) a For the rod with bottom cushion, mark the cushion plug position on the end face of the rod. (See the item of 3. 5) q Arm cylinder, bucket cylinder only 1] Screw in until piston assembly (4) contacts end face of rod, then use tool to tighten. 3 Piston assembly (4): 294 ± 29.4 Nm {30 ± 3.0 kgm} a After tightening the piston, check that there is play in plunger (5).

33

SEN02138-00

50 Disassembly and assembly

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, bucket cylinder), avoid the cushion plug position when machining. q Screw machining dimension (mm)

Cylinder

Drill diameter

Bottom hole depth

Tap used

Tap depth

Bucket

10.3

43

12 × 1.75

36

Arm

10.3

48

12 × 1.75

44

Boom

14

48

16 × 2

44

3]

After machining, wash thoroughly to remove all metal particles and dust. 4] Tighten screw (3). 2 Threaded part: Thread tightener (Locktite No. 262 or equivalent) 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm} (arm and bucket) 98 – 123 Nm {10 – 12.5 kgm} (boom) 5] Caulk thread at 4 places (a) of screw (3) with punch.

34

7)

Set piston rod assembly (2) to tool U1.

8)

Assemble cylinder tube to piston rod assembly (2). 2 Seal portion: Grease (G2-LI) a Set the end gap of the ring at the horizontal (side) position, align the axial center of shaft and cylinder tube, then insert. a After inserting, check that the ring is not broken and has not come out, then push in fully.

PC2000-8

50 Disassembly and assembly

9)

SEN02138-00

Tighten head assembly (1) with mounting bolts. 3 Mounting bolt : Cylinder

Tightening torque

Bucket

1,270 ± 200 Nm {130 ± 20 kgm}

Arm

2,110 ± 340 Nm {215 ± 35 kgm}

Boom

2,650 ± 390 Nm {270 ± 41 kgm}

10) Install piping.

PC2000-8

35

SEN02138-00

PC2000-8 Hydraulic excavator Form No. SEN02138-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 11-06 (01)

36

SEN02139-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

50 Disassembly and assembly

1

Work equipment Work equipment .............................................................................................................................................. 2 Removal and installation of bucket cylinder assembly ......................................................................... 2 Removal and installation of bucket assembly ...................................................................................... 4 Removal and installation of arm cylinder ............................................................................................. 6 Removal and installation of arm assembly........................................................................................... 8 Removal and installation of boom cylinder assembly ........................................................................ 10 Removal and installation of boom assembly ...................................................................................... 12

PC2000-8

1

SEN02139-00

50 Disassembly and assembly

Work equipment Removal and installation of bucket cylinder assembly

1

5.

Temporarily lift the bucket cylinder assembly, remove plate (6) and pull out pin (7) on the bottom side. [*2] a If the pin would not be pull out, pull out the pin on the bottom side using a bolt or eyebolt.

6.

Remove bucket cylinder assembly (8). 2 Bucket cylinder assembly: 900 kg

1

Backhoe specification Removal k

a

Contract the arm and bucket cylinder piston rods, lower the work equipment to the ground completely and set the lock lever to the lock position. After disconnecting hoses, install plugs to prevent foreign matters from entering them.

1.

Set block [1] between the bucket cylinder and the arm, and block [2] between the link and the arm respectively.

2.

Remove 3 pin fastening bolts (1) inside the link and a stopper (2), and then pull out pin (3) on the head using a forcing screw. [*1]

3.

Start the engine and contract the piston rod. Bind the piston rod with wire to prevent it from falling out.

4.

Disconnect hose (4) and lubricating hose (5).

2

PC2000-8

50 Disassembly and assembly

SEN02139-00

Installation q

Carry out the installation in the reverse order of removal.

[*1]

2

Internal bushing surface during pin assembly: Antifriction composition (LM-P) 2 Greasing after pin assembly: Grease (LM-G) k When aligning holes of the pins, absolutely do not insert fingers into a pin hole. [*2]

2

Internal bushing surface during pin assembly: Antifriction composition (LM-P) 2 Greasing after pin assembly: Grease (LM-G) k When aligning holes of the pins, absolutely do not insert fingers into a pin hole. q Adjust shim (10) so that the clearance (a) between bucket cylinder (8) bottom end face and arm (9) shall be 1 mm max. q Shim thickness: 1.0 mm

q

a

q

a

Bleeding air Bleed air, referring to "Bleeding air from each part" in Testing and adjusting. 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.

PC2000-8

3

SEN02139-00

Removal and installation of bucket assembly

50 Disassembly and assembly

1

Backhoe specification Removal k

Place the work equipment stably on the ground with the back of the bucket facing downward. Set the lock lever to the lock position.

1.

Remove 3 pin lock bolts (1), and then remove the stopper (2).

2.

Remove connecting pin (3) for the link and bucket using a forcing screw. [*1]

3.

Start the engine and contract the piston rod. Bind the link to the arm with wire to prevent the piston rod from falling out.

4.

Remove greasing piping cover (4) and disconnect greasing hose (5).

5.

Remove 6 pin cover lock bolts (6), and then remove pin cover (7). Remove 6 pin cover lock bolts (8), and then remove pin cover (9).

6. 7.

Remove arm connecting pin (10).

8.

Start the engine, raise the work equipment, disconnect the arm from the bucket and then remove the bucket assembly. 2 Bucket assembly: 10,000 kg

4

[*2]

PC2000-8

50 Disassembly and assembly

SEN02139-00

Installation q

Carry out installation in the reverse order to removal.

[*1]

2

Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. [*2]

2

Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. a Insert the O-ring at the end face of the bucket boss securely.

PC2000-8

5

SEN02139-00

Removal and installation of arm cylinder

50 Disassembly and assembly

5.

Disconnect hose (4) and lubricating hose (5) on the bottom side.

6.

Temporarily lift the arm cylinder assembly, remove the plate (6) and pull out pin (7) on the bottom side. [*2] a If the pin would not be pull out, pull out the pin on the bottom side using a bolt or eyebolt.

7.

Remove arm cylinder assembly (8).

1

Backhoe specification Removal k

a

Extend the arm cylinder piston rod to approx. 200 mm before the end of excavating stroke. Lower the work equipment completely to the ground and set the lock lever to the lock position. After disconnecting hoses, install plugs to prevent foreign matters from entering them.

1.

Set block [1] between arm cylinder (8) and the boom.

2.

Disconnect greasing hose (1) on the head side.

3.

Remove the plate (2) and then pull out the pin (3) on the head side. [*1] a If the pin would not be pull out, pull out the pin on the head side using a bolt or eyebolt.

4.

Start the engine and contract the piston rod. Bind the piston rod with wire to prevent it from falling out.

6

4

Arm cylinder assembly: 1,300 kg

PC2000-8

50 Disassembly and assembly

Installation q

Carry out installation in the reverse order to removal.

[*1]

2

Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. a

SEN02139-00

q

a

q

a

Bleeding air Bleed air, referring to "Bleeding air from each part" in Testing and adjusting. 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.

Install shim (10) of 8.0 mm thick to the clearance (a) between arm cylinder (8) head end face and arm assembly (9).

[*2]

2

Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. a Install shim (12) of 11 mm thick to the clearance (a) between arm cylinder (8) bottom end face and boom assembly (11).

PC2000-8

7

SEN02139-00

50 Disassembly and assembly

Removal and installation of arm assembly

3.

Disconnect greasing hose (1) from inside.

4.

Remove plate (2).

5.

Temporarily lift the arm cylinder and pull out pin (3) on the arm cylinder head side. [*1] a If the pin would not be pull out, pull out the pin on the head side using a bolt or eyebolt.

6.

Start the engine and contract the piston rod. Bind the piston rod with wire to prevent it from falling out.

7.

Set block [3] between the arm cylinder and the boom, and place the arm cylinder on block [3].

8.

Disconnect 2 bucket cylinder hoses (4).

9.

Disconnect greasing tube (5).

1

Backhoe specification

Symbol

V

Part No.

Part name

Necessity Q'ty New/Remodel Sketch

Special tools

796T-870-1150 Sleeve

t 1

Q

796T-870-1170 Sleeve

t 1

Q

796-870-1180

t 1

Adapter

796T-870-1190 Plate

t 1

796-900-1230

Screw

t 1

01582-33024

Nut

t 1

01643-33080

Washer

t 1

790-101-4000

Puller t 1 (1,471 kN {150 ton})

790-101-1102

Pump

Q

t 1

Removal 1.

Remove the bucket assembly, referring to "Removal of bucket assembly."

2.

Fix the link to the arm using a wire. k Extend the arm cylinder piston rod to approx. 200 mm before the end of excavating stroke. Lower the arm on to block [1] and blocking tool [2]. k Set the lock lever to the lock position and stop engine.

8

10. Remove plate (6).

PC2000-8

50 Disassembly and assembly

SEN02139-00

Installation q

Carry out installation in the reverse order to removal.

[*1]

2

Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. [*2]

2

11. Lift arm assembly (8) temporarily. a Keep the arm lowered on block [1] and blocking tool [2] (described above). q A: Sling brackets 12. Remove boom stop pin (7) using tool V.

[*2]

13. Run the engine and raise the boom.

Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. a Adjust the clearance between boom assembly (9) and arm assembly to 1.5 mm max. using shim (10). q Shim thickness: 12 mm, 9 mm, 1.5 mm and 1.0 mm

14. Lift and remove arm assembly (8). 4

Arm assembly (including bucket cylinder and link): 12,600 kg

q

a

q

a

PC2000-8

Bleeding air Bleed air, referring to "Bleeding air from each part" in Testing and adjusting. 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.

9

SEN02139-00

Removal and installation of boom cylinder assembly 1

50 Disassembly and assembly

5.

Start the engine and contract the piston rod. Bind the piston rod with wire to prevent it from falling out.

6.

Lower the boom cylinder assembly to a blocking tool and disconnect hoses (4).

7.

Disconnect greasing hose (5).

8.

Temporarily lift the boom cylinder assembly, and remove lock plate (6).

9.

Pull out pin (7) on the bottom side using an eyebolt. [*2]

Backhoe specification Removal k

a

Contract the arm and bucket cylinder piston rods, lower the work equipment to the ground completely and set the lock lever to the lock position. After disconnecting hoses, install plugs to prevent foreign matters from entering them.

1.

Disconnect greasing hose (1).

2.

Remove lock plate (2).

10. Remove boom cylinder assembly (8). 3.

Lift the boom cylinder assembly temporarily.

4.

Pull out the pin on the head side using a bolt or eyebolt to sections (A), and disconnect the piston rod from the boom. [*1]

10

4

Boom cylinder assembly: 2,400 kg

PC2000-8

50 Disassembly and assembly

Installation q

Carry out installation in the reverse order to removal.

[*1]

2

SEN02139-00

q

a

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.

Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. a Align the pin hole position by lifting the pin and piston rod.

[*2]

2

Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. a Adjust shim (10) so that the clearance (a) between bucket cylinder (8) bottom end face and arm (9) shall be 1 mm max. q Shim thickness: 1.0 mm and 1.5 mm a Install shim (11) of 16 mm thick to inside the machine body on the bottom side of boom cylinder (8).

q

a

Bleeding air Bleed air, referring to "Bleeding air from each part" in Testing and adjusting.

PC2000-8

11

SEN02139-00

Removal and installation of boom assembly 1

50 Disassembly and assembly

7.

4

Backhoe specification Removal 1.

Remove the arm assembly, referring to "Removal of arm assembly." k Lower the boom to the ground completely and set the lock lever to the lock position.

2.

Disconnect the boom cylinder assembly from the boom, referring to "Removal of boom cylinder assembly."

3.

Disconnect headlamp wiring (1).

4.

Disconnect greasing hose (2).

5.

Disconnect bucket cylinder hose (3) and arm cylinder hose (4).

6.

Lift boom assembly (5) temporarily.

12

Remove lock plate (6) and then remove 2 boom foot pins (7) using the eyebolt. [*1]

8.

Boom assembly (including arm cylinder): 21,000 kg

Lift and remove boom assembly (5).

PC2000-8

50 Disassembly and assembly

SEN02139-00

Installation q

Carry out installation in the reverse order to removal.

[*1]

2

Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. a Adjust shim (9) so that the clearance (a) between boom (5) foot end face and bracket (8) shall be 1 mm max. q Shim thickness: 1.0 mm and 1.5 mm

q

a

q

a

Bleeding air Bleed air, referring to "Bleeding air from each part" in Testing and adjusting. 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.

PC2000-8

13

SEN02139-00

PC2000-8 Hydraulic excavator Form No. SEN02139-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 11-06 (01)

14

SEN02140-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

50 Disassembly and assembly

1

Cab and its attachments Cab and its attachments ................................................................................................................................. 2 Removal and installation of operator cab assembly............................................................................. 2 Removal and installation of operator cab glass (adhesion glass) ........................................................ 5 Removal and installation of operator cab (assembly-type) ................................................................ 12 Removal and installation of cab base assembly ................................................................................ 13

PC2000-8

1

SEN02140-00

50 Disassembly and assembly

Cab and its attachments Removal and installation of operator cab assembly

1

Part name

Necessity Q'ty New/Remodel Sketch

Part No.

799-703-1200

Service tool kit

t 1

799-703-1100

Vacuum pump (100 V)

t 1

X 3 799-703-1111

Vacuum pump (220 V)

t 1

799-703-1121

Vacuum pump (240 V)

t 1

799-703-1401

Gas leak detector

t 1

Remove plate (3) and disconnect 2 air conditioner hoses (4). [*2]

5.

Disconnect air conditioner hose (5).

6.

Disconnect drain hose (6).

7.

Disconnect connector A35 (7).

8.

Disconnect 4 heater hoses (8).

9.

Disconnect clips (9) and washer hoses (10) from the cab base.

1

Special tools Symbol

4.

[*3]

Removal k k k k k

1.

2.

Lower the work equipment completely to the ground and stop the engine. Set the work equipment lock lever to the lock position. Disconnect the cable from the negative (–) terminal of the battery. Collect the refrigerant (air conditioner gas: R134a). Always wear protective glasses when collecting or filling the refrigerant (air conditioner gas: R134a). Refrigerant in your eyes could cause blindness. Only the qualified personnel shall perform collection and filling of the refrigerant. Drain coolant. 6

Coolant: 180 l

Disconnect air conditioner hose (1) from under the air conditioner unit. [*1] 10. Disconnect antenna wire (11) from the distribution board of the cab base.

3.

2

Disconnect connector M84A (2).

PC2000-8

50 Disassembly and assembly

11. Disconnect grounding wire (12) from the cab base ceiling.

SEN02140-00

16. Remove the covers (17).

12. Disconnect connectors (13). (Connector numbers read A03, A02 and A01 from the left.) 13. Disconnect PPC hoses (14). From the right Boom lower: Brown Boom raise: Green Bucket dump: Black Bucket curl: White Arm out: Yellow Arm in: Blue Right swing: Without collar band Left swing: Red 14. Disconnect PPC hoses (15). From the right Right lever P: Red Right lever T: Blue and blue Left lever P: Red and white Left lever T: Blue and white

17. Remove the mounting bolts, and then lift and remove the operator cab assembly (18). [*4] 4

Operator cab assembly: 1,850 kg

15. Disconnect PPC hoses (16) from the front of the cab base ceiling. From the right Right travel forward: Blue and black P: Red Right travel reverse: Black and black Left travel reverse: Red and black T: Blue Left travel forward: Green and black

PC2000-8

3

SEN02140-00

Installation q

50 Disassembly and assembly

1.

Adjust clearances (a) and (b) with the operator on board after having installed the operator cab assembly. q Clearance for both (a) and (b): 3 mm Max. a Shim thickness for (S1) and (S2): 1.6 mm and 3.2 mm

q

Filling of refrigerant Using tool X3, fill the air conditioner circuit with the refrigerant (air conditioner gas: R134a). a Filling amount: 950 ± 50 g (per one air compressor) a Two air compressors are used.

Carry out the installation in the reverse order of removal.

[*1], [*2], [*3] a Install the hoses without twisting. a When installing the air conditioner circuit hoses, use care so that dirt, water, may not enter. a Make sure before the installation that there is O-ring (70) at the piping connector of the air conditioner hose. a Check that there is no defect or deterioration on the O-ring. a When connecting the piping for refrigerant, apply the compressor oil for the new refrigerant to the O-ring (Denso: ND-OIL8 or ZEXEL: ZXL100PG (PAG46 or equivalent)).

a

When connecting the refrigerant piping, use double spanner to tighten the piping. 3 Hose thread M16 × 1.5 (Width across flats 19): 12 – 15 Nm {1.2 – 1.5 kgm} 3 Hose thread M22 × 1.5 (Width across flats 24): 20 – 25 Nm {2.0 – 2.5 kgm} 3 Hose thread M24 × 1.5 (Width across flats 27): 30 – 35 Nm {3.0 – 3.5 kgm} 3 M6 bolt (width across flats: 10) for the piping: 8 – 12 Nm {0.8 – 1.2 kgm}

[*4]

3

4

Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}

PC2000-8

50 Disassembly and assembly

SEN02140-00

Removal and installation of operator cab glass (adhesion glass) a a a

Removal 1

Of the 4 window glasses of the operator cab, adhesive type glasses are (1) and (2) as shown in the figure. This section describes replacement procedures of adhesive type glass (for the righthand side window glass (1)). For the front window glass (2), the same procedure applies as for the right-hand side window glass (1). (Difference between the righthand side window glass (1) is in the size and weight.)

a

Remove the window glass to be replaced according to the following procedure.

1.

Using seal cutter [1], cut the adhesive between broken window glass (7) and operator's cab (metal sheet) (8).

a

If a seal cutter is not available, make holes on the adhesive and both-sided adhesive tape with a drill and pass a fine wire (piano wire, etc.) [2] through the holes. Grip the both ends of the wire with pliers [3], etc. (or hold them by winding them onto something) and move the wire to the right and left to cut the adhesive and both-sided adhesive tape. Since the wire may be broken by the frictional heat, apply lubricant to it.

(1): Right-hand side window glass (2): Front window glass 4

Right-hand side window glass: 40 kg Front window glass: 65 kg

(The figure shows the operator's cab of a wheel loader.)

Symbol

X

Part No.

Part name

Necessity Q'ty New/Remodel Sketch

Special tools

1 793-498-1210

Lifter (Suction cup)

t 4

2 20Y-54-13180

Adapter

t 2

PC2000-8

5

SEN02140-00 a a

If the window glass is broken finely, it may be removed with knife [4] and a screwdriver. Widening the cut with a screwdriver, cut the adhesive and both-sided adhesive tape with knife [4].

50 Disassembly and assembly

Installation 1.

(The figure shows the operator's cab of a wheel loader.)

Using a knife and scraper [5], remove the remaining adhesive and both-sided adhesive tape from the metal sheets (glass sticking surfaces) of the operator's cab. a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surf a c e s . ( I f t h e pa i n t e d s u r f a c e s a r e scratched, adhesion will be lowered.) (The figure shows the operator's cab of a wheel loader.)

2.

Remove the window glass.

2.

Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and window glass (9) with white gasoline. a If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all black part on the back side of the window glass. a After cleaning the sticking surfaces, leave them for at least 5 minutes to dry. (The figure shows the operator's cab of a wheel loader.)

6

PC2000-8

50 Disassembly and assembly

3.

Apply primer (10). a The using limit of primer (10) is 4 months after the date of manufacture. Do not use primer (10) after this limit. a Use the primer within 2 hours after unpacking it. a Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Disc a r d t h e pr im e r 2 4 ho u r s a fte r i t is unpacked.) 1) Stir the primers for paint and glass sufficiently before using them. a If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a day before stirring it. (If the primer is unpacked just after taken out of the refrigerator, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.) 2) When reusing primer brush (11), wash it in white gasoline. a After washing the brush, check it again for dirt and foreign matter. a Prepare respective brushes for the paint primer glass primer.

SEN02140-00

3)

Evenly apply paint primer to the surfaces to stick both-sided adhesive tapes and the surfaces out of those surfaces on operator's cab (8) which will be coated with the adhesive. 2 Paint primer: SUNSTAR PAINT PRIMER 435-95 a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.) (The figure shows the operator's cab of PC200.)

a q q

a

a a

PC2000-8

Parts to be coated with primer: Apply the primer all over dimension (a). Dimension to apply primer (a): 30 mm Dam rubber (6) mounting dimension (b): 8.5 mm (8): Operator’s cab

After applying the primer, leave it for at least 5 minutes (within 24 hours) to dry. Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline.

7

SEN02140-00

4)

Evenly apply glass primer to the sticking surfaces of window glass (9). 2 Glass primer: SUNSTAR GLASS PRIMER 435-40 a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)

a

Parts to be coated with primer: Apply the primer to the sticking surfaces of window glass (9) and all over dimension (d) which will be on both-sided adhesive tape (6) and operator's cab (8). Do not apply the primer to the boarder about 5 mm wide between the black part and transparent part of the glass. (This is because the adhesive is photoreactive.) Black glass portion is provided to shield lights (protection of adhesive agent).) Application dimensions (d) for glass (9) primer: 30 mm Dam rubber (6) mounting dimension (b): 8.5 mm After applying the primer, leave it for at least 5 minutes (within 24 hours) to dry. Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline.

a

q q

a a

8

50 Disassembly and assembly

4.

Stick both-sided adhesive tape (6) along 8.5 mm off from the inside edge of the glass sticking section. a Do not remove the release tape of the both-sided adhesive tape on the glass sticking side before sticking the glass. a When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. a Take that the both-sided adhesive tape will not float at each corner of the window frame.

a

1)

When sticking both-sided adhesive tape (6) around a frame, do not lap its finishing end over the starting end but make clearance (e) of about 5 mm between them. Stick both-sided adhesive tape (6) for right side window glass (1) as shown in the figure.

PC2000-8

50 Disassembly and assembly

5.

Position the new window glass. 1) Check the clearance between the window glass and the operator's cab on the right, left, upper, and lower sides, and then adjust it evenly. 4 Right-hand side window glass: 40 kg Front window glass: 65 kg 2) Stick tapes [6] between window glass (9) and operator's cab (8) and draw positioning line (n). 3) Cut the tape between window glass (9) and operator's cab (8) with a knife, and then remove the window glass. a Do not remove the tapes left on the window glass and operator's cab before installing the window glass. (The figure shows the operator's cab of PC200.)

SEN02140-00

6.

Apply adhesive. a Use either of the 2 types of the adhesive. 2 Adhesive (Summer): SUNSTAR PENGUINE SEAL 580 SUPER "S" 2 Adhesive (Winter): SUNSTAR PENGUINE SEAL 580 SUPER "W" a The using limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit. a Keep the adhesive in a dark place where the temperature is below 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. 1) Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle.

2)

PC2000-8

Cut the tip of the adhesive nozzle (14) so that dimensions (q) and (r) will be as follows. q Dimension (q) : 10 mm q Dimension (r) : 15 mm

9

SEN02140-00

3)

Set adhesive cartridge (12) to caulking gun [7]. a An electric caulking gun is more efficient.

4)

Remove the release tape of the bothsided adhesive tape on the glass side. Apply adhesive (15) to the outside of bothsided adhesive tape (6) of the operator's cab. a Reconfirm that the primer is coated on the surface to coat the adhesive, then coat the adhesive. a Apply adhesive (15) to dimensions (s) and (t) of both-sided adhesive tape (6) of operator's cab (8). q Dimension (s) : 10 mm q Dimension (t) : 15 mm a Apply adhesive (15) higher than bothsided adhesive tape (6). a Apply the adhesive evenly.

5)

10

50 Disassembly and assembly

7.

Install the window glass. 1) Install window glass (9), matching it to the lines of the positioning tapes drawn in step 5. a Since the window glass cannot be removed and stuck again, stick it very carefully. a Stick the glass within 5 minutes after applying the adhesive. 2) After sticking window glass (9), press all around it until it is stuck to the both-sided adhesive tape. a Press the corners of the window glass firmly.

a

You can perform this work efficiently by pulling window glass (9) from inside of the operator's cab with suction cup (X1). (The figure shows the operator's cab of PC200.)

PC2000-8

50 Disassembly and assembly

8.

Fix the window glass. 1) After installing right window glass (1) to the operator's cab, insert stopper rubbers (X2) to 2 places (v) at the bottom of the glass to fix the glass.

SEN02140-00 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 humidity of 60%). 2) After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait at least 14 hours, at least 24 hours in total, before operating the machine actually. 11. Install window frame (17).

2)

9.

Using styrene foam blocks [9] and rubber bands [10], fix the window glass and bothsided adhesive tape to fit them completely. (The figure shows the operator's cab of PC200.)

After installing the window glass, remove the primer and adhesive from the operator's cab and window glass. a Using white gasoline, wipe off the adhesive before it is dried up.

PC2000-8

11

SEN02140-00

Removal and installation of operator cab (assembly-type)

50 Disassembly and assembly

2. 1

Removal a

This section describes replacement procedure for assembly-type window glass (left hand window glass (1), (2) and (6)).

1.

Remove window glass (1) and (2) as follows: 1) Lift window glass (1) and (2) and separate them from the lower frame (F). 2) Remove window glass (1) and (2) by tilting them sideways.

Remove window glass (6) as follows: 1) Remove 33 bolts (4) to remove frame (3) assembly. 2) Remove 4 screws (5) bolts each from Y and Z to disassemble frame (3). 3) Remove window glass (6).

Installation q

12

Carry out the installation in the reverse order of removal.

PC2000-8

50 Disassembly and assembly

Removal and installation of cab base assembly

SEN02140-00

1

Removal 1.

Remove the operator cab assembly, referring to "Removal and installation of operator cab assembly."

2.

Remove hand rail (1) and floor (2).

3.

Disconnect PPC hoses (3). From the top

9.

Pull out harness (11) from the cab base. (See the preceding section)

10. Disconnect connectors A05 (12), A04 (13) and A22 (14). 11. Disconnect 2 heater hoses (15).

4.

Disconnect connectors A11 (4), A12 (5), A25 (6) and A10 (7) from right rear of the cab base.

5.

Pull out harness (8) from the cab base.

12. Temporarily lift cab base assembly (16). a Special brackets (A) are provided.

6.

Disconnect 7 connectors (9) from left rear of the cab base. From the top B01, B02, B03, B04, B05, A27, A24

7.

Disconnect clips (10).

8.

Pull out harness (11) from the cab base. (See the following section)

PC2000-8

13

SEN02140-00

13. Remove mounting bolts (17) under the cab base. [*1]

50 Disassembly and assembly

15. Lift and remove cab base assembly (16). a Work equipment is not installed in the picture. 4

Cab base assembly: 2,000 kg

14. Remove mounting bolts (18) in the middle (and right-hand side) of the cab base. [*2]

Installation q

Carry out the installation in the reverse order of removal.

[*1], [*2] 3 Mounting bolts: 455 – 565 Nm {46.5 – 58 kgm}

a

14

Cab base mounting bolts

PC2000-8

SEN02140-00

PC2000-8 Hydraulic excavator Form No. SEN02140-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 11-06 (01)

16

SEN02141-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

50 Disassembly and assembly

1

Electrical system Electrical system ............................................................................................................................................. 2 Removal and installation of air conditioner unit assembly ................................................................... 2 Removal and installation of monitor assembly ..................................................................................... 6 Removal and installation of engine controller assembly ...................................................................... 7 Removal and installation of pump controller assembly ........................................................................ 8 Removal and installation of pump controller assembly ........................................................................ 8 Removal and installation of VHMS controller assembly....................................................................... 9 Removal and installation of Orbcomm terminal assembly for VHMS................................................... 9

PC2000-8

1

SEN02141-00

50 Disassembly and assembly

Electrical system

1

Removal and installation of air conditioner unit assembly

1

Symbol

Part No.

Part name

Necessity Q'ty New/Remodel Sketch

Special tools

799-703-1200

Service tool kit

t 2

799-703-1100

Vacuum pump (100 V)

t 1

X 3 799-703-1111

Vacuum pump (220 V)

t 1

799-703-1121

Vacuum pump (240 V)

t 1

799-703-1401

Gas leak detector

t 1

4.

Remove covers (5), (6) and (7).

5.

Remove ducts (8) and (9).

6.

Disconnect connector M84B (10) from under.

7.

Remove plate (11) and disconnect 2 air conditioner hoses (12) and (13). [*1]

8.

Disconnect 2 heater hoses (14).

9.

Disconnect drain hose (15).

Removal k k k k k

1.

Lower the work equipment completely to the ground and stop the engine. Set the work equipment lock lever to the lock position. Disconnect the negative (–) terminal of the battery beforehand. Collect the refrigerant (air conditioner gas: R134a). Always wear protective glasses when collecting or filling the refrigerant (air conditioner gas: R134a). Refrigerant in your eyes could cause blindness. Only the qualified personnel shall perform collection and filling of the refrigerant. Drain coolant. 6

2. 3.

2

Coolant: 180 l

Remove covers (1) and (2) from the rear of the operator's cab.

10. Disconnect connector A35 (16).

Remove outside air filters (3) and plate (4).

PC2000-8

50 Disassembly and assembly

11. Remove duct (17) for the foot.

SEN02141-00

19. Remove ducts (30) and (31).

12. Disconnect clips (18) and (19). 13. Disconnect 2 heater hoses (20). 14. Disconnect drain hose (21). 15. Disconnect grommet (22).

20. Remove face duct (32) and rear duct (33). a Before removing both ducts (32) and (33), remove their mounting bolts.

16. Disconnect connector M84A (23). 17. Remove plate (24) and disconnect two air conditioner hoses (25). [*2] 18. Disconnect connectors M33A (26), M27A (27), M33B (28) and M27B (29).

21. Remove defroster ducts (34) and (35).

PC2000-8

3

SEN02141-00

22. Remove air conditioner unit (36). a (44): Underside of air conditioner unit

23. Remove defroster duct (37) and rear duct (38). 24. Remove bracket (39) and face duct (40).

50 Disassembly and assembly

27. Remove air conditioner unit (44).

Reference a D1 and D2 are equipped with the following ducts: D1: Foot duct D2: Foot duct, rear duct and defroster duct a The air blow from upper and lower air conditioner units is mixed by these ducts and the already removed ducts, and is sent to the operator's cab.

25. Remove face duct (41). 26. Remove defroster ducts (42) and (43).

q

a

4

Conceptual diagram of air conditioner and duct layout FCD: Face duct RD: Rear duct DD: Defroster duct FD: Foot duct

PC2000-8

50 Disassembly and assembly a

DD: Defroster duct FD: Foot duct F: Inside air filter

SEN02141-00

Installation q

Carry out the installation in the reverse order of removal.

[*1], [*2] a Take care to prevent the hose of the air conditioner circuit from entry of dusts, dirt or water. a Before proceeding to the installation, check that the O-ring is provided at the air conditioner hose connection. a Check the O-ring for scratches or degradation. a When connecting the air conditioner hose, apply the O-rings with the compressor oil for coolant R134a (Denso: ND-OIL8 or Zexel: ZXL100PG (PAG46 or equivalent)), and tighten them with a double wrench. 3 M6 bolt (width across flats: 10) for the piping: 8 – 12 Nm {0.8 – 1.2 kgm} q

PC2000-8

Filling of coolant (air conditioner gas) Using tool X3, fill the air conditioner circuit with the coolant (air conditioner gas: R134a). a Filling amount: 950 ± 50 g (Per unit of air conditioner compressor) a Two air compressors are used.

5

SEN02141-00

Removal and installation of monitor assembly

50 Disassembly and assembly

3.

Disconnect connectors CM01 (4) and CM02 (5) from the rear of the monitor panel assembly (2). [*1] a NC: Non-connected connector

4.

Remove monitor panel assembly (2).

1

Removal k k k

Lower the work equipment completely to the ground and stop the engine. Set the work equipment lock lever to the lock position. Disconnect the negative (–) terminal of the battery beforehand.

1.

Remove panel (1).

2.

Remove cover (3) from the rear of the monitor panel assembly (2).

Installation q

Carry out the installation in the reverse order of removal.

[*1] Care must be taken not to connect connector CM01 (4) and CM02 (5) for the monitor panel assembly to non-connected connectors (NC) by error.

6

PC2000-8

50 Disassembly and assembly

Removal and installation of engine controller assembly

SEN02141-00

Installation 1

q

Removal k k k

1.

Lower the work equipment completely to the ground and stop the engine. Set the work equipment lock lever to the lock position. Disconnect the negative (–) terminal of the battery beforehand. Remove engine controller cover (1) from inside the power container.

[*1] q

Make sure inside (particularly the bottom) of the controller connector is free from sands, dusts or water. If such foreign substances are present, clean them completely with the air blow. (Sands, dusts or water can cause defect contact or allow commingling of water.)

a

Reference Replacement procedure of O-ring seal on power supply connector CE06 (5) O-ring seal: 1010-074-0406 (Nihon-Deutsch Ltd.)

q

2.

Disconnect connectors CE05 (3), ENG (4) and CE06 (5) from the engine controller assembly (2). [*1] a Connectors (3) and (4): Unlock using a hexagonal 4-mm wrench.

3.

Remove engine controller assembly (2). a Remove the opposite side in the same procedures.

PC2000-8

Installation is done in the reverse order of removal.

1)

Remove cover (8) by pressing the claw with tweezers [1].

2)

Remove O-ring (9) using tweezers [1].

7

SEN02141-00

50 Disassembly and assembly

Removal and installation of pump controller assembly 1 Removal k k k

Lower the work equipment completely to the ground and stop the engine. Set the work equipment lock lever to the lock position. Disconnect the negative (–) terminal of the battery beforehand.

1.

Open cover (1) from the rear of the operator's cab.

2.

Disconnect connectors (2) to (7). a All the connectors: Unlock using the hexagonal 4-mm wrench.

3.

Remove pump controller assemblies (8) and (9).

Installation q

8

Carry out the installation in the reverse order of removal.

PC2000-8

50 Disassembly and assembly

Removal and installation of VHMS controller assembly 1 Removal k k k

1. 2.

3.

Lower the work equipment completely to the ground and stop the engine. Set the work equipment lock lever to the lock position. Disconnect the negative (–) terminal of the battery beforehand. Open distribution board cover from the cab base. Disconnect connectors CV03A (1), CV01 (2), CV04A (3), CV02B (4), CV02A (5) and CV04B (6). [*1]

SEN02141-00

Removal and installation of Orbcomm terminal assembly for VHMS

1

Removal k k k

Lower the work equipment completely to the ground and stop the engine. Set the work equipment lock lever to the lock position. Disconnect the negative (–) terminal of the battery beforehand.

1.

Open distribution board cover from the cab base.

2.

Disconnect connector (1). a Turn the connector counterclockwise while pressing it toward the controller.

3.

Disconnect connector CK01 (2).

4.

Remove VHMS Orbcomm terminal assembly (4).

Remove VHMS controller assembly (7).

Installation q

Carry out the installation in the reverse order of removal.

[*1] Care must be taken not to insert connectors CV03A (1) (white) and CV02A (5) (green) in reverse to wrong mating receptacles.

PC2000-8

Installation q

Carry out the installation in the reverse order of removal.

9

SEN02141-00

PC2000-8 Hydraulic excavator Form No. SEN02141-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 11-06 (01)

10

SEN01629-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

90 Diagrams and drawings

1

Hydraulic diagrams and drawings Hydraulic diagrams and drawings................................................................................................................... 3 Hydraulic circuit diagram...................................................................................................................... 3

PC2000-8

1

Hydraulic diagrams and drawings

Hydraulic circuit diagram PC2000-8

1

Hydraulic circuit diagram

1

SEN01629-00

PC2000-8

3

SEN01629-00

PC2000-8 Hydraulic excavator Form No. SEN01629-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 09-06 (01)

6

SEN01630-03

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC2000-8

Machine model

Serial number

PC2000-8

20001 and up

90 Diagrams and drawings

1

Electrical diagrams and drawings Electrical diagrams and drawingss ................................................................................................................. 3 Electrical circuit diagram (1/2).............................................................................................................. 3 Electrical circuit diagram (2/2).............................................................................................................. 5 Connector arrangement diagram ......................................................................................................... 7

PC2000-8

1

SEN01630-03

2

90 Diagrams and drawings

PC2000-8

Electrical diagrams and drawingss Electrical circuit diagram (1/2)

Electrical circuit diagram (1/2) PC2000-8

SEN01630-03 PC2000-8

3

Electrical circuit diagram (2/2)

Electrical circuit diagram (2/2) PC2000-8

SEN01630-03 PC2000-8

5

Connector arrangement diagram PC2000-8

Connector arrangement diagram Connector No. 815 A01 A02 A03 A04 A05 A06 A07 A08 A09 A10 A11 A12 A13 A14 A15 A17 A19 A20 A20A A20B A21 A22 A23 A24 A24 A25 A27 A29 A31 A32 A33 A34 A35 ANR1 ANR2 B01 B02 B03 B04 B05 B11 B12A B12B B13 B14A B14B B15A B15B B16A B16B B17 B18 B21A B21B B21C B22A B22B B22C B23A B23B B24A B24B B25A B25B B26A B26B B27A B27B B28A B28B B28C B29A B29B B30A B30B C10 C11 CE02 CE03 CE05 CE06 CK01 CM01 CM02 CM05 CM850.L CM850.R CN.ANR CN1 CN1 CN2 CN2 CN3 CN3 CN4 CN4 CN5 CN5 CN6 CN6 CP01 CP02 CP03 CP04 CP05 CP06 CV01 CV02A CV02B CV03A PC2000-8

Model

Number of pins

HD36 DRC DRC DRC DRC DRC DRC DT DT DRC DT DT DT DT DT DT DT DT DT

14 70 70 70 70 40 70 6 6 40 12 12 12 12 12 6 4 2 6

DT DTP DTP DTHD DT DT DT DT DT DT DT DT DT Terminal Terminal DTHD DTHD DTHD DTHD DTHD Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal DT DT DRC DTP DRC DTP DRC 070 070 IRA-A20 Terminal Terminal DT

2 4 4 1 12 2 4 4 8 6 12 12 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 50 4 50 4 40 18 12 8 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 24 40 40 24 40 40 20 18 12 18

DRC DRC DRC DRC DRC DRC 070 070 070 070

Component name Intermediate connector (Male) (connected to E01) Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Emergency stop switch Emergency stop switch Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Service connector (+12 V) Intermediate connector Air heater relay terminal Air heater relay terminal Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector (backup lamp) (OPT) Emergency stop prolix switch Swing brake emergency drive switch Pump 1 emergency drive switch Pump 2 emergency drive switch Bottom dump control valve Alternator R terminal Alternator R terminal Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Model selection pump controller Model selection pump controller Engine controller (Left bank) Engine controller (Left bank) Engine controller (Right bank) Engine controller (Right bank) ORBCOM controller Monitor Monitor Rear camera (OPT) GND (Engine controller) (Left bank) GND (Engine controller) (Right bank) Intermediate connector Injector #1 (Left bank) Injector #1 (Right bank) Injector #2 (Left bank) Injector #2 (Right bank) Injector #3 (Left bank) Injector #3 (Right bank) Injector #4 (Left bank) Injector #4 (Right bank) Injector #5 (Left bank) Injector #5 (Right bank) Injector #6 (Left bank) Injector #6 (Right bank) Pump controller 1 Pump controller 1 Pump controller 1 Pump controller 2 Pump controller 2 Pump controller 2 VHMS controller VHMS controller VHMS controller VHMS controller

Address of stereogram

Connector No.

AW-3 AB-9, AL-9 AB-9, AL-9 AB-9, AM-9 AO-2 AO-2 A-1 BH-6 J-9 L-1 AE-8 AE-9 AE-8 AE-8 AE-4, AN-2 AN-3 AE-4, AN-2

CV04A CV04B D01 D02 D03 D04 D05 D06 DA1 DA2 DA3 DA4 DA5 DA6 DW1 DW2 DW3 E01 ENBP ENG (L) ENG (R) F01 G G

M-9 A-2 B-2 G-9 AO-1 A-1 AP-2 E-1 AE-8 AP-2 M-2 AC-3 AC-3 AC-4 AC-3 L-1, AA-6 BB-4 BB-4 AP-3 AP-3 AP-3 AP-3 AP-3 M-9 M-9 M-9 M-9 M-9 M-9 N-9 M-9 N-9 M-9 M-9 M-8 AO-8 AO-8 AO-8 AO-9 AO-9 AO-9 AO-9 AO-9 AO-9 AO-9 AP-9 AP-9 AO-8 AO-8 AO-7 AO-7 AP-7 AP-7 AP-7 AP-8 AP-8 AP-8 AP-8 Z-8 Z-6 BC-5 BC-5 BG-6 BG-6 AN-3 P-6 P-5 BA-8 AZ-1 AX-1 AZ-5 BB-3 AZ-5 BB-3 AY-5 BB-2 AY-5 BA-2 AX-5 AY-5 AX-4 AX-4 Z-8 Z-7 Z-7 Z-5 Z-5 Z-5 AN-4 AN-5 AN-6 AN-5

GND CM850.L GND.R H01 H02 H03 H04 H05 H06 H07 H11 H14 H15 J1939 JC01 JC01 JC02 JC02 JC03 K01 K01A K01A K01B L.P L.S L01A L01B L01C L01D L02A L02B L03 L04A L04B L04C L04D L05A L05B L05C L06 L06B L07 L08A L08B L10 L11 L12 L13 L14 L20 L21 L22 L23 L25 L26 M01 M02 M03 M04 M05A M05B M06A M06B M07A M07B M08A M08B M10 M11 M12 M14 M16 M27A M27B M29A M29B M30A M30B M33A M33B M34 M35 M36 M36 M37 M79 M84A

Model 070 070 SWP SWP SWP KES1 SWP

Number of pins

Component name

Address of stereogram

Connector No.

AN-6 AN-6 AC-1 AC-2 AC-2 AC-2 AC-2

M84B N04 N05 N06 N07 N09A/B NE NE NE NEL NER NF1 OLLV P01 P02 P03 P04 P05 P06 P07 P08 P09 P10 P11 P12 P13 P17 P19 P20 P21A P21C P21D P21E P22 P23A P23B P24 P25 P26 P27 P28 P29 P32 P33 P34 P35 P36 P37 P38 P39 P40 P41A P41B P41C P41D P45 P48 PAMB PCV1 PCV1 PCV2 PCV2 PFUEL PFUEL PIM POIL R.P R.S R01A R01B R02A R02B R03A R03B R03C R03D R04B R05 R06 R07 R08 R09 R10 R11 R12 R13 R14 R15A R15B R15C R16A R16B R16C R17 R20 R30A R30B R31A R31B R32A R32B R33A R33B RES RES1 RES2 RES3 REV RW1 RW2 RW3

SUMITOMO SUMITOMO

14 10 8 8 8 2 8 8 2 2 2 2 2 2 2 2 2 14 3 60 60 20 3 3

VHMS controller VHMS controller Diode Diode Diode Diode Diode Working lamp diode Blower diode Blower diode Condenser diode Condenser diode Compressor diode Compressor diode Wiper diode Wiper diode Washer diode Intermediate connector (Female) (connected to 815) Blow-by pressure sensor Engine controller (Left bank) Engine controller (Right bank) Fuse box G sensor (Left bank) G sensor (Right bank)

AW-3 AX-5 BA-8 AZ-1 AE-2 AY-5 BB-2

Terminal

1

GND (Engine controller) (Left bank)

AZ-6

Terminal DT DT DT DT DT DT DT 090 DT DT DT

1 8 12 8 8 20 12 3 2 8 8 4 6 8 6 6 9 3 3 2 2 14 14 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 9 2 2 2 6 6 2 2 2 2 2 2 2 4 2 2 2 18 18 20 20 16 16 4 4 1 1 3 2 3 2 4

GND (Engine controller) (Right bank) Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Starter switch Intermediate connector Intermediate connector Intermediate connector Branch block (Left bank) Branch block (Right bank) Branch block (Left bank) Branch block (Right bank) Branch block (Left bank) Resistor Pump 1 emergency drive resistance Pump 1 emergency drive resistance Pump 2 emergency drive resistance Intermediate connector (Male) Intermediate connector (Female) Boom working lamp, upper right Boom working lamp, upper left Boom working lamp, lower right Boom working lamp, lower left Fuel tank upper headlamp Fuel tank upper downlamp Cab lamp Headlamp Headlamp Headlamp Headlamp Beacon lamp Intermediate connector Beacon lamp (OPT) Step lamp Step and ladder lamps Flash lamp Engine room lamp Engine room lamp Cab base lamp Side lamp (Cab base) Fuel tank upper-right downlamp Pump room lamp Left skew lamp (Cab base) Emergency stop lamp Ladder warning lamp Automatic grease warning lamp Fan reverse rotation warning lamp Strainer warning lamp Emergency prolix warning lamp Radio Speaker (Left) Speaker (Right) Cigarette lighter Upper wiper motor Lower wiper motor Window washer Window washer Horn (Treble tone) Horn (Treble tone) Horn (Bass tone) Horn (Bass tone) Service connector (+24 V) DC/DC converter Service connector (+12 V) Travel alarm buzzer Truck counter buzzer Air conditioner unit (Upper) Air conditioner unit (Lower) AC control panel AC control panel AC control panel AC control panel Air conditioner unit (Upper) Air conditioner unit (Lower) A/C compressor electromagnetic clutch A/C compressor electromagnetic clutch Condenser Air suspension seat Condenser Socket Triple pressure switch

AY-1 Z-4 X-2 Z-4 Y-3 AB-7 AB-7 W-9 P-7 Y-3 X-3 AX-1 AZ-9 AY-1 BA-9 AY-1 BA-9

DT DT DT DT DT DT KES1 KES1 KES1 HD36 DT DRC DRC

DT M M

DT DT DT DT DT DT M DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT 090 090 090 090 090 090 PA M M DT DT DT KES KES YAZAKI YAZAKI YAZAKI YAZAKI DT M DT DT KES YAZAKI YAZAKI AMP AMP AMP AMP SUMITOMO SUMITOMO X X DT DT DT M DT

AB-5 AB-4 AA-5 AB-4 AA-4 AB-4 P-2

AN-4 AN-4 AW-3 AW-3

C-5 C-4 AQ-8 AF-6 AF-3 AF-7 AF-4 AU-9 J-9 J-9 AV-8 M-5 AF-2 G-9 L-8 AN-8 AN-5 C-5 BE-8 AH-1 O-7 O-9 O-9 P-7 O-8 O-8 V-9 AV-8 AT-9 U-9 AS-8 AR-1 AM-1 AL-1 AG-1 AF-5 AF-2 AF-6 AD-1 V-1 M-2 P-4 Y-9 Y-9 T-9 T-9 U-9 T-9 Z-9 Y-9 I-9 H-9 J-1 R-8 J-1 V-9 Z-8

Model DT DT DT DT DT DT

X DT DT DT DT DT DT DT DT DT X X X X X DT DT M DT DT DT DT DT DT DT DT AMP AMP DT DT DT AMP AMP AMP AMP DT DT DT DT DT DT DT DT DT DT DT AMP SUMITOMO SUMITOMO SUMITOMO SUMITOMO AMP AMP SUMITOMO FRAMATOME

Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal

Terminal Terminal Terminal Terminal Terminal Terminal

Number of pins 4 12 8 12 12 3 3 2 3 3 2 4 2 3 3 3 3 3 3 3 3 2 2 2 2 2 2 2 3 2 2 2 2 2 2 2 2 3 3 4 4 2 3 3 3 3 4 4 2 2 2 3 3 3 3 3 3 3 2 2 2 2 3 3 3 4 14 14 1 1 1 1 1 1 1 1 1 5 5 5 6 6 6 6 5 5 6 1 1 1 1 1 1 5 5 5 5 4 4 5 5 5 5 2 2 3 3 2 4 4 4

Component name Triple pressure switch Intermediate connector Intermediate connector Service connector Multilink Intermediate connector Intermediate connector (Left bank) (Female) Intermediate connector (Right bank) (Male) Engine position sensor Intermediate connector (Left bank) (Male) Intermediate connector (Right bank) (Female) Service connector Engine oil level sensor Boom RAISE PPC pressure sensor Bucket CURL PPC pressure sensor Bucket DUMP PPC pressure sensor Arm OUT PPC pressure sensor Arm IN PPC pressure sensor Left swing PPC pressure sensor Right swing PPC pressure sensor Right swing PPC pressure sensor Right travel (forward) PPC pressure switch Right travel (reverse) PPC pressure switch Left travel (forward) PPC pressure switch Left travel (reverse) PPC pressure switch Service valve PPC pressure switch Service connector PTO oil temperature sensor Fuel control dial Fuel level sensor Fuel level (High) sensor Fuel level (Middle) sensor Fuel level (Low) sensor Hydraulic oil temperature sensor Air cleaner clogging sensor Air cleaner clogging sensor Radiator coolant level sensor VL1 pressure sensor VL2 pressure sensor J/S differential pressure sensor (VL1) J/S differential pressure sensor (VL2) Air temperature sensor VR1 pressure sensor VR2 pressure sensor Fan pump pressure sensor (O/C) Fan pump pressure sensor (RAD) J/S differential pressure sensor (VR1) J/S differential pressure sensor (VR2) Hydraulic oil low temperature sensor Hydraulic oil level sensor Hydraulic oil filter clogging sensor Intermediate connector (Exhaust temperature sensor) Intermediate connector (Exhaust temperature sensor) Intermediate connector (Exhaust temperature sensor) Intermediate connector (Exhaust temperature sensor) Wiper proximity switch Grease pump discharge pressure sensor Ambient pressure sensor Fuel pump #1 (Left bank) Fuel pump #1 (Right bank) Fuel pump #2 (Left bank) Fuel pump #2 (Right bank) Common rail pressure sensor (Left bank) Common rail pressure sensor (Right bank) Boost pressure sensor Oil pressure sensor Intermediate connector (Male) Intermediate connector (Female) Battery relay (Right) E terminal Battery relay (Left) E terminal Battery relay (Right) BR terminal Battery relay (Left) BR terminal Battery relay (Right) M terminal Battery relay (Left) M terminal Battery relay (Right) M terminal Battery relay (Left) M terminal Battery relay (Left) B terminal PPC lock starter cut relay Hydraulic oil strainer off stating cut relay Step lamp relay Work lamp relay Side rear lamp relay Right work lamp relay Left work lamp relay Swing parking brake relay Flash light relay Horn relay Intake air heater relay Intake air heater relay Intake air heater relay Intake air heater relay Intake air heater relay Intake air heater relay Pre heater relay Beacon relay Blower relay Blower relay Compressor relay Compressor relay Condenser relay Condenser relay Condenser relay (Hi) Condenser relay (Hi) Pull up resistor (Right bank) Pull up resistor (Left bank) Resistor (Left bank) Resistor (Left bank) Connector Upper wiper relay Upper wiper brake relay Lower wiper relay

Address of stereogram

Connector No.

Z-6 AC-2 AC-1 W-2 S-9

RW4 RW5 S01 S02 S04 S05 S06 S07 S10 S11 S13 S13A S14 S15 S16 S17 S23A S23B S24 S27A S27B S28 S29 S30 S30A S31 S32 SR1 SR1 SR2 SR2 SR3 SR3 SR4 SR4 ST1 ST2 SW1 SW2 SW3 SW4 T01 T01 T02 T02 T03 T06 T10A T10B T11 T12 T14 TAMB TB01 TB02 TB03 TB04 TB05 TB12 TB13 TB14 TB15 TB16 TE01 TE02 TE04 TE05 TE06 TE07 TE08 TFUEL TFUEL TIM TM1 TOIL TR1 TR2 TR3 TS1 TW1 TW2 TWTR V01 V02 V03 V04 V05 V06 V07 V08 V09 V10 V11 V12 V13 V14 V15 V16 V17 V18 V19 V20 V21A V21B V25 V30 VH16 VH17 VH18 VH19

AW-2 AW-2 AY-1 AW-2 AW-2 Z-7 AY-6 AI-9 AI-9 AI-9 AH-9 AH-9 AH-9 AG-8 AG-8 AG-8 AF-8 AF-8 AF-7

BE-2 Q-7 C-3 C-6 C-4 C-3 J-1 BC-6 BC-6 F-9 G-1 E-1 AK-9 AJ-9 AK-1 C-6 C-7 BH-4 BF-2 F-1 D-1 I-1 K-1 I-1 BC-3, BC-4 BC-3, BC-4 BC-3 BC-3, BD-2 AQ-7 D-9 AW-4 AZ-6 BB-2 AX-6 BB-2 BA-7 BA-1 BA-9 BA-7 AX-1 AX-1 M-7 M-7 M-7 N-7 M-8 M-7 M-8 M-7 M-8 AC-4 AC-4 AD-5 AE-2 AE-3 AE-3 AE-3 AD-5 AD-4 AE-3 N-8 N-8 N-8 N-9 N-9 N-8 AD-5 AC-4 AB-6 AB-6 AA-6 AB-6 AA-6 AA-5 AA-6 AA-5 BA-1 BA-8 AW-2 AW-2 AW-3 Q-1 P-1 S-1

Model

Number of pins

SWP SWP SWP SWP SWP 090 090 SWP M M SWP SWP SWP DT DT DT DT DT DT DT DT DT DT DT Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal DT DT Terminal Terminal Terminal Terminal Terminal Terminal

4 5 6 6 6 6 6 6 3 3 6 2 3 6 6 6 3 3 3 2 2 2 2 6 6 2 3 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1

Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal PACKARD Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal PACKARD PACKARD PACKARD Terminal PACKARD Terminal Terminal Terminal Terminal Terminal Terminal PACKARD DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT

1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 2 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

Component name Lower wiper brake relay Washer relay Starter switch Light switch Swing lock switch Machine push up switch Boom shockless control switch Beacon switch Horn switch Dump counter switch Step light switch Service connector PPC hydraulic lock switch Grease mode select switch Room lamp switch Sub lamp switch Hydraulic tank strainer proximity switch Hydraulic tank strainer proximity switch Ladder limit lamp Engine room lamp switch Engine room lamp switch Pump room lamp switch Cab base lamp switch Step light switch Maintenance light switch Grease remain Hi level Grease remain Lo level Wiper relay terminal Wiper relay terminal Wiper relay terminal Wiper relay terminal Wiper relay terminal Wiper relay terminal Wiper relay terminal Wiper relay terminal Stator motor Stator motor Emergency stop switch C1 terminal Emergency stop switch N01 terminal Emergency stop switch NC1 terminal Emergency stop switch C2 terminal Cab GND Battery (Left) GND Radio body GND Battery (Left) GND Battery (Left) GND Radio body GND Cab base GND Cab base GND Cab base GND Cab base GND Revolving frame GND Air temperature sensor Cab base GND Cab base GND Cab base GND Cab base GND Cab base GND GND GND GND GND GND GND GND GND GND GND GND GND Fuel temperature sensor (Left bank) Fuel temperature sensor (Right bank) Air intake manifold temperature sensor GND Engine oil temperature sensor GND (Revolving frame) GND (Revolving frame) GND (Revolving frame) GND GND GND Coolant sensor Variable back pressure Swing priority Main 2-stage relief valve Arm throttle valve (Left) Arm throttle valve (Right) Boom throttle valve Travel straight 2-stage safety valve boom head Boom shockless control valve Boom shockless control valve No. 1 main pump EPC solenoid No. 1 main pump EPC solenoid No. 2 main pump EPC solenoid No. 2 main pump EPC solenoid Fan pump Fan pump Fan pump reverse solenoid (O/C) Fan pump reverse solenoid (RAD) Bucket high cancel solenoid Swing parking brake PPC hydraulic lock valve PPC hydraulic lock valve Grease pump solenoid OPT connector Exhaust temperature sensor (LF) Exhaust temperature sensor (LR) Exhaust temperature sensor (RF) Exhaust temperature sensor (RR)

Address of stereogram S-1 T-1 Y-2 Q-8 Q-9 P-9 P-9 P-9 Q-7 S-8 Q-9 R-8 P-9 P-8 Q-8 H-1 I-1 M-4 H-9 I-9 BF-7 AN-8 B-6 B-5 D-9 E-9 Z-1, AA-1 AA-3, AB-2 Z-2, AA-1 AA-3, AB-2 Z-2, AA-1 AA-3, AB-3 Z-2, AB-1 AB-2, AB-3 BA-8 BA-8 B-8, BH-8 A-9, BH-7 A-9, BG-7 A-8, BG-7 W-2 A-2 W-9 A-2 M-4 V-9 AI-1 AJ-1 AI-1 AJ-1 M-3 BA-9 AP-1 AP-1 AP-2 AP-2 AP-1 AN-7 AC-8 AC-8 AD-9 AD-9 BE-2 BH-6 BC-2 BD-2 BD-2 BE-2 BE-2 AW-7 BB-3 BA-9 J-9 BA-7 K-1 K-1 K-1 B-8, BG-8 AR-8 AR-1 BA-1 A-3 A-3 A-3 A-3 A-4 A-4 A-4 A-4 AE-7 AD-7 BH-5 BH-4 BH-5 BH-5 BG-2 BG-2 BH-4 H-9 E-1 G-1 AD-7 AD-7 E-9 BC-7 BD-7 BD-8 BD-8

SEN01630-03

7

90 Diagrams and drawings

PC2000-8

SEN01630-03

9

SEN01630-03

PC2000-8 Hydraulic excavator Form No. SEN01630-03

© 2007 KOMATSU All Rights Reserved Printed in Japan 05-07 (01)

10