Shop Manual (PC600LC-8)

SEN00128-15
HYDRAULIC
EXCAVATOR
-8
PC600
PC600LC -8
SERIAL NUMBERS
PC600- 30001
PC600LC- 30001
and up
SEN00130-15
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up
00 Index and foreword

Index
Composition of shop manual ............................................................................................................................... 2
Table of contents .................................................................................................................................................. 4
PC600-8
SEN00130-15
Composition of shop manual

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN00128-15

Index
Foreword and general information
SEN00129-15
SEN00130-15 q
SEN00131-04
01 Specification
Specification and technical data
SEN00132-03
SEN00133-03
10 Structure, function and maintenance standard

Engine and cooling system
Power train
Undercarriage and frame
Hydraulic system, Part 1
Work equipment
Cab and its attachments
Electrical system
SEN00134-08
SEN00135-02
SEN00136-01
SEN00137-01
SEN00138-01
SEN00139-04 q
SEN00140-03
SEN00141-00
SEN00142-05
20 Standard value table

Standard service value table
SEN00394-04
SEN00395-04
30 Testing and adjusting

Testing and adjusting, Part 1
SEN00443-04
SEN00444-04
SEN00445-03
40 Troubleshooting
Failure code table and fuse locations
General information on troubleshooting
Troubleshooting by failure code (Display of code), Part 1
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)
SEN00446-06
SEN03960-04
SEN00447-04
SEN00448-03
SEN00449-02
SEN00450-02
SEN00451-03
SEN00452-02
SEN00453-02
PC600-8
SEN00130-15
50 Disassembly and assembly

General information on disassembly and assembly
Engine and cooling system, Part 1
Power train
Hydraulic system
Work equipment
Electrical system
SEN01061-05
SEN01062-04
SEN01063-02
SEN01064-02
SEN01065-03
SEN01066-03
SEN01067-03
SEN01068-02
SEN01069-01
SEN01070-02
90 Diagrams and drawings

Hydraulic diagrams and drawings
Electrical diagrams and drawings
SEN00143-05
SEN00144-03
SEN00145-04
PC600-8
SEN00130-15
Table of contents
Index
SEN00130-15
Composition of shop manual ........................................................................................................
2
Table of contents...........................................................................................................................
4
SEN00131-04
Safety notice .................................................................................................................................
2
How to read the shop manual.......................................................................................................
7
Explanation of terms for maintenance standard ...........................................................................
9
Handling of electric equipment and hydraulic component ............................................................ 11
Handling of connectors newly used for engines ........................................................................... 20
How to read electric wire code...................................................................................................... 23
Precautions when carrying out operation ..................................................................................... 26
Method of disassembling and connecting push-pull type coupler ................................................ 29
Standard tightening torque table ................................................................................................... 32
Conversion table ........................................................................................................................... 36
01 Specification
01 Specification
SEN00133-03
Specification and technical data .......................................................................................................
2
Specification drawings ..................................................................................................................
2
Working range drawings ...............................................................................................................
4
Specifications................................................................................................................................
6
Weight table .................................................................................................................................. 14
Table of fuel, coolant and lubricants ............................................................................................. 18
SEN00135-02
Engine and cooling system ..............................................................................................................
2
Parts related to engine..................................................................................................................
2
PTO ..............................................................................................................................................
4
Fan, control and PTO lubrication pump ........................................................................................
6
Radiator, oil cooler ........................................................................................................................
7
Power train
SEN00136-01
Power train .......................................................................................................................................
2
Power train....................................................................................................................................
2
Final drive .....................................................................................................................................
5
Sprocket........................................................................................................................................
8
Swing circle................................................................................................................................... 10
Swing machinery .......................................................................................................................... 12
SEN00137-01
Undercarriage and frame .................................................................................................................
2
Track frame, recoil spring .............................................................................................................
2
Idler...............................................................................................................................................
4
Carrier roller..................................................................................................................................
6
Track roller ....................................................................................................................................
7
Track shoe ....................................................................................................................................
8
SEN00138-01
Hydraulic system, Part 1 ..................................................................................................................
2
Hydraulic piping drawing...............................................................................................................
2
Hydraulic tank, hydraulic filter .......................................................................................................
4
Hydraulic pump (piston pump)......................................................................................................
6
Line oil filter................................................................................................................................... 34
Cooling fan pump.......................................................................................................................... 36
Cooling fan motor ......................................................................................................................... 44
PC600-8
SEN00130-15

SEN00139-04
Hydraulic system, Part 2 ..................................................................................................................
2
Control valve.................................................................................................................................
2
Swing motor.................................................................................................................................. 21
Swing brake .................................................................................................................................. 24
Safety valve .................................................................................................................................. 25
Reverse prevention valve ............................................................................................................. 27
Center swivel joint ........................................................................................................................ 30
Travel motor.................................................................................................................................. 31
Parking brake ............................................................................................................................... 36
Brake valve ................................................................................................................................... 38
Set pressures varying mechanism ............................................................................................... 41
Valve control ................................................................................................................................. 42
Work equipment, swing PPC valve............................................................................................... 44
Travel PPC valve .......................................................................................................................... 48
Service PPC valve ........................................................................................................................ 50
PPC accumulator.......................................................................................................................... 51
PPC shuttle valve ......................................................................................................................... 52
Solenoid valve .............................................................................................................................. 53
Boom holding valve ...................................................................................................................... 58
Boom LOWER regeneration valve ............................................................................................... 62
Quick return valve......................................................................................................................... 65
Hydraulic cylinder ......................................................................................................................... 68
Work equipment
SEN00140-03
Work equipment ...............................................................................................................................
2
Work equipment............................................................................................................................
2
Dimensions of work equipment ....................................................................................................
6
SEN00141-00
Cab and its attachments...................................................................................................................
2
Air conditioner piping ....................................................................................................................
2
Electrical system
SEN00142-05
Engine control...............................................................................................................................
2
Machine control system diagram ..................................................................................................
7
Monitor system ............................................................................................................................. 31
Sensors ........................................................................................................................................ 46
KOMTRAX system ....................................................................................................................... 50
SEN00395-04
Standard value table for engine ....................................................................................................
2
Standard value table for chassis...................................................................................................
3
SEN00444-04
Tools for testing, adjusting and troubleshooting ...........................................................................
4
Measuring engine speed ..............................................................................................................
7
Measuring intake air pressure (boost pressure) ...........................................................................
8
Measuring exhaust gas temperature ............................................................................................
9
Measuring exhaust gas color........................................................................................................ 10
Adjusting valve clearance ............................................................................................................. 11
Measuring compression pressure ................................................................................................ 12
Measuring blow-by pressure ........................................................................................................ 14
Measuring engine oil pressure ..................................................................................................... 14
Testing EGR valve and bypass valve drive oil pressure ............................................................... 15
Handling equipment in fuel circuit................................................................................................. 16
Releasing remaining pressure in fuel system ............................................................................... 16
Measuring fuel pressure ............................................................................................................... 17
PC600-8
SEN00130-15
Reduced cylinder mode operation ................................................................................................ 18

No-injection cranking .................................................................................................................... 18
Testing leakage from pressure limiter and return rate from injector.............................................. 19
Bleeding air from fuel circuit ......................................................................................................... 21
Testing fuel system for leakage .................................................................................................... 23
Testing and adjusting alternator belt tension ................................................................................ 24
Testing and adjusting air conditioner compressor belt tension ..................................................... 25
Testing clearance of swing circle bearing ..................................................................................... 26
Testing and adjusting track shoe tension...................................................................................... 27
Testing and adjusting work equipment, swing, and travel circuit oil pressures............................. 28
Testing and adjusting control circuit oil pressure .......................................................................... 33
Testing and adjusting piston pump control oil pressure ................................................................ 35
Testing servo piston stroke ........................................................................................................... 41
Measuring PPC valve output pressure ......................................................................................... 42
Measuring outlet pressures of solenoid valve and PPC shuttle valve .......................................... 46
Adjusting work equipment, swing PPC valve................................................................................ 52
Testing and adjusting travel deviation........................................................................................... 53
Measuring fan speed .................................................................................................................... 55
Measuring fan circuit oil pressure ................................................................................................. 55
Inspection of locations of hydraulic drift of work equipment ......................................................... 56
Measuring oil leakage................................................................................................................... 57
Releasing remaining pressure in hydraulic circuit ........................................................................ 61
Bleeding air from each part........................................................................................................... 62
Inspection procedures for diode ................................................................................................... 65
SEN00445-03
Special function of machine monitor .............................................................................................
2
Handling controller voltage circuit ................................................................................................. 36
Procedure for turning on KOMTRAX terminal .............................................................................. 37
KOMTRAX terminal lamp indications ........................................................................................... 40
Preparation work for troubleshooting electrical system ................................................................ 43
Adjusting mirrors........................................................................................................................... 45
Pm-clinic service........................................................................................................................... 46
Undercarriage inspection.............................................................................................................. 52
40 Troubleshooting
SEN03960-04
Failure codes table .......................................................................................................................
2
Fuse locations...............................................................................................................................
6
SEN00447-04
Points to remember when troubleshooting ...................................................................................
2
Sequence of events in troubleshooting.........................................................................................
3
Checks before troubleshooting .....................................................................................................
4
Classification and procedures of troubleshooting .........................................................................
5
Information contained in troubleshooting table .............................................................................
6
Failure-looking phenomenon and troubleshooting No. .................................................................
8
Connection table for connector pin numbers ................................................................................ 12
T- branch box and T- branch adapter table................................................................................... 48
SEN00448-03
Failure code [A000N1] Eng. Hi Out of Std ....................................................................................
3
Failure code [AA10NX] Aircleaner clogging..................................................................................
4
Failure code [AB00KE] Charge Voltage Low ................................................................................
6
Failure code [B@BAZG] Eng. Oil Press. Low...............................................................................
8
Failure code [B@BAZK] Eng. Oil Level Low................................................................................. 10
Failure code [B@BCNS] Eng. Water Overheat ............................................................................ 11
Failure code [B@BCZK] Eng. Water Lvl Low ............................................................................... 12
Failure code [B@HANS] Hydr. Oil Overheat ................................................................................ 14
Failure code [CA111] ECM Critical Internal Failure....................................................................... 15
Failure code [CA115] Eng Ne and Bkup Speed Sens Error.......................................................... 16
PC600-8
SEN00130-15
Failure code [CA122] Chg Air Press Sensor High Error ............................................................... 18
Failure code [CA123] Chg Air Press Sensor Low Error................................................................ 20
Failure code [CA131] Throttle Sensor High Error ......................................................................... 22
Failure code [CA132] Throttle Sensor Low Error.......................................................................... 24
Failure code [CA135] Eng Oil Press Sensor High Error ............................................................... 26
Failure code [CA141] Eng Oil Press Sensor Low Error ................................................................ 28
Failure code [CA144] Coolant Temp Sens High Error .................................................................. 30
Failure code [CA145] Coolant Temp Sens Low Error ................................................................... 32
Failure code [CA153] Chg Air Temp Sensor High Error ............................................................... 34
Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................ 36
Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................... 36
Failure code [CA221] Ambient Press Sens High Error ................................................................. 38
Failure code [CA222] Ambient Press Sens Low Error.................................................................. 40
Failure code [CA227] Sens Supply 2 Volt High Error ................................................................... 42
Failure code [CA234] Eng Overspeed .......................................................................................... 44
Failure code [CA238] Ne Speed Sens Supply Volt Error .............................................................. 45
Failure code [CA263] Fuel Temp Sensor High Error .................................................................... 46
Failure code [CA265] Fuel Temp Sensor Low Error ..................................................................... 48
Failure code [CA271] IMV/PCV1 Short Error ............................................................................... 49
Failure code [CA272] IMV/PCV1 Open Error ............................................................................... 50
Failure code [CA273] PCV2 Short Error ....................................................................................... 51
Failure code [CA274] PCV2 Open Error....................................................................................... 52
SEN00449-02
Failure code [CA322] Inj #1 (L#1) Open/Short Error ....................................................................
4
6
8
Failure code [CA325] Inj #6 (L#6) Open/Short Error .................................................................... 10
Failure code [CA342] Calibration Code Incompatibility ................................................................ 16
Failure code [CA351] Injectors Drive Circuit Error........................................................................ 17
Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................... 19
Failure code [CA386] Sens Supply 1 Volt High Error ................................................................... 20
Failure code [CA441] Battery Voltage Low Error .......................................................................... 22
Failure code [CA442] Battery Voltage High Error ......................................................................... 22
Failure code [CA449] Rail Press Very High Error ......................................................................... 23
Failure code [CA451] Rail Press Sensor High Error..................................................................... 24
Failure code [CA452] Rail Press Sensor Low Error ..................................................................... 26
Failure code [CA553] Rail Press High Error ................................................................................. 26
Failure code [CA554] Rail Press Sensor In Range Error ............................................................. 27
Failure code [CA559] Rail Press Low Error .................................................................................. 28
Failure code [CA689] Eng Ne Speed Sensor Error ...................................................................... 32
Failure code [CA731] Eng Bkup Speed Sens Phase Error........................................................... 34
Failure code [CA757] All Persistent Data Lost Error..................................................................... 35
Failure code [CA778] Engine Bkup Speed Sensor Error .............................................................. 36
Failure code [CA1228] EGR Valve Servo Error 1 ......................................................................... 38
Failure code [CA1625] EGR Valve Servo Error 2 ......................................................................... 39
Failure code [CA1626] BP Valve Sol Current High Error.............................................................. 40
Failure code [CA1627] BP Valve Sol Current Low Error............................................................... 42
Failure code [CA1628] Bypass Valve Servo Error 1 ..................................................................... 43
Failure code [CA1629] Bypass Valve Servo Error 2 ..................................................................... 44
Failure code [CA1631] BP Valve Pos Sens High Error................................................................. 45
Failure code [CA1632] BP Valve Pos Sens Low Error ................................................................. 47
Failure code [CA1633] KOMNET Datalink Timeout Error............................................................. 48
Failure code [CA1642] EGR Inlet Press Sens Low Error ............................................................. 51
Failure code [CA1653] EGR Inlet Press Sens High Error ............................................................ 52
Failure code [CA2185] Throt Sens Sup Volt High Error ............................................................... 54
Failure code [CA2186] Throt Sens Sup Volt Low Error ................................................................ 56
Failure code [CA2249] Rail Press Very Low Error........................................................................ 57
PC600-8
SEN00130-15
Failure code [CA2271] EGR Valve Pos Sens High Error.............................................................. 58

Failure code [CA2272] EGR Valve Pos Sens Low Error............................................................... 60
Failure code [CA2351] EGR Valve Sol Current High Error ........................................................... 62
Failure code [CA2352] EGR Valve Sol Current Low Error............................................................ 64
Failure code [CA2555] Grid Htr Relay Volt Low Error................................................................... 65
Failure code [CA2556] Grid Htr Relay Volt High Error.................................................................. 66
SEN00450-02
Failure code [D110KB] Battery Relay Drive S/C ...........................................................................
4
Failure code [D163KB] Flash Light Relay S/C..............................................................................
6
Failure code [D195KB] Step Light Relay S/C ...............................................................................
8
Failure code [DA22KK] Pump Solenoid Power Low Error ............................................................ 10
Failure code [DA25KP] Press. Sensor Power Abnormality .......................................................... 12
Failure code [DA2SKQ] Model Selection Abnormality.................................................................. 14
Failure code [DA80MA] Auto. Lub Abnormal................................................................................ 16
Failure code [DA2RMC] Pump Comm. Abnormality..................................................................... 18
Failure code [DAFRMC] Monitor Comm. Abnormality .................................................................. 20
Failure code [DGE5KY] Ambi. Temp. Sensor S/C ........................................................................ 22
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C ................................................................... 23
Failure code [DHPAMA] F pump P. Sensor Abnormality .............................................................. 24
Failure code [DHPBMA] R pump P. Sensor Abnormality.............................................................. 26
Failure code [DV20KB] Travel Alarm S/C ..................................................................................... 28
Failure code [DW43KA] Travel Speed Sol. Disc. .......................................................................... 30
Failure code [DW43KB] Travel Speed Sol. S/C ............................................................................ 32
Failure code [DW45KA] Swing Brake Sol. Disc............................................................................ 34
Failure code [DW45KB] Swing Brake Sol. S/C............................................................................. 36
Failure code [DW48KA] CO Cancel Sol. Disc. ............................................................................. 38
Failure code [DW48KB] CO Cancel Sol. S/C ............................................................................... 40
Failure code [DW7BKA] Fan Reverse Sol. Disc. .......................................................................... 42
Failure code [DW7BKB] Fan Reverse Sol. S/C ............................................................................ 43
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc. ........................................................... 44
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C ............................................................. 46
Failure code [DWK0KA] 2-stage Relief Sol. Disc. ........................................................................ 48
Failure code [DWK0KB] 2-stage Relief Sol. S/C .......................................................................... 50
Failure code [DX16KA] Fan Pump EPC Sol. Disc. ....................................................................... 52
Failure code [DX16KB] Fan Pump EPC Sol. S/C ......................................................................... 54
Failure code [DXA0KA] TVC Sol. Disc. ........................................................................................ 56
Failure code [DXA0KB] TVC Sol. S/C .......................................................................................... 58
Failure code [DY20KA] Wiper Working Abnormality..................................................................... 60
Failure code [DY20MA] Wiper Parking Abnormality ..................................................................... 62
Failure code [DY2CKB] Washer Drive S/C ................................................................................... 66
Failure code [DY2DKB] Wiper Drive (For) S/C ............................................................................. 68
Failure code [DY2EKB] Wiper Drive (Rev) S/C ............................................................................ 72
SEN00451-03
Before carrying out troubleshooting E-mode ................................................................................
4
Information contained in troubleshooting table .............................................................................
6
E-1 Engine does not start (Engine does not rotate)......................................................................
8
E-2 Preheater does not operate ................................................................................................... 12
E-3 Auto engine warm-up device does not work .......................................................................... 14
E-4 Auto-decelerator does not operate......................................................................................... 15
E-5 All work equipment, swing and travel do not move ................................................................ 16
E-6 Power max. function does not operate................................................................................... 18
E-7 Machine push-up function does not operate normally ........................................................... 19
E-8 Any item is not displayed on machine monitor....................................................................... 21
E-9 Part of display on machine monitor is missing ....................................................................... 22
E-10 Machine monitor displays contents irrelevant to the model ................................................. 22
E-11 Fuel level monitor red lamp lights up while engine is running .............................................. 23
E-12 Engine coolant temperature gauge does not display correctly ............................................ 24
E-13 Hydraulic oil temperature gauge does not display correctly................................................. 26
PC600-8
SEN00130-15
E-14 Fuel gauge does not display correctly ................................................................................. 27

E-15 Swing lock monitor does not display correctly ..................................................................... 28
E-16 When monitor switch is operated, nothing is displayed ....................................................... 30
E-17 Wiper and window washer do not work ............................................................................... 32
E-18 "Boom Raise" is not correctly displayed in monitoring function ........................................... 40
E-19 "Boom Lower" is not correctly displayed in monitoring function........................................... 42
E-20 "Arm IN" is not correctly displayed in monitoring function.................................................... 44
E-21 "Arm OUT" is not correctly displayed in monitoring function................................................ 45
E-22 "Bucket CURL" is not correctly displayed in monitoring function ......................................... 46
E-23 "Bucket DUMP" is not correctly displayed in monitoring function ........................................ 47
E-24 "Swing" is not correctly displayed in monitoring function ..................................................... 48
E-25 "Travel" is not correctly displayed in monitoring function ..................................................... 50
E-26 Air conditioner does not work............................................................................................... 52
E-27 Step light does not light up or go off..................................................................................... 54
E-28 Electric grease gun does not operate .................................................................................. 58
E-29 Travel alarm does not sound or does not stop sounding ..................................................... 60
E-30 Horn does not sound............................................................................................................ 62
E-31 Bottom dump does not move ............................................................................................... 64
Troubleshooting of hydraulic and mechanical system (H-mode)
SEN00452-02
Before troubleshooting H-mode....................................................................................................
3
Information in troubleshooting table..............................................................................................
8
H-1 Speed or power of all work equipment, travel, and swing is low............................................ 10
H-2 Engine speed lowers remarkably or engine stalls.................................................................. 12
H-3 All work equipment, travel, and swing systems do not work.................................................. 14
H-4 Abnormal sound is heard from around pump ........................................................................ 16
H-5 Auto-decelerator is not reset.................................................................................................. 17
H-6 Boom speed or power is low.................................................................................................. 18
H-7 Arm speed or power is low .................................................................................................... 20
H-8 Bucket speed or power is low ................................................................................................ 21
H-9 Boom does not move ............................................................................................................. 22
H-10 Arm does not move.............................................................................................................. 22
H-11 Bucket does not move.......................................................................................................... 23
H-12 Bottom dump does not move ............................................................................................... 23
H-13 Hydraulic drift of work equipment is large ............................................................................ 24
H-14 Time lag of work equipment is large .................................................................................... 25
H-15 Power max. function does not operate or stop .................................................................... 26
H-16 Machine push-up function does not operate or stop............................................................ 26
H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is low .... 27
H-18 When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing,
travel speed is low ............................................................................................................... 27
H-19 When arm and swing are operated simultaneously, swing speed is low ............................. 28
H-20 Machine deviates in one direction ....................................................................................... 29
H-21 Machine deviates largely at start ......................................................................................... 31
H-22 Travel deviation is large during compound operation .......................................................... 32
H-23 Travel speed or power is low ............................................................................................... 33
H-24 Machine does not travel (only one track) ............................................................................. 34
H-25 Travel speed does not change............................................................................................. 35
H-26 Upper structure does not swing ........................................................................................... 36
H-27 Swing speed or acceleration is low...................................................................................... 37
H-28 Upper structure overruns excessively when it stops swinging............................................. 38
H-29 Large shock is made when upper structure stops swinging ................................................ 39
H-30 Large abnormal sound is made when upper structure stops swinging ................................ 40
H-31 Hydraulic drift of swing is large ............................................................................................ 41
SEN00453-02
Method of using troubleshooting chart .........................................................................................
3
S-1 Starting performance is poor ..................................................................................................
6
S-2 Engine does not start .............................................................................................................
8
S-3 Engine does not pick up smoothly ......................................................................................... 12
PC600-8
SEN00130-15
S-4 Engine stops during operations..............................................................................................

S-5 Engine does not rotate smoothly............................................................................................
S-6 Engine lacks output (or lacks power) .....................................................................................
S-7 Exhaust smoke is black (incomplete combustion) .................................................................
S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................................
S-9 Oil becomes contaminated quickly.........................................................................................
S-10 Fuel consumption is excessive ............................................................................................
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ...................................
S-12 Oil pressure drops ................................................................................................................
S-13 Oil level rises (Entry of coolant or fuel) ................................................................................
S-14 Coolant temperature becomes too high (overheating).........................................................
S-15 Abnormal noise is made.......................................................................................................
S-16 Vibration is excessive...........................................................................................................
13
14
15
16
17
18
19
20
21
22
24
25
26

General information on disassembly and assembly
SEN01062-04
How to read this manual ...............................................................................................................
2
Coating materials list ....................................................................................................................
4
Special tools list ............................................................................................................................
7
Sketches of special tools .............................................................................................................. 13
SEN01063-02
Removal and installation of fuel supply pump assembly ..............................................................
2
Removal and installation of cylinder head assembly ....................................................................
8
Removal and installation of fuel injector assembly ....................................................................... 24
Removal and installation of engine front seal ............................................................................... 27
Removal and installation of engine rear seal ................................................................................ 31
SEN01064-02
Removal and installation of engine, PTO and hydraulic pump assembly .....................................
2
Removal and installation of radiator assembly .............................................................................
9
Removal and installation of hydraulic oil cooler assembly............................................................ 11
Removal and installation of aftercooler assembly......................................................................... 13
Removal and installation of fan motor assembly .......................................................................... 15
Removal and installation of fuel tank assembly ............................................................................ 19
Power train
SEN01065-03
Removal and installation of PTO assembly ..................................................................................
2
Disassembly and assembly of PTO assembly..............................................................................
4
Removal and installation of swing motor and swing machinery assembly ...................................
7
Disassembly and assembly of swing machinery assembly ..........................................................
8
Removal and installation of swing circle assembly ....................................................................... 15
Disassembly and assembly of final drive assembly...................................................................... 16
SEN01066-03
Removal and installation of track shoe assembly .........................................................................
2
Disassembly and assembly of 1 link in field .................................................................................
4
Removal and installation of idler, recoil spring assembly .............................................................
8
Disassembly and assembly of idler assembly ..............................................................................
9
Disassembly and assembly of recoil spring assembly.................................................................. 12
Removal and installation of track roller assembly......................................................................... 14
Disassembly and assembly of track roller assembly .................................................................... 15
Removal and installation of carrier roller assembly ...................................................................... 18
Disassembly and assembly of carrier roller assembly.................................................................. 19
Removal and installation of revolving frame assembly ................................................................. 22
Removal and installation of counterweight assembly ................................................................... 24
Removal and installation of counterweight remover assembly ..................................................... 25
Hydraulic system
SEN01067-03
2
Removal and installation of hydraulic tank assembly ...................................................................
Removal and installation of hydraulic pump assembly .................................................................
4
Removal and installation of control valve and solenoid valve assembly ......................................
7
Disassembly and assembly of control valve assembly.................................................................
9
10
PC600-8
SEN00130-15
Disassembly and assembly of main control valve assembly ........................................................ 10

Removal and installation of swing motor assembly ...................................................................... 14
Removal and installation of center swivel joint assembly ............................................................. 15
Disassembly and assembly of center swivel joint assembly......................................................... 16
Disassembly and assembly of work equipment PPC valve assembly.......................................... 18
Disassembly and assembly of travel PPC valve assembly .......................................................... 20
Disassembly and assembly of hydraulic cylinder assembly ......................................................... 23
Disassembly and assembly of grease gun assembly ................................................................... 29
Work equipment
SEN01068-02
Removal and installation of bucket cylinder assembly (Backhoe specification) ...........................
2
Removal and installation of bucket cylinder assembly (Loading shovel specification) .................
4
Removal and installation of arm cylinder assembly (Backhoe specification)................................
6
Removal and installation of arm cylinder assembly (Loading shovel specification) .....................
8
Removal and installation of boom cylinder assembly (Backhoe specification)............................. 10
Removal and installation of boom cylinder assembly (Loading shovel specification)................... 12
Removal and installation of bottom dump cylinder assembly (Loading shovel specification)....... 14
Removal and installation of bucket assembly (Backhoe specification)......................................... 15
Removal and installation of bucket assembly (Loading shovel specification) .............................. 17
Removal and installation of arm assembly (Backhoe specification) ............................................. 18
Removal and installation of arm assembly (Loading shovel specification)................................... 20
Removal and installation of boom assembly (Backhoe specification) .......................................... 21
Removal and installation of boom assembly (Loading shovel specification) ................................ 23
Removal and installation of work equipment (Backhoe specification) .......................................... 25
Removal and installation of work equipment (Loading shovel specification)................................ 27
SEN01069-01
Removal and installation of operators cab...................................................................................
2
Removal and installation of operators cab glass (stuck glass) ....................................................
5
Removal and installation of front window assembly ..................................................................... 15
Electrical system
SEN01070-02
Removal and installation of air conditioner unit assembly ............................................................
2
Removal and installation of engine controller assembly...............................................................
4
Removal and Installation of KOMTRAX terminal assembly..........................................................
6
Removal and installation of pump controller assembly.................................................................
6
Removal and installation of monitor assembly .............................................................................
7
SEN00144-03
Hydraulic circuit diagram (1/4) (Backhoe specification)................................................................
3
Hydraulic circuit diagram (2/4) (ATT specification) .......................................................................
5
Hydraulic circuit diagram (3/4) (Loading shovel specification)......................................................
7
Hydraulic circuit diagram (4/4) (Loading shovel specification)......................................................
9
SEN00145-04
Electrical circuit diagram (1/6) ......................................................................................................
3
5
7
9
Electrical circuit diagram (5/6) ...................................................................................................... 11
Electrical circuit diagram (6/6) ...................................................................................................... 13
Connector arrangement diagram.................................................................................................. 15
Electrical circuit diagram for air conditioner .................................................................................. 17
PC600-8
11
SEN00130-15
PC600, 600LC-8 Hydraulic excavator

Form No. SEN00130-15
2011 KOMATSU
All Rights Reserved
Printed in Japan 07-11
12
SEN00131-04
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
PC600-8
SEN00131-04
Safety notice
(Rev. 2008/08)
1
Important safety notice

Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety labels stuck to
the machine. For the locations of the
safety labels and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.
7)
8)
9)
If welding repairs are needed, always

have a trained and experienced welder
carry out the work. When carrying out
weld in g wo rk , al way s wear wel din g
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition. Take rests in
specified safe places.
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)
Wearing shielding goggles and protectors

(for welding work)
9 Good physical condition and preparation

10
Precautions against work which you are

not used to or you are used to too much
PC600-8
SEN00131-04
2.
3.
Preparations for work

1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, support the machine with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
m a c h i n e . N e v e r j u m p o n o r o ff t h e
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
6)
Precautions during work

1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
11)
PC600-8
7)
8)
9)
10)
12)
13)
14)
15)
16)
When removing a cover which is under

internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
When removing components, be careful
not to break or damage the electrical wiring. Damaged wiring may cause electrical
fires.
When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
SEN00131-04
4.
Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q
Do not stand under the load.
q
Do not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allowable load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
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
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
q
After the wire ropes are stretched,
stop the crane and check the condition of the slung load, wire ropes, and
pads.
PC600-8
SEN00131-04
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.
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.
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.
PC600-8
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
The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
SEN00131-04
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air conditioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recovering or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2)

a
Example of O-ring (Fitted to every joint of

hoses and tubes)
For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
Connection
1] When installing the air conditioner circuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
PC600-8
SEN00131-04
How to read the shop manual

q
q
q
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.
PC600-8
SEN00131-04
3.
4.
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 )
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
Safety
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when

selecting hoisting wire, or when working posture is important, etc.
Tightening
torque
Coat
Oil, coolant
Drain
Remarks
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 { }.
PC600-8
SEN00131-04
Explanation of terms for maintenance standard
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1.
Standard size and tolerance

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

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

the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size
60
PC600-8
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
SEN00131-04
2.
Standard clearance and standard value

The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.
5.
3.
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.
4.
Repair limit and allowable value or allowable dimension

q
The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q
If a part is worn to the repair limit, it must
be replaced or repaired.
q
The performance and function of a product lowers while it is used. A value which
the product can be used without causing a
problem is called the allowable value or
allowable dimension.
q
If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.
10
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
PC600-8
Handling of electric equipment and hydraulic component
SEN00131-04
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)
PC600-8
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.
11
SEN00131-04
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
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.
PC600-8
3.
SEN00131-04
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
PC600-8
When removing from clips

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

clip, pull the connector in a parallel
direction to the clip for removing stoppers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
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.
13
SEN00131-04
2)
14
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.
PC600-8
SEN00131-04
3)
PC600-8
Heavy duty wire connector (DT 8-pole, 12pole)

Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizontally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
Disconnection
Connection (Example of
incomplete setting of (a))
15
SEN00131-04
4)
16
Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as follows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
PC600-8
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.
PC600-8
SEN00131-04
17
SEN00131-04
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 opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4.
Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil 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
PC600-8
5.
Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6.
Flushing operations
After disassembling and assembling the 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,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
PC600-8
SEN00131-04
19
SEN00131-04
Handling of connectors newly used for engines

a
1.
Mainly, following engines are object for following connectors.

q
95E-5
q
107E-1
q
114E-3
q
125E-5
q
140E-5
q
170E-5
q
12V140E-3
Slide lock type
(FRAMATOME-3, FRAMATOME-2)
q
95 170, 12V140 engines
q
Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE
(95 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
2.
Pull lock type (PACKARD-2)

95 170, 12V140 engines
q
Various temperature sensors
Example)
Intake air temperature sensor in
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
etc.
Disconnect the connector by pulling lock
(B) (on the wiring harness side) of connector (2) outward.
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
PC600-8
SEN00131-04
3.
Push lock type

q
95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the following procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q
114 engine
107, 114 engines

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

(4) in the direction of the arrow.
107 engine
2)
PC600-8
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.
21
SEN00131-04
q
4)
95, 125 170, 12V140 engines

While pressing lock (E) of the connector,
pull out connector (5) in the direction of
the arrow.
Example)
Fuel pressure sensor in common rail:
PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector)

140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
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

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
PC600-8
SEN00131-04
How to read electric wire code

a
The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Type
Low-voltage
wire for
automobile
Thin-cover
low-voltage
wire for
automobile
Symbol
AV
AVS
Heat-resistant low-voltAEX
age wire for
automobile
PC600-8
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance

Soft polyvinyl chloride
Insulator
Soft polyvinyl chloride
Conductor

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
SEN00131-04
2.
Dimensions
(Table 2)
Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
area (mm2)
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
CovAV
Standard
4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
15
20
30
40
50
60
85
100
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
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
24
PC600-8
SEN00131-04
3.
Color codes table
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
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
PC600-8
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
R
B
R
D
Y
G
L
WG
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
SEN00131-04
Precautions when carrying out operation
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1.
q
q
q
q
q
q
q
q
q
q
Precautions when carrying out removal work

If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number
02
03
04
05
06
10
12
2)
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
PC600-8
2.
q
q
q
q
q
q
q
q
q
q
q
q
q
a
3.
SEN00131-04
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.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
PC600-8
27
SEN00131-04
4)
5)
28
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.
PC600-8
SEN00131-04
Method of disassembling and connecting push-pull type coupler

k
k
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1.
Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2.
Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC600-8
29
SEN00131-04
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
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
PC600-8
SEN00131-04
Type 3
1.
2.
Disconnection
1) Hold the tightening portion and push body
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)
PC600-8
31
SEN00131-04
Standard tightening torque table

1.
Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt

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

mm
6
8
10
12
a Fig. A
Width across flats

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

mm
10
12
14
17
Tightening torque
Nm
kgm
5.9 9.8
0.6 1.0
13.7 23.5
1.4 2.4
34.3 46.1
3.5 4.7
74.5 90.2
7.6 9.2
a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32
PC600-8
SEN00131-04
2.
Table of tightening torques for split flange bolts

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

mm
10
12
16
3.
Tightening torque
Nm
59 74
98 123
235 285
kgm
6.0 7.5
10.0 12.5
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.
Width across flats

mm
14
17
22
Thread diameter
mm
14
20
24
33
42
Width across flats

mm
Tightening torque Nm {kgm}

Range
Target
35 63 { 3.5 6.5}
44 { 4.5}
84 132 { 8.5 13.5}
103 {10.5}
Varies depending
on type of connec- 128 186 {13.0 19.0}
157 {16.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}
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
PC600-8
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
Width across flats

mm
14
17
19
22
24
27
30
32
32
36

Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}
33
SEN00131-04
5.
Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
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}
Taper seal
Thread size
(mm)
14
18
22
24
30
33
36
42
Face seal
Nominal No.
Thread
Number of
diameter (mm)
threads, type of
(Reference)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer
diameter
of pipe
(mm)
Width
across
flats
(mm)
8
10
12
15 (16)
22 (20)
19
22
24 (27)
30 (32)
36

Range
Target
14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Thread diameter
Nominal No.
(mm)
Number of threads,
(Reference)
type of thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UN
25.4
1-3/16-12UN
30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Bolts and nuts
Thread size
mm
6
8
10
12
14
34
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
PC600-8
SEN00131-04
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size
mm
6
8
10
12
14
9.
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
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.
Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4
PC600-8
Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51
35
SEN00131-04
Conversion table
Method of using the conversion table

The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1.
Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
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
PC600-8
SEN00131-04
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
2
0
0.264
0.528
2.642
2.906
3.170
5.283
5.548
5.812
7.925
8.189
8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321 1.585
1.849
2.113
2.378
3.963 4.227
4.491
4.755
5.019
6.604 6.869
7.133
7.397
7.661
9.246 9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
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
PC600-8
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
37
SEN00131-04
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
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
PC600-8
SEN00131-04
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
PC600-8
39
SEN00131-04
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
F
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
PC600-8
PC600-8
SEN00131-04
41
SEN00131-04

2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)
42
SEN00133-03
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up
01 Specification
Specification drawings .................................................................................................................................... 2
Working range drawings ................................................................................................................................. 4
Specifications.................................................................................................................................................. 6
Weight table.................................................................................................................................................. 14
Table of fuel, coolant and lubricants ............................................................................................................. 18
PC600-8
SEN00133-03
01 Specification

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

Working ranges
Unit
PC600-8
PC600LC-8
Max. digging reach
mm
13,020
13,020
Max. digging depth
mm
8,490
8,490
Max. digging height
mm
11,880
11,880
Max. vertical wall digging depth
mm
7,510
7,510
Max. dumping height
mm
7,960
7,960
Max. digging reach at ground level
mm
12,800
12,800
PC600-8
SEN00133-03
01 Specification
Working ranges
Unit
PC600-8
PC600LC-8
Max. digging reach
mm
9,190
9,190
Max. digging reach at ground level
mm
8,850
8,850
Max. digging height
mm
10,090
10,090
Max. digging depth
mm
3,495
3,495
Min. digging radius at ground level
mm
5,135
5,135
Min. turning radius of work

equipment
mm
5,515
5,515
PC600-8
SEN00133-03
01 Specification
Specifications
Performance
Working ranges
PC600-8
Machine model
PC600-8
Serial number
30001 and up
Bucket capacity
m3
2.7
Weight of machine
kg
57,300
Max. digging depth
mm
8,490
Max. vertical wall depth
mm
7,510
Max. digging reach
mm
13,020
Max. reach at ground level
mm
12,800
Max. digging height
mm
11,880
Max. dumping height
mm
7,960
kN {kg}
294.3 {30,000}
Max. digging force

(using power max. function)
(316.9 {32,300})
Swing speed
rpm
8.3
Swing max. slope angle
deg.
17
Travel speed
km/h
Low speed: 3.0

High speed: 4.9
Gradeability
35
deg.
2
kPa {kg/cm }
102 {1.04}
Overall length (for transport)
mm
12,910
Overall width
mm
3,195
Overall width of track
mm
3,900
Overall height (for transport)
mm
4,300
Overall height to top of cab
mm
3,435
Ground clearance of
mm
1,365
mm
780
Tail swing radius
mm
3,900
Min. swing radius of work
mm
5,370
mm
10,020
Length of track on ground
mm
4,250
Track gauge
mm
3,300
Height of machine cab
mm
3,070
Ground pressure (standard triple
Dimensions
grouser shoe width: 600 mm)
counterweight
equipment
Height of work equipment
at min. swing radius
PC600-8
SEN00133-03
01 Specification
Machine model
PC600-8
Serial number
30001 and up
mm
l {cc}
KOMATSU SAA6D140E-5
4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler (air cooled)
6 140 165
15.24 {15,240}
Flywheel horsepower
Max. torque
kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}
323/1,800 {432/1,800}
1,944/1,400 {198.4/1,400}
Max. speed at no load

Min. speed at no load
rpm
rpm
1,950
800
Model
Type
Performance
Engine
No. of cylinders bore stroke

Piston displacement
Starting motor
Alternator
Battery
24V, 11 kW
24V, 50A
12V, 175 Ah 2
CF68-4
Carrier roller
3 on each side
Track roller
8 on each side
Track shoe
Assembly-type triple grouser, 49 on each side
Fan pump
Type
Variable swash plate type: LPV75
Type
Fixed swash plate type: LMF75
Fan motor
Hydraulic motor Control valve Hydraulic pump
Set pressure
Hydraulic cylinder
Hydraulic system
Hydraulic system
Fan system Undercarriage
Radiator core type
MPa {kg/cm2}
Type No.
Delivery
Set pressure
24.5 {250}
Variable displacement piston type: HPV95+95 2,
piston + gear type: LPV75 + SAL(2)56 + (2)8
l /min
Piston type: 410 2, gear type: 137
MPa {kg/cm2}
Piston type: 34.3 {350}, gear type: 2.9 {30}
Type No.
4-spool + 5-spool type 1
Control method
Hydraulic
Travel motor
KMV335ADT, Piston type

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

(with safety valve, shaft brake, reverse prevention valve): 2
Type
Boom
Arm
Bucket
Double-acting
piston
Double-acting
piston
Double-acting
piston
Inside diameter of cylinder
mm
185
200
185
Diameter of piston rod
mm
120
140
130
Stroke
mm
1,725
2,045
1,425
Max. distance between pins
mm
4,182
4,933
3,577
Min. distance between pins
mm
2,457
2,888
2,152
Hydraulic tank
Hydraulic filter
Hydraulic cooler
PC600-8
Box-shaped, sealed
Tank return side
CF42-1 (Air cooled)
SEN00133-03
01 Specification
Performance
Working ranges
PC600LC-8
Machine model
PC600LC-8
Serial number
30001 and up
Bucket capacity
m3
2.7
Weight of machine
kg
58,300
Max. digging depth
mm
8,490
mm
7,510
Max. digging reach
mm
13,020
mm
12,800
Max. digging height
mm
11,880
Max. dumping height
mm
7,960
kN {kg}
294.3 {30,000}
Max. digging force

(using power max. function)
(316.9 {32,300})
Swing speed
rpm
8.3
deg.
17
Travel speed
km/h
Low speed: 3.0

High speed: 4.9
Gradeability
deg.
35
kPa {kg/cm2}
96 {0.98}
mm
12,910
Overall width
mm
3,195
mm
3,900
mm
4,300
mm
3,435
Ground clearance of
mm
1,365
mm
780
Tail swing radius
mm
3,900
mm
5,370
mm
10,020
mm
4,600
Track gauge
mm
3,300
mm
3,070
Dimensions
counterweight
equipment
PC600-8
SEN00133-03
01 Specification
Machine model
PC600LC-8
Serial number
30001 and up
mm
l {cc}
KOMATSU SAA6D140E-5
6 140 165
15.24 {15,240}
Flywheel horsepower
Max. torque
kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}
323/1,800 {432/1,800}
1,944/1,400 {198.4/1,400}

rpm
rpm
1,950
800
Model
Type
Performance
Engine

Piston displacement
Starting motor
Alternator
Battery
24V, 11 kW
24V, 50A
12V, 175 Ah 2
CF68-4
Carrier roller
3 on each side
Track roller
9 on each side
Track shoe
Assembly-type triple grouser, 52 on each side
Fan pump
Type
Type
Fan motor
Set pressure
Hydraulic cylinder
Hydraulic system
Hydraulic system
Radiator core type
MPa {kg/cm2}
Type No.
Delivery
Set pressure
24.5 {250}
l /min
MPa {kg/cm2}
Type No.
Control method
Hydraulic
Travel motor

Swing motor

Type
Boom
Arm
Bucket
Double-acting
piston
Double-acting
piston
Double-acting
piston
mm
185
200
185
mm
120
140
130
Stroke
mm
1,725
2,045
1,425
mm
4,182
4,933
3,577
mm
2,457
2,888
2,152
Hydraulic tank
Hydraulic filter
Hydraulic cooler
PC600-8
Box-shaped, sealed
Tank return side
CF42-1 (Air cooled)
SEN00133-03
01 Specification

PC600-8
PC600-8
Machine model
Serial number
m
4.0
Weight of machine
kg
61,300
Max. digging depth
mm
3,495
mm
Max. digging reach
mm
9,190
mm
8,850
Max. digging height
mm
10,090
Max. dumping height
mm
6,705
kN {kg}
386 {39,400}
Swing speed
rpm
8.3
deg.
15.5
Travel speed
km/h
Low speed: 3.0

High speed: 4.9
Gradeability
deg.
Performance
Working ranges
Bucket capacity
Max. digging force
Dimensions

10
55001 and up
3
35
2
kPa {kg/cm }
109 {1.11}
mm
8,915
Overall width
mm
3,195
mm
3,900
mm
5,530
mm
3,435
Ground clearance of
counterweight
mm
1,365
mm
780
Tail swing radius
mm
3,900

equipment
mm
5,515

mm
6,480
mm
4,250
Track gauge
mm
3,300
mm
3,070
PC600-8
SEN00133-03
01 Specification
Machine model
PC600-8
Serial number
55001 and up
Model
Type
Performance
Engine

Piston displacement
KOMATSU SAA6D140E-5
6 140 165
15.24 {15,240}
mm
l {cc}
Flywheel horsepower
kW/rpm {HP/rpm}
323/1,800 {432/1,800}
Max. torque
Nm/rpm {kgm/rpm}
1,944/1,400 {198.4/1,400}
rpm
1,950
rpm
800
Starting motor
Alternator
Battery
24V, 11 kW
24V, 50A
12V, 175 Ah 2
CF68-4
Carrier roller
3 on each side
Track roller
8 on each side
Track shoe
Assembly-type double grouser, 49 on each side
Fan pump
Type
Type
Fan motor
Set pressure
Hydraulic system
Radiator core type
MPa {kg/cm }
Type No.
Delivery
Set pressure
24.5 {250}
l /min
MPa {kg/cm2}
Type No.
Control method
Hydraulic
Travel motor

Swing motor

Hydraulic cylinder
Hydraulic system
Boom
Arm
Bucket
Bottom dump
Double-acting Double-acting Double-acting Double-acting

piston
piston
piston
piston
Type
mm
185
200
160
140
mm
130
140
110
90
Stroke
mm
1,410
1,500
1,400
335
mm
4,147
3,878
3,750
1,235
mm
2,737
2,378
2,350
900
Hydraulic tank
Hydraulic filter
Hydraulic cooler
PC600-8
Box-shaped, sealed
Tank return side
CF42-1 (Air cooled)
11
SEN00133-03
01 Specification
PC600LC-8
PC600LC-8
Machine model
Serial number
m
4.0
Weight of machine
kg
62,300
Max. digging depth
mm
3,495
mm
Max. digging reach
mm
9,190
mm
8,850
Max. digging height
mm
10,090
Max. dumping height
mm
6,705
kN {kg}
386 {39,400}
Swing speed
rpm
8.3
deg.
15.5
Travel speed
km/h
Low speed: 3.0

High speed: 4.9
Gradeability
deg.
Performance
Working ranges
Bucket capacity
Max. digging force
Dimensions
35
2
kPa {kg/cm }
102 {1.04}
mm
8,915
Overall width
mm
3,195
mm
3,900
mm
5,530
mm
3,435
Ground clearance of
counterweight
mm
1,365
mm
780
Tail swing radius
mm
3,900

equipment
mm
5,515

mm
6,480
mm
4,600
Track gauge
mm
3,300
mm
3,070

12
55001 and up
3
PC600-8
SEN00133-03
01 Specification
Machine model
PC600LC-8
Serial number
55001 and up
Model
Type
Performance
Engine

Piston displacement
KOMATSU SAA6D140E-5
6 140 165
15.24 {15,240}
mm
l {cc}
Flywheel horsepower
kW/rpm {HP/rpm}
323/1,800 {432/1,800}
Max. torque
Nm/rpm {kgm/rpm}
1,944/1,400 {198.4/1,400}
rpm
1,950
rpm
800
Starting motor
Alternator
Battery
24V, 11 kW
24V, 50A
12V, 175 Ah 2
CF68-4
Carrier roller
3 on each side
Track roller
9 on each side
Track shoe
Assembly-type double grouser, 52 on each side
Fan pump
Type
Type
Fan motor
Set pressure
Hydraulic system
Radiator core type
MPa {kg/cm }
Type No.
Delivery
Set pressure
24.5 {250}
l /min
MPa {kg/cm2}
Type No.
Control method
Hydraulic
Travel motor

Swing motor

Hydraulic cylinder
Hydraulic system
Boom
Arm
Bucket
Bottom dump
Double-acting Double-acting Double-acting Double-acting

piston
piston
piston
piston
Type
mm
185
200
160
140
mm
130
140
110
90
Stroke
mm
1,410
1,500
1,400
335
mm
4,147
3,878
3,750
1,235
mm
2,737
2,378
2,350
900
Hydraulic tank
Hydraulic filter
Hydraulic cooler
PC600-8
Box-shaped, sealed
Tank return side
CF42-1 (Air cooled)
13
SEN00133-03
01 Specification
Weight table
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model
PC600-8
PC600LC-8
Serial number
30001 and up
30001 and up
Engine assembly
2,610
2,610
Engine
1,965
1,965
PTO (incl. lubricating piping)
285
285
Hydraulic pump
305
305
Fan, control and PTO lubrication pump
55
55
Radiator, oil cooler assembly
268
268
Hydraulic tank, filter assembly (excl. hydraulic oil)
455
455
Fuel tank (excl. fuel)
520
520
4,640
4,640
Operator's cab
280
280
Operator's seat
35
35
Counterweight
10,750
10,750
Swing machinery
743
743
Control valve
301
301
Swing motor
61 2
61 2
Travel motor
268 2
268 2
Fan motor
25
25
Center swivel joint
43
43
15,152
15,664
Center frame
3,998
3,998
Track frame
2,207 2
2,355 2
Swing circle
1,136
1,136
Idler
342 2
342 2
Idler cushion
452 2
452 2
Carrier roller
50 6
50 6
Track roller
108 16
108 18
Final drive (incl. travel motor)
994 2
994 2
Revolving frame
Track frame assembly

(Excluding step, roller guard, shoe assembly, and
lower piping)
14
PC600-8
SEN00133-03
01 Specification
Unit: kg
Machine model
PC600-8
PC600LC-8
Serial number
30001 and up
30001 and up
Standard triple grouser shoe (600 mm)
5,930
6,290
Wide triple grouser shoe
6,750
7,170
Boom assembly
4,820
4,820
Arm assembly
3,250
3,250
Bucket assembly
2,430
2,430
496 2
496 2
Arm cylinder assembly
734
734
Bucket cylinder assembly
482
482
Link assembly (large)
345
345
Link assembly (small)
149 + 26 2 + 76 + 104 + 36
149 + 26 2 + 76 + 104 + 36
Arm pin
32 + 55
32 + 55
Bucket pin
55 + 62
55 + 62
Link pin
45 2
45 2
Track shoe assembly
Boom cylinder assembly
Boom pin
PC600-8
(750 mm)
15
SEN00133-03
01 Specification

Unit: kg
Machine model
PC600-8
PC600LC-8
Serial number
55001 and up
55001 and up
Engine assembly
2,610
2,610
Engine
1,965
1,965
PTO (incl. lubricating piping)
285
285
Hydraulic pump
305
305
55
55
Radiator, oil cooler assembly
268
268
Hydraulic tank, filter assembly (excl. hydraulic oil)
455
455
Fuel tank (excl. fuel)
520
520
4,640
4,640
Operator's cab
280
280
Operator's seat
35
35
Counterweight
10,750
10,750
Swing machinery
743
743
Control valve
301
301
Swing motor
61 2
61 2
Travel motor
268 2
268 2
Fan motor
25
25
Center swivel joint
43
43
15,152
15,664
Center frame
3,998
3,998
Track frame
2,207 2
2,355 2
Swing circle
1,136
1,136
Idler
342 2
342 2
Idler cushion
452 2
452 2
Carrier roller
50 6
50 6
Track roller
108 14
108 14
Final drive (incl. travel motor)
994 2
994 2
Revolving frame
Track frame assembly

(Excluding step, roller guard, shoe assembly, and
lower piping)
16
PC600-8
SEN00133-03
01 Specification
Unit: kg
Machine model
PC600-8
PC600LC-8
Serial number
55001 and up
55001 and up
5,760
6,120
Boom assembly
3,880
3,880
Arm assembly
2,770
2,770
Bucket assembly
6,080
6,080
524 2
524 2
569
569
Bucket cylinder assembly
406 2
406 2
Bottom dump cylinder assembly
114 2
114 2
149 + 26 2 + 104 + 97
149 + 26 2 + 104 + 97
110 + 32
110 + 32
55 2 + 37 2
55 2 + 37 2
19 2 + 10 2 + 17 2
19 2 + 10 2 + 17 2
Track shoe assembly

Standard double grouser shoe (600 mm)
Wide triple grouser shoe
Boom cylinder assembly

Arm cylinder assembly
Boom pin
Arm pin
Bucket pin
Bucket connecting pin
PC600-8
17
SEN00133-03
01 Specification
Table of fuel, coolant and lubricants

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

2008 KOMATSU
All Rights Reserved
20
SEN00135-02
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up
10 Structure, function and

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

Parts related to engine
1. Air cleaner
2. Intake connector
3. Muffler
4. Front engine mount

5. Rear engine mount
PC600-8
SEN00135-02
Unit: mm
No.
Check item
Free height of front mount
rubber
Free height of rear mount
rubber
PC600-8
Criteria
Remedy
Standard size
Repair limit
126
134
Replace
SEN00135-02
PTO
1.
2.
3.
4.
5.
6.
7.
Connection plate
PTO case
Driven gear (No. of teeth: 40)
Drive gear (No. of teeth: 36)
Oil level gauge
Main shaft
Breather
a. Center of crankshaft (Center of SAL56 shaft)

b. Center of HPV95+95 shaft
c. Center of HPV95+95 shaft
Specifications
Lubricating oil: 7.2 l
Reducation ratio: Input shaft (SAL56 shaft) = 1
36
HPV95+95 shaft =
= 0.9
40
PC600-8
SEN00135-02
Unit: mm
No.
Check item
Backlash between drive gear

and driven gear
Criteria
Remedy
Standard clearance
Clearance limit
0.23 0.74
Backlash of SAL56 pump

input shaft
0.273 0.374
10
Backlash between main

shaft and connecting hub
assenbly
0.074 0.226
PC600-8
Adjust
SEN00135-02

LPV75 + SAL56 + 8
Unit: mm
No.
Check item
Clearance between
gear case and side
plate
Clearance between
bearing inner dia.
and gear shaft outer
dia.
Model
Standard clearance
Clearance limit
SAL56
0.13 0.18
0.22
SAL8
0.10 0.15
0.19
SAL56
0.067 0.125
0.20
SAL8
0.067 0.125
0.20
Pin insertion depth

4
SAL56
SAL8
Replace
Standard size
Tolerance
Repair limit
12
0
0.5
12
0
0.5
Delivery
Oil: EO10-CD
Oil temp.: 45 55C
Remedy
Criteria
(MPa {kg/cm2})
Standard
delivery
(l/min.)
Delivery
limit
(l/min.)
2,500
2.9 {30}
134
124
2,500
2.9 {30}
19
17
Speed
(rpm)
Delivery
pressure
PC600-8
SEN00135-02
Radiator, oil cooler
1.
2.
3.
4.
5.
Reservoir tank
Radiator inlet hose
Radiator
Radiator cap
Oil cooler
PC600-8
6. Fan
7. Shroud
8. Radiator outlet hose
Specifications
Radiator: CF68-4
Oil cooler: CF42-1
SEN00135-02

2009 KOMATSU
All Rights Reserved
SEN00136-01
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

Power train
Power train
Power train ..................................................................................................................................................... 2
Final drive ....................................................................................................................................................... 5
Sprocket.......................................................................................................................................................... 8
Swing circle .................................................................................................................................................. 10
Swing machinery .......................................................................................................................................... 12
PC600-8
SEN00136-01
Power train
Power train
PC600-8
SEN00136-01
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Idler
Center swivel joint
Swing motor (KMF90ABE-3)
Control valve
Final drive, sprocket
Travel motor (KMV335ADT)
Engine
PTO
No. 2 pump (HPV95+95)
Fan pump (LPV75)
PC600-8
11.
12.
13.
14.
15.
16.
17.
Control pump (SAL56)

PTO lubrication pump
No. 1 pump (HPV95+95)
Swing machinery
Swing circle
Travel speed solenoid valve
Swing brake solenoid valve
A. Control valve
B. Swing brake solenoid valve
SEN00136-01
PC600-8
SEN00136-01
Final drive
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Level plug
Drain plug
No. 1 planetary gear (No. of teeth: 50)
No. 1 sun gear (No. of teeth: 12)
No. 1 planetary carrier
Cover
No. 1 ring gear (No. of teeth: 114)
Hub
Sprocket
Floating seal
Travel motor
No. 2 ring gear (No. of teeth: 70)
Specifications
Reduction ratio: 12+114 x
12
= 62.000
PC600-8
14+70
14
+1
SEN00136-01
PC600-8
SEN00136-01
Unit: mm
No.
16
Check item
Backlash between No. 2
planet carrier and motor
Criteria
Remedy
Standard clearance
Clearance limit
0.06 0.21
17
Backlash between No. 2 planet

gear and No. 2 ring gear
0.21 0.69
1.10
18

planet gear and No. 1 ring
gear
0.18 0.63
1.10
19
Backlash between No. 2 sun

gear and No. 2 planet gear
0.17 0.62
1.00
20

0.14 0.45
1.00
21

planet carrier and No. 2 sun
gear
0.16 0.56
1.00
22
End play of sprocket shaft
0.10 0.15
Standard size
Repair limit
23
Sprocket tooth width

104
101.5
24
Wear of sprocket teeth
PC600-8
Replace
Repair limit: 6
Rebuild or
replace
Replace
SEN00136-01
Sprocket
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
350.1
338.1
Wear of tooth tip
Thickness of tooth root
24.4
18.4
Width of tooth
104
101.5
Wear of tooth shape
Rebuild or
replace
Repair limit: 6 (measure with sprocket tooth shape)
PC600-8
SEN00136-01
Sprocket tooth shape of real dimension
a The above drawing is reduced to 60%. Enlarge it to 168% to return it to the full scale and make a copy on
an OHP sheet.
PC600-8
SEN00136-01
Swing circle
STD
1. Swing circle inner race (No. of teeth: 100)

2. Ball
3. Swing circle outer race
Specifications
Reduction raito: 100
13
= 7.692
Amount of grease: 31 l (G2-LI)
a. Inner race soft zone "S" position

b. Outer rae soft zone "S" position
Unit: mm
No.
Check item
Clearance of bearing in axial

direction (when mounted on
machine)
10
Criteria
Remedy
Standard clearance
Clearance limit
0.10 0.25
3.2
Replace
PC600-8
SEN00136-01
If equipped
PC600-8
11
SEN00136-01
Swing machinery
12
PC600-8
SEN00136-01
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Swing pinion (No. of teeth: 13)

Cover
Case
Coupling
Ring gear (No. of teeth: 95)
Cover
Swing motor
Oil level gauge
Specifications
Reduction raito:
21+95
16+95
x
21
16
= 38.321
Unit: mm
No.
15
Check item
Backlash between swing
motor shaft and No. 1 sun
gear
Criteria
Remedy
Standard clearance
Clearance limit
0.15 0.49
16

carrier and No. 2 sun gear
0.38 0.66
1.20
17

gear and ring gear
0.17 0.57
1.00
18

0.15 0.49
0.90
19

carrier and coupling
0.06 0.25
20
Clearance between plate and

coupling
0.38 0.82
21

0.15 0.49
1.00
22
Backlash between swing pinion

and swing circle
0 0.126
2.00
23
Backlash between coupling

and swing pinion
0.07 0.23
24

gear and ring gear
0.15 0.57
1.10
Wear of swing pinion oil seal

contact surface
Standard size
Repair limit
25
PC600-8
Replace
140.3 0.100
Repair hard
chrome plating or replace
13
SEN00136-01

2009 KOMATSU
All Rights Reserved
14
SEN00137-01
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

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

Track frame, recoil spring
1.
2.
3.
4.
5.
6.
7.
8.
Idler
Track frame
Carrier roller
Center frame
Final drive
Track roller
Track shoe
Center guard
The dimensions and number of track rollers may differ according to the model, but the basic structure is
the same.
No. of track rollers.
Model
No. of rollers (each side)
PC600-8
PC600LC-8
PC600-8
SEN00137-01
Unit: mm
No.
Check item
Standard size
10
11
Recoil spring
Top-to-bottom width of idler

guide
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
859 x 299
715
292 kN
{29,770 kg}
233.6 kN
{23,816 kg}
Standard
size
Tolerance
Repair limit
Track frame
163.5
163.5 0
Idler support
161
161 0
Track frame
329
329 0
334
Idler support
324
322
Left-to-right width of idler

guide
PC600-8
Remedy
Criteria
+4
+1
+4
Replace
167.5
159
Rebuild or
replace
SEN00137-01
Idler
PC600-8
SEN00137-01
Unit: mm
No.
Check item
Criteria
Outside diameter of
protruding part
Remedy
Standard size
Repair limit
761
Outside diameter of tread

surface
716
704
Height of tread
22.5
28.5
Thickness of tread
26
20
Overall width
234
Width of tread
56
62
Clearance between shaft and

bushing
Standard
size
110
Interference between idler

and bushing
Standard
size
120
Tolerance
Shaft
Hole
Standard
clearance
0.120
0.207
+0.480
+0.420
0.540
0.687
Tolerance
Clearance
limit
Shaft
Hole
Standard
interference
Interference limit
+0.087
+0.037
0.036
0.136
0.073
0.223
Standard clearance
Clearance limit
0.35 0.88
Play of axial direction
PC600-8
Rebuild or
replace
Replace
bushing
Replace
SEN00137-01
Carrier roller
Unit: mm
No.
Check item
Criteria
Standard size
Repair limit
210
Outside diameter of flange
180
170
Width of tread
53
Thickness of tread
42.5
37.5
Width of flange
15

bushing
Standard
size
68
Interference between roller

and bushing
Standard
size
73
Remedy
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
+0.09
+0.07
+0.43
+0.18
0.09
0.36
Interference limit
Tolerance
Shaft
Hole
Standard
interference
+0.38
+0.33
+0.24
+0.21
0.09
0.17
Standard clearance
Clearance limit
0.62 0.93
Replace
Play of roller in axial direction
PC600-8
SEN00137-01
Track roller
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
260
Outside diameter of flange

surface
220
208
Thickness of tread
56.2
50.2
Overall width
325
Width of tread
63
Width of flange
39.5

bushing
Standard
size
100
Interference between roller

and bushing
Standard
size
107.6
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.140
0.207
+0.390
+0.330
0.470
0.597
1.5
Interference limit
Tolerance
Shaft
Hole
Standard
interference
+0.087
+0.037
+0.020
0.015
0.017
0.102
Standard clearance
Clearance limit
0.5 1.1
Play of axial direction
PC600-8
Rebuild or
replace
Replace
bushing
Replace
SEN00137-01
Track shoe
a P portion shows the link of buhing press fitting end.
PC600-8
SEN00137-01
Unit: mm
No.
Check item
Remedy
Criteria
Standard size
Repair limit
228.9
231.9
Link pitch
Reverse or
replace
When turned
Standard size
2
Bushing outside diameter

79
Link height
Thickness of link metal

(bushing press-fitting portion)
74
Standard size
Repair limit
14.6
9.6
133
123
33.75
23.75
219.8
Shoe bolt pitch
Rebuild or
replace
Replace
76.2
9
Link
11
Inside width
122.4
Overall
width
61.4
Tread width
54.5
12
Protrusion of pin
3.7
13
Protrusion of regular bushing
9.6
14
Overall length of pin
290
15
Overall length of bushing
16
Thickness of spacer
17
18
Adjust or
replace
169
10
Impact load
Thickness of bushing metal
Normal load
Press-fitting
force
*19
Repair or
replace
Adjust or
replace
200.6
Bushing
127.4 343 kN {13 35 ton}
Regular pin
196.1 490 kN {20 50 ton}
Master pin
156.9 431 kN {16 44 ton}
*:Dry type track link

PC600-8
SEN00137-01
Unit: mm
No.
Check item
a. Regular
link
20
Remedy
Criteria
Tightening torque
(Nm {kgm})
Additional tightening
angle (deg.)
784.578.5 {808}
12010
Shoe bolt
Retighten
b. Master
link
Tightening torque
(Nm {kgm})
Additional tightening
angle (deg.)
Lower limit torque

(Nm {kgm})
Tolerance
Standard size
21
22
Interference between bushing

and link
Interference between regular

pin and link
Hole
72.9
+0.050
+0.050
0.326
0.400
0.326 0.450
48.8
+0.180
+0.080
0.238
0.300
0.318 0.480
Tolerance
Standard size
23
Clearance between regular pin

and bushing
49.6
Shaft
Hole
0.62
0.72
+0.6
+0.6
Tolerance
Standard size
*24
Interference between master

pin and link
48.8
Shaft
Hole
+0.030
+0.030
0.238
0.300
Tolerance
Standard size
*25
Standard
interference
Shaft
Clearance between master pin

and bushing
49.2
Shaft
Hole
0.65
0.75
+0.60
+0.60
Standard
clearance
0.62 1.32
Adjust or
replace
Standard
interference
0.238 0.330
Standard
clearance
0.65 1.35
*: Dry type track link
10
PC600-8
SEN00137-01
Double shoe
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
48
27
Height
Height
48
Thickness
17
34
Rebuild or
replace
Length at bottom
5
34
26
Length at tip
7
8
26
Standard size
Repair limit
65
44
Thickness
PC600-8
11
SEN00137-01
Triple grouser shoe
Unit: mm
No.
1
2
Check item
Criteria
Remedy
Standard size
Repair limit
37
22
Height
Thickness
18
33
Length of bottom
27
25.5
Length at tip
17.5
7
8
12
Rebuild or
replace
23.5
Standard size
Repair limit
55
40
Thickness
PC600-8
SEN00137-01
Standard shoe
Model
PC600-8
PC600LC-8
600
600
228.6
228.6
49
52
Item
Shoe width (mm)
(triple shoe)
Link pitch (mm)
No. of shoes
(each side)
Selection of track shoe

Select the most suitable track shoe from the following table
PC600-8
PC600LC-8
Specifications
Category
Specifications
Category
Standard
600 mm triple
600 mm triple
If equipped
700 mm triple
If equipped
750 mm triple
750 mm triple
If equipped
900 mm triple
900 mm triple
Category
Use
Precautions when using
Rocky ground,
normal river soil
Travel in Lo speed when traveling on rough ground with obstacles such as large
boulders and fallen trees.
Normal soil, soft

land
Cannot be used on rough ground where there are large obstacles such as boulders
and fallen trees.
Travel in Hi speed only on flat ground; when it is impossible to avoid traveling over
obstacles, lower the travel speed to approx. half of Lo speed.
Extremely soft
ground (swampy
ground)
Use only for ground where A and B sink and are impossible to use.
Cannot be used on rough ground where there are large obstacles such as boulders
and fallen trees
Travel in Hi speed only on flat ground; when it is impossible to avoid traveling over
obstacles, lower the travel speed to approx. half of Lo speed.
Paved surface
The shoes are flat, so they have low gradeability
Paved surface
The shoes are made of rubber, so be careful when traveling on rough ground
a Categories B and C are wide shoes, so there

are restrictions on their use. Therefore, before
using, check the restrictions and consider carefully the conditions of use before recommending
a suitable shoe width. If necessary, give the customer guidance in their use.
PC600-8
a When selecting the shoe width, select the narrowest shoe possible within the range that will
give no problem with flotation and ground pressure.
If a wider shoe than necessary is used, there will
be a large load on the shoe, and this may lead
to bending of the shoe, cracking of the links,
breakage of the pins, loosening of the shoe
bolts, or other problems.
13
SEN00137-01

2006 KOMATSU
All Rights Reserved
14
SEN00138-01
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

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

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

No. 1 main pump
Model: HPV95+95
PA1
PA2
PD11
PD21
PCF
PCR
PD
PS
PT
PSV
PECN
: Front pump discharge port

: Rear pump discharge port
: Drain port
: Drain port
: CO selector pilot port
: Jet sensor downstream pressure IN port
: Pump suction port
: Jet sensor upstream pressure IN port
: Servo basic pressure IN port
: CO+NC valve output pressure output port
1.
2.
3.
4.
5.
6.
7.
Front pump
Front servo valve
Front CO+NC valve
Rear servo valve
Rear CO+NC valve
TVC valve
Rear pump
PC600-8
SEN00138-01
No. 1 main pump
PSV1
PSV2
PSV1A
PSV1B
PSV2A
PSV2B
PC600-8
: Servo valve basic pressure port

: Servo piston output port
: Servo valve output port
SEN00138-01
1.
2.
3.
4.
5.
6.
7.
Front shaft
Front cradle
Front case
Rocker cam
Piston
Cylinder block
Valve plate
8.
9.
10.
11.
12.
13.
14.
Front end cap

Coupling
Impeller
Rear end cap
Valve plate
Cylinder block
Piston
15.
16.
17.
18.
19.
Rear case
Rocker cam
Rear cradle
Rear shaft
Servo piston
PC600-8
SEN00138-01
Servo valve
1. Servo valve assembly (No. 1 front)
P1
PE
: Main pump pressure IN port

: TVC valve output pressure front, rear
interconnection port
PCO : CO selector pilot port
PD
PT
PAC : Servo actuator port
PDR : Servo valve drain OUT port
PPO : Servo basic pressure IN port
PECN : CO+NC valve output pressure output port
PC600-8
1. CO+NC valve
2. Servo valve
SEN00138-01
2. Servo valve (No. 1 front)
P2
: Main pump pressure OUT port
PDR : CO+NC valve drain IN port
PECN : CO+NC valve output pressure IN port
10
PC600-8
SEN00138-01
3. Servo valve assembly (No. 1 rear)
P1
P2
PCO
PAC
PDR
PPO
PD
PE
PT

: Servo actuator port
: Servo valve drain OUT port
: TVC valve output pressure front, rear
interconnection port
PC600-8
1.
2.
3.
4.
TVC valve
CO+NC valve
Connector
Servo valve
11
SEN00138-01
4. Servo valve (No. 1 rear)
P1
P2
PDR
PPO
PECN
12
:
:
:
:
:
Main pump pressure OUT port

CO+NC valve drain IN port
Servo basic pressure OUT port
CO+NC valve output pressure IN port
PC600-8
SEN00138-01
Structure
(The following illustration shows the servo valve for No. 1 rear.)
1.
2.
3.
4.
5.
6.
Locknut
Cover
Plug
Spring
Valve body
Arm
7.
8.
9.
10.
11.
12.
Pin
Piston
Locknut
Plug
Locknut
Cover
13.
14.
15.
16.
17.
18.
Sleeve
Piston
Spring
Plug
Cover
Locknut
Function
Discharge amounts Q1 and Q2 of main pumps P1
and P2 are controlled individually by the respective
servo valves. The relationship between pump discharge amount Q and input signal PECN to the
servo valve is as shown in the graph on the right. Q
varies in proportion to PECN.
PC600-8
13
SEN00138-01
1) Operation in direction of increase of pump discharge amount (max. angle)
Operation
The control pump pressure PPO is taken to port
a.
Signal pressure PECN from the NC valve is taken from port b to chamber c.
When signal pressure PECN rises, piston (8) is
pushed to the right by the pressure in chamber c,
and stops at a point where it balances the pressure of springs (4) and (4A).
At the same time, arm (6) uses servo piston (19)
as a fulcrum and sways to the right in the same
way as piston (8). This moves guide spool (13) to
the right.
When guide spool (13) moves, port a and port d
are closed and port d is connected to drain
chamber e. As a result, servo piston chamber f is
also interconnected with drain chamber e
through port g and port d.
14
At the same time, port a is interconnected with

port h, so the pressure oil flows through port i to
servo piston chamber j, pushes servo piston (19)
to the right, increases the swash plate angle in
the main piston pump and increases the pump
discharge amount.
When servo piston (19) moves, arm (6) rotates
counterclockwise with its center at pin (7) and
moves guide spool (13) to the left. Port a, port d
and port h close, so the discharge increases by
an amount that matches signal pressure PECN.
PC600-8
SEN00138-01
2) Operation in direction of decrease of pump discharge amount (min. angle)
Operation
When signal pressure PECN goes down, piston
(8) moves to the left and stops at a point where
the pressure in chamber c balances the pressure
of springs (4) and (4A).
At the same time, arm (6) uses servo piston (19)
as a fulcrum and sways to the left in the same
way as piston (8). This moves guide spool (13) to
the left.
When guide spool (13) moves, port a and port h
are closed and port h is connected to drain
chamber e. As a result, servo piston chamber j is
also interconnected with drain chamber e
through port i and port h.
PC600-8
At the same time, port a is interconnected with

port d, so the oil flows through port g to servo piston chamber f, pushes servo piston (19) to the
left, decreases the swash plate angle in the main
piston pump and decreases the pump discharge
amount.
When servo piston (19) moves, arm (6) rotates
counterclockwise with its center at pin (7). Guide
spool (13) is moved to the right and closes port
a, port d and port h, so the discharge decreases
by an amount that matches signal pressure
PECN.
15
SEN00138-01
TVC valve
PPO
P1
P2
PDR
PE
16

: TVC valve drain OUT port
: TVC valve output pressure OUT port
1.
2.
3.
4.
Spring
Spool
Piston
Piston
5.
6.
7.
8.
Sleeve
Piston
Body
Solenoid
PC600-8
SEN00138-01
Function
When the power mode is P-mode or E-mode, the
pump discharge amount is set properly with the
command current sent from the controller according to the engine speed.
When the emergency pump drive switch is

turned ON, the pump discharge amount is controlled according to the pump discharge pressure
(load) by sensing the oil pressure at constant
pump absorption torque.
1) When command current value from controller is small in P and E mode
Operation
The command current sent from the controller
actuates solenoid push pin (9) and spool (2)
moves. When this happens, spool (2) stops at a
point where it balances the total of the force of
spring (1), the force of push pin (9), and the force
of TVC output pressure PE acting on piston (3).
At this time, since the command current and the
force of push pin (9) are small, spool (2) is balanced on the lower side.
PC600-8
As a result, ports "a" and "b" are opened almost

fully and almost all the oil from the control pump
is output as TVC valve output pressure PE.
Then, TVC valve output pressure PE and signal
pressure PECN increase, thus the pump discharge amount increases.
17
SEN00138-01
2) When command current value from controller is large in P and E mode
Operation
The command current sent from the controller
moves push pin (9), which moves spool (2).
Spool (2) stops at a position where it is balanced
with spring (1). At this time, since the command
current and the force of push pin (9) are large,
spool (2) is balanced on the upper side.
18
As a result, the oil flow from the control pump is

reduced between ports "a" and "b" and the open
areas of port "b" and port "c" (drain port) increase. Then, TVC valve output pressure PE
and signal pressure PECN lower, thus the pump
discharge amount decreases.
PC600-8
SEN00138-01
3) When emergency pump drive switch is turned ON and pump load is small
Operation
If the emergency pump drive switch is turned
ON, the command current increases and the
force of solenoid push pin (9) becomes larger.
As a result, spring (1) is kept compressed.
PC600-8
Since main pump discharge pressures P1 and

P2 are low, spring (1) keeps pressing spool (2)
down. As a result, control pump discharge pressure PPO becomes equal to TVC valve output
pressure PE. At this time, TVC valve output
pressure PE and the pump discharge amount increase.
19
SEN00138-01
4) When emergency pump drive switch is turned ON and pump load is large
Operation
When main pump discharge pressure P1 (or P2)
increases, spool (2) is moved up by piston (4) or
piston (6). As a result, the flow of oil from port a
to port b is throttled by the notch in the spool. At
the same time, the area of the opening at port b
and port c (drain port) becomes larger. In this
way, TVC valve output pressure PE goes down,
and the pump discharge amount decreases.
20
PC600-8
SEN00138-01
CO+NC valve
1. CO+NC valve (No. 1 front)
P
PEFR : TVC valve output pressure front, rear interconnection port
PE
: TVC valve output pressure detection port
PC600-8
PD
PT
PDR
PECN

: CO+NC valve drain OUT port
: CO+NC valve output pressure OUT port
21
SEN00138-01
2. CO+NC valve (No. 1 rear)
P1I
P1O
P2I
P2O
PEFR
Main pump pressure IN port (front)

Main pump pressure IN port (rear)
TVC valve output pressure front, rear interconnection port
PEI
: TVC valve output pressure IN port
22
:
:
:
:
:
PD
PT
PDRI : TVC valve drain IN port
PDRO : CO+NC valve drain OUT port
PPOI : Servo basic pressure IN port
PPOO : Servo basic pressure OUT port
PECN : CO+NC valve output pressure OUT port
PC600-8
CO valve
1. Plug
2. Piston
3. Spring
4. Spool
5. Piston
6. Plug
PC600-8
SEN00138-01
NC valve
7. Plug
8. Sleeve
9. Piston
10. Spool
11. Spring
12. Plug
23
SEN00138-01
3. CO valve
Function
When the load becomes large during operations
and the main pump discharge pressure rises to a
point close to relief pressure, the cut-off function
of the CO valve acts to reduce the pump discharge in order to reduce relief loss.
At the same time, it has a cut-off cancel function

actuated by the pilot pressure from the heavy-lift
solenoid valve.
The CO valve is controlled by balancing the
spring with the total of main pump discharge
pressure P and CO valve output pressure PEC.
1) When main pump discharge pressure is lower than relief pressure
Operation
Spool (4) is pressed down by spring (3). As a result, ports "a" and "b" are opened fully, and TVC
valve output pressure PE is equal to CO valve
output pressure PEC.
Accordingly, CO valve output pressure PEC, signal pressure PECN, and pump discharge
amount become maximum.
24
PC600-8
SEN00138-01
2) When main pump discharge pressure becomes close to relief pressure
Operation
If the load increases and main pump discharge
pressure P increases near to the relief pressure,
main pump discharge pressure P presses piston
(5). At the same time, CO valve output pressure
PEC presses piston (5) and spool (4) moves up.
As a result, oil flow from port "a" to port "b" is reduced by the notch of the spool and the open areas of port "b" and port "c" (drain port) increase.
Accordingly, CO valve output pressure PEC and
signal pressure PECN lower and the pump discharge amount becomes minimum.
PC600-8
25
SEN00138-01
3) When cut-off function is canceled by 2-stage relief solenoid valve
Operation
If the 2-stage relief solenoid valve is turned ON,
its pilot pressure PCO is lead in the port and piston (2) is pressed down. Accordingly, seat (6)
touches seat (7) and locks spool (4).
As a result, even if main pump discharge pressure P increases to the relief pressure, spool (4)
does not operate. Accordingly, CO valve output
pressure PEC keeps maximum and the pump
discharge amount does not decrease.
26
PC600-8
SEN00138-01
4. NC valve
Function
The NC valve controls the main pump discharge
amount to reduce the neutral loss and fine control loss according to the moving distance of the
control valve spool.
The main pump discharge amount is controlled

by balance of the sum of jet sensor upstream
pressure PT and NC valve output pressure
PECN and the sum of the force of NC valve
spring (12) and jet sensor downstream pressure
PD.
The jet sensor senses the flow of the oil returning
through the control valve to the tank and use it as
PT and PD of the NC valve.
1) When control valve is at neutral
Operation
When the control valve is at neutral, jet sensor
differential pressure (PT PD) becomes the
maximum, and the force of jet sensor output
pressure PT pushing piston (10) becomes larger
than the total of the force of spring (12) and the
force of jet sensor output pressure PD pushing
the bottom of spool (11).
PC600-8
As a result, spool (11) is pushed down, so the

flow from port c to port b is throttled, and the area
of the opening of port b and port a (drain port) becomes larger. In this way, NC valve output pressure PECN becomes the minimum, and the main
pump discharge amount also becomes the minimum.
27
SEN00138-01
2) When control lever is operated
Operation
When the control lever is moved, the jet sensor
differential pressure (PT PD) goes down in accordance with the movement of the control lever.
Spool (11) is pushed up, and the area of the
opening of port c and port b becomes larger. In
this way, NC valve output pressure PECN becomes larger and the discharge amount from the
main pump increases. In other words, the pump
discharge amount increases according to the
amount that the control lever is operated.
28
PC600-8
SEN00138-01
No. 2 main pump

Model: HPV95+95
PA1
PA2
PD12
PD22
PS
PSV
PECN
: Front pump discharge port

: Rear pump discharge port
: Drain port
: Drain port
: Pump suction port
: CO+NC valve output pressure port
PC600-8
1.
2.
3.
4.
Front pump
Front servo valve
Rear servo valve
Rear pump
29
SEN00138-01
No. 2 main pump
PSV1
PSV2
PSV1A
PSV1B
PSV2A
PSV2B
30

PC600-8
SEN00138-01
1.
2.
3.
4.
5.
6.
7.
Front shaft
Front cradle
Front case
Rocker cam
Piston
Cylinder block
Valve plate
PC600-8
8.
9.
10.
11.
12.
13.
14.
Front end cap

Coupling
Impeller
Rear end cap
Valve plate
Cylinder block
Piston
15.
16.
17.
18.
19.
Rear case
Rocker cam
Rear cradle
Rear shaft
Servo piston
31
SEN00138-01
Servo valve
1. Servo valve (No. 2 front)
P1
P2
PAC
PDR
PPO
PECN
32
:
:
:
:
:
:
Main pump pressure IN port

Main pump pressure IN port
Servo actuator port
Servo valve drain OUT port
Servo basic pressure IN port
CO+NC valve output pressure IN port
1. Servo valve
PC600-8
SEN00138-01
2. Servo valve (No. 2 rear)
P2
PAC
PDR
PPO
PECN

: Servo actuator port
: Servo valve drain OUT port
: CO+NC valve output pressure IN port
PC600-8
1. Servo valve
33
SEN00138-01
Line oil filter
1. Cover
2. Element
3. Case
Outline
There are two line oil filters installed to the discharge
side of the main pump. They protect the circuit and
equipment by removing all dirt and dust from the oil.
A: From main pump

B: To control valve
34
PC600-8
PC600-8
SEN00138-01
35
SEN00138-01
Cooling fan pump

LPV75
P1
PS
Pa
Pe
P1C
Pen
36
:
:
:
:
:
:
Pump discharge port

Pump suction port
Pump control basic pressure
Pump control pressure
Pump pressure detection port
Pump control pressure detection port
PD2 : Pump drain port

PC600-8
SEN00138-01
1.
2.
3.
4.
5.
6.
Shaft
Oil seal
Case
Rocker cam
Shoe
Piston
PC600-8
7.
8.
9.
10.
11.
12.
Cylinder block
Valve plate
Spring
Servo piston
Ball
End cap
37
SEN00138-01
Function
The rotation and torque of the engine are transmitted to the shaft of this pump and converted
into hydraulic energy in this pump. This pump
discharges the pressurized oil according to the
load.
The discharge of this pump can be changed by
changing the swash plate angle in it.
38
Structure
Cylinder block (7) is supported on shaft (1)
through spline a. Shaft (1) is supported by the
front and rear bearings.
The end of piston (6) has a spherical hollow
which is combined with shoe (5). Piston (6) and
shoe (5) form a spherical bearing.
Rocker cam (4) has plane A. Shoe (5) is kept
pressed against plane A and slid circularly.
Rocker cam (4) slides around ball (11).
Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
Cylinder block (7) rotates relatively against valve
plate (8), sealing the pressurized oil, and the hydraulic balance is maintained properly.
The oil in each cylinder of cylinder block (7) can
be sucked and discharged through valve plate
(8).
PC600-8
SEN00138-01
Operation
1. Operation of pump
Cylinder block (7) rotates together with shaft (1)
and shoe (5) slides on plane A. At this time, rocker cam (4) tilts around ball (11). As a result, angle
between center line X of rocker cam (4) and
the axis of cylinder block (7) changes. Angle is
called the swash plate angle.
If angle is made between center line X of rocker cam (7) and the axis of cylinder block (7),
plane A works as a cam for shoe (5).
Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between volumes E and F in cylinder block (7). As a resurlt,
each piston (6) sucks and discharges oil by F
E.
In other words, if cylinder block (7) rotates and
the volume of chamber E is decreased, the oil is
discharged from chamber E. On the other hand,
the volume of chamber F is increased and the oil
is sucked in chamber F. (In the figure, chamber
F is at the end of the suction stroke and chamber
E is at the end of the discharge stroke.)
If center line X of rocker cam (4) is equal to the
axis of cylinder block (7) (the swash plate angle
is 0), there is not a difference between volumes
E and F in cylinder block (7) and oil is not sucked
or discharged. (The swash plate angle is not set
to 0 actually, however.)
In short, swash plate angle
is in proportion to
the pump discharge.
PC600-8
39
SEN00138-01
2. Control of discharge
If swash plate angle
is increased, the difference between volumes E and F is increased, and
so discharge Q is increased. Swash plate angle
is changed with servo piston (10).
Servo piston (10) reciprocates straight according
to the signal pressure of the servo valve. This
straight motion is transmitted to rocker cam (4).
Then, rocker cam (4) supported on ball (11)
slides around ball (11).
40
PC600-8
SEN00138-01
Servo valve
P : EPC valve basic pressure

T : Drain
PE : Control piston pressure
PH : Pump discharge pressure
1.
2.
3.
4.
5.
6.
7.
Plug
Lever
Retainer
Seat
Spool
Piston
Sleeve
PC600-8
41
SEN00138-01
Function
The servo valve controls the current input to the
EPC valve and the swash plate angle of the
pump so that they will be related as shown in the
figure below.
42
The relationship between the input current to the

EPC valve and the output pressure of EPC valve
F is as follows.
PC600-8
SEN00138-01
Operation
The output pressure of the EPC valve is applied
to the piston chamber to push piston (6). Piston
(6) pushes spool (5) until it is balanced with the
spring.
Then, the land of the servo piston pressure passage is connected to the pump discharge passages by the cut of spool (5) and the discharge
pressure is led to the servo piston.
The servo piston is raised by the rocker cam. The
position feedback is applied and the lever moves
to compress the spring.
If spool (5) is pushed back, the pump discharge
circuit and the servo piston circuit are shut off.
The pressure in the servo piston chamber lowers
and the rocker cam returns toward the maximum
swash plate angle.
These processes are repeated until the swash
plate is fixed to a position where the EPC output
pressure is balanced with the spring force.
Accordingly as the EPC output pressure is
heightened, the swash plate angle is decreased.
As the EPC output pressure is lowered, the
swash plate angle is increased.
PC600-8
43
SEN00138-01
Cooling fan motor

Type: LMF75
P : From fan pump

TC : To tank
T : From oil cooler to tank
44
Specifications
Type: LMF75
Capacity: 75 cm3/rev
Rated speed: 1,430 rpm
Rated flow rate: 112 l/min
Cracking pressure of check valve:
78.5 kPa {0.8 kg/cm2}
PC600-8
SEN00138-01
1.
2.
3.
4.
5.
6.
7.
8.
Output shaft
Case
Thrust plate
Shoe
Piston
Cylinder block
Valve plate
End cover
PC600-8
9.
10.
11.
12.
13.
14.
15.
Center spring
Check valve spring
Check valve
Pilot valve
Reversible valve spool
Safety valve
Reversible valve spring
45
SEN00138-01
1. Hydraulic motor unit

Function
This hydraulic motor is called a swash plate type
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump into
rotary motion.
Principle of operation
The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on supply side of the Y-Y line
connecting the top dead center and bottom dead
center of the stroke of piston (4).
The oil sent to supply side of cylinder block (5)
presses pistons (4) (4 or 5 pieces) and generates
force F1(F1 kg = P kg/cm2 x x/4D2 cm2).
This force is applied to thrust plate (2).
Since thrust plate (2) is fixed to the angle of
degrees to output shaft (1), the force is divided
into components F2 and F3.
The radial component F3 generates torque
against the Y-Y line connecting the top dead
center and bottom dead center (T = F3 x ri).
The resultant of this torque [T =
( F3 x ri)] rotates cylinder block (5) through the piston.
Since cylinder block (5) is coupled with the output shaft by means of spline, the output shaft revolves to transmit the torque.
46
PC600-8
SEN00138-01
2. Suction valve
Function
If the fan pump stops, the hydraulic oil does not
flow into the motor. Since the motor continues
revolution because of the force of inertia, however, the pressure on the outlet side of the motor
rises.
When the oil stops flowing in from inlet port P, the
suction valve sucks in the oil on the outlet side
and supplies it to the port MA where there is not
sufficient oil to prevent cavitation.
Operation
1) When pump is started
If the hydraulic oil from the pump is supplied to
port P and the pressure on MA side rises and
starting torque is generated in the motor, the motor starts revolution. The oil on outlet MB side of
the motor returns through port T to the tank.
2) When pump is stopped

If the engine is stopped and the input revolution
of the fan pump lowers to 0 rpm, the hydraulic oil
from the pump is not supplied to port P anymore.
As the hydraulic oil is not supplied to MA side of
the motor, the motor speed lowers gradually to
stop.
If the motor shaft is revolved by the force of inertia while the oil flow in port P is reducing, the oil
in port T on the outlet side is sent by the suction
valve to MA side to prevent cavitation.
PC600-8
47
SEN00138-01
3. Operation of reversible valve

1) When ON-OFF solenoid for reversible valve
is turned OFF
If ON-OFF solenoid (1) for reversible valve is
turned "OFF", the hydraulic oil from the pump is
blocked by ON-OFF reversible valve (2) and port
C is connected to the tank circuit.
Accordingly, reversible valve spool (3) is pushed
by reversible valve spool spring (4) to the right to
open motor port MA and then the hydraulic oil
flows in to revolve the motor forward (clockwise).
2) When ON-OFF solenoid for reversible valve

is turned ON
If ON-OFF solenoid (1) for reversible valve is
turned "ON", ON-OFF reversible valve (2)
changes to let the hydraulic oil from the pump
flow through port C into spool chamber D.
The hydraulic oil in chamber D pushes reversible
valve spool (3) to the left against reversible valve
spool spring (4).
As a result, motor port MB opens and the hydraulic oil flows in to revolve the motor in reverse
(counterclockwise).
48
PC600-8
SEN00138-01
4. Safety valve
Function
When the engine is started, the pressure in port
P of the fan motor is heightened in some cases.
Safety valve (1) is installed to protect the fan system circuit.
Operation
If the pressure in port P rises above the cracking
pressure of safety valve (1), valve (2) of safety
valve (1) opens to release the hydraulic oil into
port T.
By this operation, generation of abnormal pressure in port P is prevented.
PC600-8
49
SEN00138-01

2006 KOMATSU
All Rights Reserved
50
SEN00139-04
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

Control valve................................................................................................................................................... 2
Swing motor.................................................................................................................................................. 21
Swing brake .................................................................................................................................................. 24
Safety valve .................................................................................................................................................. 25
Reverse prevention valve ............................................................................................................................. 27
Center swivel joint ........................................................................................................................................ 30
Travel motor.................................................................................................................................................. 31
Parking brake ............................................................................................................................................... 36
Brake valve ................................................................................................................................................... 38
Set pressures varying mechanism ............................................................................................................... 41
Valve control ................................................................................................................................................. 42
Work equipment, swing PPC valve............................................................................................................... 44
Travel PPC valve .......................................................................................................................................... 48
Service PPC valve ........................................................................................................................................ 50
PPC accumulator.......................................................................................................................................... 51
PPC shuttle valve ......................................................................................................................................... 52
Solenoid valve .............................................................................................................................................. 53
Boom holding valve ...................................................................................................................................... 58
Boom LOWER regeneration valve ............................................................................................................... 62
Quick return valve......................................................................................................................................... 65
Hydraulic cylinder ......................................................................................................................................... 68
PC600-8
SEN00139-04

Control valve
Outline
This control valve consists of a 4-spool valve and
a 5-spool valve, and a travel shuttle valve is also
installed to it. Furthermore, a straight-travel
valve, arm throttle valve, and swing priority valve
are built in.
The 4-spool and 5-spool valves are connected
by bolts to form one unit, and internal merging of
the oil flow makes it even more compact and
easy to maintain.
A1L : To L.H. travel motor PB port
A2L : To boom cylinder bottom
A3L : To bucket cylinder head
A1R : To swing motor MA port
A3R : Service
A4R : To arm cylinder head
A5R : To R.H. travel motor PA port
B1L : To L.H. travel motor PA port
B2L : To boom cylinder head
B3L : To bucket cylinder bottom
B1R : To swing motor MB port
B3R : Service
B4R : To arm cylinder bottom
B5R : To R.H. travel motor PB port
NCAL : To rear NC valve
NCBL : To rear NC valve
NCAR : To front NC valve
NCBR : To front NC valve
P3
: From arm PPC shuttle valve
P4
: From boom, bucket PPC shuttle valve
P5
: From swing PPC shuttle valve
P6
: Work equipment oil pressure switch
P1AL
P2AL
P3AL
P4AL
P1AR
P3AR
P4AR
P5AR
P1BL
P2BL
P3BL
P1BR
P3BR
P4BR
P5BR
PL
PR
PRL
PRR
T
TS
: From L.H. travel PPC valve

: From boom PPC valve
: From bucket PPC valve
: From arm PPC valve
: From swing PPC valve
: Service
: From R.H. travel PPC valve
: From L.H. travel PPC valve
: From boom PPC valve
: From bucket PPC valve
: From swing PPC valve
: Service
: From R.H. travel PPC valve
: From rear main pump
: From front main pump
: From 2-stage relief solenoid valve
: From 2-stage relief solenoid valve
: To tank
: To tank
1. Travel shuttle valve

2. 4-spool valve
(straight-travel valve, arm throttle valve built in)
3. 5-spool valve (swing priority valve built in)
PC600-8
SEN00139-04
4-spool valve + 5-spool valve (with travel shuttle valve)
PC600-8
SEN00139-04
Cross-sectional diagram
(1/4)
1.
2.
3.
4.
5.
Spool return spring

Spool (L.H. travel)
Spool (boom Lo)
Spool (bucket Lo)
Spool (arm Hi)
6.
7.
8.
9.
10.
Jet sensor orifice

Jet sensor relief valve
Main relief valve
Spool (straight-travel)
Spool (arm throttle)
PC600-8
SEN00139-04
Unit: mm
No.
Check item
Remedy
Criteria
Standard size
11
12
Spool return spring
Spool return spring
PC600-8
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
87.6 x 21.2
54.5
192 N
{19.6 kg}
154 N
{15.7 kg}
58.1 x 26.5
52.5
324 N
{33.0 kg}
259 N
{26.4 kg}
Replace
spring if
damaged or
deformed
SEN00139-04
(2/4)
1.
2.
3.
4.
5.
Spool return spring

Spool (swing)
Spool (boom Hi)
Spool (service / bucket Hi)
Spool (arm Lo)
6.
7.
8.
9.
10.
Spool (R.H. travel)

Jet sensor relief valve
Jet sensor orifice
Main relief valve
Spool (swing priority)
PC600-8
SEN00139-04
Unit: mm
No.
Check item
Remedy
Criteria
Standard size
11
Spool return spring
PC600-8
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
53.8 x 26.5
52.5
104 N
{10.6 kg}
83.4 N
{8.50 kg}
Replace
spring if
damaged or
deformed
SEN00139-04
(3/4)
1.
2.
3.
4.
5.
6.
7.
Check valve
Check valve spring
Spool (L.H. travel)
Spool (straight-travel)
Spool (swing priority)
Spool (swing)
Suction valve
8.
9.
10.
11.
12.
13.
Spool (boom Lo)

Check valve
Spool (boom Hi)
Suction valve
Suction valve
Suction valve
PC600-8
SEN00139-04
Unit: mm
No.
Check item
Remedy
Criteria
Standard size
14
Check valve spring
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
20.8 x 12.2
13.5
12.7 N
{1.3 kg}
10.2 N
{1.04 kg}
15
Check valve spring
31.8 x 7.6
26.5
0.98 N
{0.10 kg}
0.78 N
{0.08 kg}
16
Spool return spring
30.7 x 32.5
26.5
255 N
{26.0 kg}
204 N
{20.8 kg}
17
Spool return spring
54.0 x 34.2
52.0
255 N
{26.0 kg}
204 N
{20.8 kg}
18
Spool return spring
54.8 x 34.0
53.5
125 N
{12.7 kg}
100 N
{10.2 kg}
19
Spool return spring
21.0 x 16.9
18.2
207 N
{21.1 kg}
20
Spool return spring
54.9 x 34.0
53.5
125 N
{12.7 kg}
100 N
{10.2 kg}
21
Check valve spring
55.9 x 30.2
29.0
7.85 N
{0.80 kg}
6.28 N
{0.64 kg}
PC600-8
Replace
spring if
damaged or
deformed
SEN00139-04
(4/4)
1.
2.
3.
4.
5.
6.
10
Suction-safety valve
Spool (bucket Lo)
Spool (arm throttle)
Spool (service / bucket Hi)
Spool (arm Hi)
Check valve
7.
8.
9.
10.
11.
12.
Spool (arm Lo)

Check valve
Spool (R.H. travel)
Suction valve
PC600-8
SEN00139-04
Unit: mm
No.
Check item
Standard size
13
Spool return spring
Remedy
Criteria
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
54.8 x 34.0
53.5
125 N
{12.7 kg}
100 N
{10.2 kg}
14
Spool return spring
30.7 x 32.5
26.5
255 N
{26.0 kg}
204 N
{20.8 kg}
15
Spool return spring
54.0 x 34.2
52.0
255 N
{26.0 kg}
204 N
{20.8 kg}
16
Spool return spring
54.8 x 34.0
53.5
125 N
{12.7 kg}
100 N
{10.2 kg}
17
Spool return spring
54.9 x 34.0
53.5
125 N
{12.7 kg}
100 N
{10.2 kg}
18
Check valve spring
55.9 x 30.2
29.0
7.85 N
{0.80 kg}
6.28 N
{0.64 kg}
PC600-8
Replace
spring if
damaged or
deformed
11
SEN00139-04
Travel shuttle valve
P0
P1
P2
P3
P4
P5
P4A
P5A
T
12
: To straight-travel valve
: From L.H. travel valve A1L port
: From L.H. travel valve B1L port
: From arm shuttle valve
: From boom, bucket shuttle valve
: From swing shuttle valve
: To arm throttle valve
: To swing priority valve
: To tank
1.
2.
3.
4.
5.
Cover
Spool return spring
Body
Spool
Orifice
PC600-8
SEN00139-04
Function
The travel shuttle valve is installed to the top of
the 4-spool valve control valve. It brings the PPC
valve pressures from the L.H. travel, work equipment, and swing.
It also sends pilot pressure to the straight-travel
valve when the travel and work equipment or
travel and swing are operated at the same time.
1. When travel is operated independently
Operation
When the travel FORWARD is operated, pilot
pressure oil flows from the L.H. travel circuit to
port P1 and pushes the spool to the right. Ports
P3, P4, and P5 are interconnected with port P0
through the groove in the spool to the straighttravel valve.
However, when the work equipment and swing
control levers are at NEUTRAL, the pilot pressure oil from the PPC valve does not flow, so it
also does not flow to the straight-travel valve.
PC600-8
When the travel REVERSE is operated, the pressure oil is sent to port P2 and pushes the spool
to the left.
13
SEN00139-04
2. During simultaneous operation
Operation
When the arm and travel FORWARD are operated at the same time, pilot pressure oil flows from
the L.H. travel circuit to port P1 and pushes the
spool to the right.
When the arm is operated, pilot pressure oil also
flows to port P3 from the arm PPC shuttle valve.
This passes through the groove in the spool and
port P0, and flows to the straight-travel valve.
14
The pilot pressure oil from the swing PPC shuttle

valve flows from port P5 port P0 straighttravel valve, and the pilot pressure oil from the
boom and bucket PPC shuttle valves flows from
port P4 port P0 straight-travel valve.
PC600-8
SEN00139-04
Straight-travel valve
Function
When the travel is operated at the same time as
the swing, boom, arm, or bucket, the pressure oil
flowing to the left and right travel circuits is divided and sent to the boom, arm, or bucket circuit.
If the oil in one travel circuit is divided off, the
amount of oil supplied to the travel motor will be
less than in the travel circuit which is not divided,
so the drop in the supply of oil to the travel motor
will cause the machine to deviate.
To prevent this, the straight-travel valve is

switched to interconnect the left and right travel
circuits. This ensures that the amount of oil supplied to the left and right travel motors is equal.
As a result, the left and right travel motors both
rotate at the same speed, and there is little travel
deviation.
1. When travel is operated independently
Operation
No pilot pressure flows from the travel shuttle
valve, so the straight-travel valve is not actuated.
Because of this, port PL (L.H. travel circuit) and
port PR (R.H. travel circuit) are not interconnected, and each circuit remains independent.
PC600-8
15
SEN00139-04
2. When travel and work equipment are operated at same time
Operation
The pilot oil from the travel shuttle valve presses
the spool of straight travel valve (1).
Accordingly, port PL is connected to the right and
left travel motors and oil of the same quantity is
fed to the right and left travel motors. Since the
right and left travel motors rotate at the same
speed, the machine deviates less.
16
PC600-8
SEN00139-04
Swing priority valve

Function
When the swing and arm are operated at the
same time, a large amount of the pressure oil
flows to the arm circuit where the load is small, so
little pressure oil flows to the swing circuit.
This makes the arm speed too fast for the swing
speed, and causes poor combination in simultaneous operation.
To overcome this, the swing priority valve is actuated to throttle the pressure oil flowing to the
arm Lo control valve in order to restrict the arm
speed and improve the simultaneous operation
performance.
1. When swing is at HOLD
Operation
No pilot pressure oil flows from the travel shuttle
valve, so the swing priority valve is not actuated.
For this reason, all the pressure oil from the front
main pump passes through port PR and flows to
the arm Lo control valve.
PC600-8
17
SEN00139-04
2. When swing is operated
Operation
When the swing is operated, the pilot pressure oil
from the travel shuttle valve pushes spool (1) of
the swing priority valve to the left.
As a result, the pressure oil flowing from the front
main pump through port PR to the arm Lo control
valve is throttled, and the arm speed is restricted
to improve the simultaneous operation performance.
18
PC600-8
SEN00139-04
Arm throttle valve

Function
When arm and boom are operated at same time
When the arm and boom are operated at the
same time, a large amount of the pressure oil
flows to the arm circuit where the load is small, so
little pressure oil flows to the boom circuit.
This makes the arm speed too fast for the boom
speed, and causes poor combination in simultaneous operation. This is a particular problem
when the arm OUT and boom RAISE are operated at the same time.
To overcome this, the arm throttle valve is actuated to throttle the pressure oil flowing to the arm
Hi control valve in order to restrict the arm speed
and improve the simultaneous operation performance.
When arm and bucket are operated at same time

The arm is actuated by the merged flow from two
pumps and the bucket is actuated by the oil from
one pump.
In this condition, if the arm and bucket are operated at the same time, a large amount of the
pressure oil flows to the arm circuit, so little pressure oil flows to the bucket circuit. This makes
the arm speed too fast for the bucket speed, and
causes poor combination in simultaneous operation. This is a particular problem when the arm
OUT and bucket CURL are operated at the same
time.
To overcome this, the arm throttle valve is actuated to throttle the pressure oil flowing to the arm
Hi control valve in order to restrict the arm speed
and improve the simultaneous operation performance.
1. When arm is operated independently
Operation
No pilot pressure oil flows from the travel shuttle
valve, so the arm throttle valve is not actuated.
PC600-8
For this reason, all the pressure oil from the rear
main pump passes through port PL and flows to
the arm Hi control valve.
19
SEN00139-04
2. When arm and boom or bucket are operated at same time
Operation
When the arm and boom or bucket are operated
at the same time, the pilot pressure oil from the
travel shuttle valve pushes spool (1) of the arm
throttle valve to the right.
As a result, the pressure oil flowing from the rear
main pump to the arm Hi control valve is throttled, and the arm speed is restricted to improve
the simultaneous operation performance.
20
PC600-8
SEN00139-04
Swing motor
Model: KMF90ABE-3 (with reverse prevention valve)
T1
S
MA
MB
B
: To tank
: From control valve
: From swing brake solenoid valve
PC600-8
Specifications
Model: KMF90ABE-3
Theoretical delivery: 87.8 cc/rev
Safety valve set pressure: 25.5 MPa {260 kg/cm2}
Rated speed: 2,320 rpm
Brake release pressure: 2.06 MPa {21.0 kg/cm2}
21
SEN00139-04
1.
2.
3.
4.
5.
6.
7.
22
Drive shaft
Spacer
Case
Disc
Plate
Brake ring
Brake piston
8.
9.
10.
11.
12.
13.
14.
Housing
Reverse prevention valve
Center spring
Cylinder block
Valve plate
Piston
Center shaft
15.
16.
17.
18.
19.
20.
Safety valve
Check valve
Check valve spring
Shuttle valve
Shuttle valve spring
Brake spring
PC600-8
SEN00139-04
Unit: mm
No.
Check item
Remedy
Criteria
Standard size
21
22
Check valve spring
Shuttle valve spring
PC600-8
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
62.5 x 20.0
39
3.04 N
{0.31 kg}
2.45 N
{0.25 kg}
16.4 x 8.9
11.5
13.7 N
{1.4 kg}
11 N
{1.12 kg}
Replace
spring if
damaged or
deformed
23
SEN00139-04
Swing brake
Operation
1. When swing brake solenoid valve is de-energized
If the swing brake solenoid valve is de-energized, the flow of pressurized oil from the control
pump is shut off, and port B is connected to the
tank circuit.
As a result, brake piston (7) is pushed down by
brake spring (8), pushes disc (4) and plate (5) together, and the brake is applied.
2. When swing brake solenoid valve is energized

When the swing brake solenoid valve is energized, the valve is switched, and pressurized oil
from the control pump enters port B and flows to
brake chamber A.
The pressurized oil entering chamber A overcomes brake spring (8) and brake piston (7)
moves up. As a result, disc (4) and plate (5) are
separated and the brake is released.
24
PC600-8
SEN00139-04
Safety valve
Outline
The safety valve portion consists of check valves
(2) and (3), shuttle valves (4) and (5), and relief
valve (1).
Function
When the swing is stopped, the outlet port circuit
of the motor is closed by the control valve, but
the motor continues to be turned by the inertia of
the swing. As a result, the pressure at the outlet
port of the motor becomes abnormally high and
there is danger that the motor will be damaged.
The safety valve is installed to prevent this problem. It acts to release the abnormally high pressure oil from the outlet port (high-pressure side)
of the motor and send it to the back pressure
valve and prevent damage to the motor.
Operation
1. When starting swing
If the swing control lever is operated to swing to
the right, the pressurized oil from the pump passes through the control valve and is supplied to
port MA.
When this happens, the pressure at port MA rises and starting force is generated in the motor,
so the motor starts to turn. The oil from the outlet
port of the motor flows from port MB through the
control valve and returns to the tank.
PC600-8
25
SEN00139-04
2. When stopping swing

When the swing control lever is returned to the
neutral position, no more pressurized oil is supplied from the pump to port MA. At the same
time, the oil from the outlet port of the motor returns from the control valve to the tank, and the
circuit is closed. The pressure at port MB rises,
and rotating resistance to the motor is generated,
so the brake starts to take effect.
If the pressure at port MB rises higher than the
pressure at port MA, shuttle valve (4) is pushed
and chamber C becomes the same pressure as
port MB. The pressure then rises to the set pressure of relief valve (1). In this way, a high brake
torque is generated in the motor, and the motor
stops.
When relief valve (1) is being actuated, the relieved oil and oil from back pressure valve is supplied to port MA through check valve (3) to
prevent cavitation at port MA.
26
PC600-8
SEN00139-04
Reverse prevention valve
MA
T1
MB
T2
: Port
: Port
: Port
: Port
PC600-8
1.
2.
3.
4.
5.
6.
7.
Valve body
Spool (MA side)
Spring (MA side)
Plug (MA side)
Spool (MB side)
Spring (MB side)
Plug (MB side)
27
SEN00139-04
Explanation of effect
28
PC600-8
SEN00139-04
Function
When the swing is stopped, this valve reduces
the rocking motion of the swing body due to the
inertia of the swing body, backlash of the machinery system, the compressibility of the hydraulic oil, etc.
This valve is effective to prevent the cargo from
being spilled when the swing is stopped as well
as to shorten recycle time (excellent in the positioning accuracy and the next operation can be
started quickly).
Operation
1. When the braking pressure is present at port
MB
MB pressure is introduced to chamber d via the
notch and spool (5) makes a stroke motion to the
left, pressing spring (6) due to the difference in
area (D1>D2) and the interconnection of MB to e
is established.
On this occasion, MA pressure is less than the
set pressure of spring (3), so that spool (2) does
not make a stoke motion and the pressure oil is
closed by spool (2), and the braking force is secured.
2. When the motor stopped temporarily

The motor is reversed by the shutoff pressure
that occurred at port MB. (First reversal)
On this occasion, the reverse pressure is generated at port MA side. This pressure at port MA is
introduced to chamber a, and spool (2) makes a
stroke motion to the right, pressing spring (3),
and the interconnection of MA to b is established.
Also, the interconnection of b to f is established
through the drill hole of spool (5) and the reverse
pressure at port MA is bypassed to port T, thereby preventing the second reversal.
PC600-8
29
SEN00139-04
Center swivel joint
1.
2.
3.
4.
5.
Cover
Body
Slipper seal
O-ring
Shaft
A1.
A2.
B1.
B2.
C1.
C2.
From control valve port A5R

To R.H. travel motor REVERSE port PB
From control valve port A1L
To L.H. travel motor REVERSE port PA
From control valve port B5R
To R.H. travel motor FORWARD port PA
D1.
D2.
E1.
E2.
T1.
T2.
From control valve port B1L

To L.H. travel motor FORWARD port PB
From travel speed EPC valve
To L.H. and R.H. travel motors port P
To tank
From L.H. and R.H. travel motors port T
Unit: mm
No.
Check item
Clearance between rotor and

shaft
30
Remedy
Criteria
Standard size
Standard clearance
Clearance limit
90
0.056 0.105
0.111
Replace
PC600-8
SEN00139-04
Travel motor
Model: KMV335ADT
P
T
PA
PB
:
:
:
:
From travel speed solenoid valve

To tank
From control valve
From control valve
PC600-8
Specifications
Model: KMV335ADT
Theoretical delivery: Minimum 217 cc/rev
Maximum 336 cc/rev
Brake release pressure:
1.27 0.39 MPa {13.0 4.0 kg/cm2}
Travel speed selector pressure:
0.93 0.25 MPa {9.50 2.50 kg/cm2}
31
SEN00139-04
1.
2.
3.
4.
5.
6.
7.
32
Output shaft
Motor case
Piston
Cylinder block
Valve plate
End cover
Slow return valve
8.
9.
10.
11.
12.
13.
14.
Plug
Regulator piston
Plate
Disc
Check valve spring
Check valve
Counterbalance valve
15.
16.
17.
18.
19.
20.
Spool return spring

Safety valve
Regulator valve
Spring
Brake spring
Brake piston
PC600-8
SEN00139-04
Unit: mm
No.
Check item
Remedy
Criteria
Standard size
21
Spool return spring
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
62.5 x 32
42.0
427 N
{43.5 kg}
341 N
{34.8 kg}
22
Check valve spring
62.5 x 20.0
39.0
3.04 N
{0.31 kg}
2.45 N
{0.25 kg}
23
Regulator piston spring
55.0 x 9.0
50.0
98.1 N
{10.0 kg}
78.5 N
{8.0 kg}
PC600-8
Replace
spring if
damaged or
deformed
33
SEN00139-04
1. At low speed (motor swash plate angle at maximum)
Operation
When the solenoid valve is de-energized, the pilot pressure oil from the control pump does not
flow to port P. For this reason, regulator valve
(17) is pushed upward in the direction of the arrow by spring (18).
The main pressure oil from the control valve
pushes shuttle valve (7), goes through end cover
(6), and acts on chamber a of regulator piston
(9). At the same time, the main pressure passes
through passage c and acts on chamber b
through regulator valve (17).
34
Because of this, propulsion force equal to the difference in area of chambers a and b (Ab Aa)
of regulator piston (9) acts in a downward direction.
As a result, valve plate (5) and cylinder block (4)
move in the maximum swash plate angle direction, the motor capacity becomes the maximum,
and the system is set to low speed.
PC600-8
SEN00139-04
2. At high speed (motor swash plate angle at minimum)
Operation
When the solenoid valve is energized, the pilot
pressure oil from the control pump flows to port
P, and pushes regulator valve (17) down.
Because of this, the main pressure oil and the oil
in chamber d is shut off by regulator valve (17),
and the oil in chamber b is drained inside the
case.
A propulsion force generated by the pressure oil
in chamber a of regulator piston (9) then acts upward.
PC600-8
As a result, valve plate (5) and cylinder block (4)

move in the minimum swash plate angle direction, the motor capacity becomes the minimum,
and the system is set to high speed.
35
SEN00139-04
Parking brake
1. When starting to travel
Operation
When the travel lever is operated, the pressurized oil from the pump actuates counterbalance
valve spool (14), opens the circuit to the parking
brake, and flows into chamber e of brake piston
(20). It overcomes the force of spring (19), and
pushes piston (20) to the right.
When this happens, the force pushing plate (10)
and disc (11) together is lost, so plate (10) and
disc (11) separate and the brake is released.
36
PC600-8
SEN00139-04
2. When stopping travel
Operation
When the travel lever is placed in neutral, counterbalance valve spool (14) returns to the neutral
position and the circuit to the parking brake is
closed.
The pressurized oil in chamber e of brake piston
(20) passes through the throttle of slow return
valve (7) until spool (14) of the counterbalance
valve returns to neutral.
When spool (14) of the counterbalance valve returns to the neutral position, the oil is drained inside the case from throttle f of brake piston (20)
and brake piston (20) is pushed fully to the left by
spring (19).
PC600-8
As a result, plate (10) and disc (11) are pushed

together, and the brake is applied.
A time delay is provided by having the pressurized oil pass through a throttle in slow return
valve (7) when the brake piston returns, and this
ensures that the brake is applied after the machine stops.
37
SEN00139-04
Brake valve
Operation of brake valve
The brake valve consists of a check valve, counterbalance valve, and safety valve in a circuit as
shown in the diagram on the right.
The function and operation of each component is
as given below.
1. Counterbalance valve, check valve

Function
When traveling downhill, the weight of the machine makes it try to travel faster than the speed
of the motor.
As a result, if the machine travels with the engine
at low speed, the motor will rotate without load
and the machine will run away, which is extremely dangerous.
To prevent this, these valves act to make the machine travel according to the engine speed
(pump discharge amount).
Operation when pressurized oil is supplied

When the travel lever is operated, the pressurized oil from the control valve is supplied to port
PA. It pushes open check valve (13A) and flows
from motor inlet port MA to motor outlet port MB.
However, the motor outlet port is closed by check
valve (13B) and spool (14), so the pressure at
the supply side rises.
38
The pressurized oil at the supply side flows from

orifice E1 in spool (14) and orifice E2 in the piston to chamber S1. When the pressure in chamber S1 goes above the spool switching pressure,
spool (14) is pushed to the right.
As a result, port MB and port PB are connected,
the outlet port side of the motor is opened, and
the motor starts to rotate.
PC600-8
SEN00139-04
Operation of brake when traveling downhill

If the machine tries to run away when traveling
downhill, the motor will turn under no load, so the
pressure at the motor inlet port will drop, and the
pressure in chamber S1 through orifices E1 and
E2 will also drop.
When the pressure in chamber S1 drops below
the spool switching pressure, spool (14) is returned to the left by spring (15), and outlet port
MB is throttled.
As a result, the pressure at the outlet port side
rises, resistance is generated to the rotation of
the motor, and this prevents the machine from
running away.
In other words, the spool moves to a position
where the pressure at outlet port MB balances
the pressure at the inlet port and the force generated by the weight of the machine. It throttles the
outlet port circuit and controls the travel speed
according to the amount of oil discharged from
the pump.
2. Safety valve (2-direction operation, 2-stage
set safety valve)
Function
When travel is stopped (or when traveling downhill), the circuits at the inlet and outlet ports of the
motor are closed by the counterbalance valve.
However, the motor is rotated by inertia, so the
pressure at the outlet port of the motor will become abnormally high and will damage the motor
or piping. The safety valve acts to release this
abnormal pressure and send it to the inlet port
side of the motor to prevent damage to the equipment.
Operation in both directions
1) When pressure in chamber MB has become
high (when rotating clockwise)
When the travel is stopped (or when traveling
downhill), chamber MB in the outlet port circuit is
closed by the check valve of the counterbalance
valve, but the pressure at the outlet port rises because of inertia.
If the pressure goes above the set pressure, the

force produced by the difference in area between
D1 and D2 [x/4(D1 2 D2 2) x pressure] overcomes the force of the spring and moves the
poppet to the left, so the oil flows to chamber MA
in the circuit on the opposite side.
PC600-8
39
SEN00139-04
2) When pressure in chamber MA has become

high (when rotating counterclockwise)
When the travel is stopped (or when traveling
downhill), chamber MA in the outlet port circuit is
closed by the check valve of the counterbalance
valve, but the pressure at the outlet port rises because of inertia.
40
If the pressure goes above the set pressure, the

force produced by the difference in area between
D1 and D3 [x/4(D3 2 D1 2 ) x pressure] overcomes the force of the spring and moves the
poppet to the left, so the oil flows to chamber MB
in the circuit on the opposite side.
PC600-8
SEN00139-04
Set pressures varying mechanism

Function
1. When starting travel (high-pressure setting)
When the travel lever is operated, the pressurized oil from the pump actuates counterbalance
valve spool (14), and opens the pilot circuit to the
safety valve. The oil passes from chamber G to
passage H and flows into chamber J, pushes the
piston to the right, and compresses the spring to
make the set load larger.
Because of this, the set pressure of the safety
valve is switched to the high pressure setting,
and a large drawbar pull is made available.
2. When stopping travel (low-pressure setting)

When the travel lever is placed at neutral, the
pressure in chamber PA drops and counterbalance valve spool (14) returns to the neutral position.
While the counterbalance valve spool is returning to the neutral position, the pressurized oil in
chamber J passes through passage H, and escapes to chamber PA from chamber G. The piston moves to the left, and the set load becomes
smaller.
Because of this, the set pressure of the safety
valve is switched to the low-pressure setting and
relieves the shock when reducing speed.
Set pressure of safety valve
High-pressure setting
: 37.8 MPa {385 kg/cm2}
(at starting and traveling)
Low-pressure setting
(at stopping)
PC600-8
: 27.5 MPa {280 kg/cm2}
41
SEN00139-04
Valve control
1.
2.
3.
4.
5.
6.
7.
Travel PPC valve

Service PPC valve
Service pedal
L.H. travel lever
R.H. travel lever
Right PPC valve
Right work
equipment lever
8. Solenoid valve
9. Accumulator
42
10.
11.
12.
13.
14.
Solenoid valve
Control valve
Hydraulic pump
Shuttle valve
PPC safety lock
solenoid valve
15. Left work equipment
lever
16. Left PPC valve
Lever positions
A. NEUTRAL
B. Boom RAISE
C. Boom LOWER
D. Bucket DUMP
E. Bucket CURL
F. NEUTRAL
G. Arm IN
H. Arm OUT
J.
K.
L.
M.
N.
Swing RIGHT
Swing LEFT
NEUTRAL
Travel REVERSE
Travel FORWARD
PC600-8
PC600-8
SEN00139-04
43
SEN00139-04
Work equipment, swing PPC valve
P : From safety lock solenoid valve

T : To tank
44
P1
P2
P3
P4
: L.H. PPC: Arm OUT/R.H. PPC: Boom LOWER

: L.H. PPC: Arm IN/R.H. PPC: Boom RAISE
: L.H. PPC: Right swing/R.H. PPC: Bucket CURL
: L.H. PPC: Left swing/R.H. PPC: Bucket DUMP
PC600-8
SEN00139-04
1.
2.
3.
4.
5.
6.
Spool
Metering spring
Centering spring
Piston
Disc
Nut (for connecting lever)
7.
8.
9.
10.
11.
Joint
Plate
Retainer
Body
Filter
Unit: mm
No.
Check item
Remedy
Criteria
Standard size
12
Centering spring
(for P3, P4)
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
38.7 x 15.5
34.0
9.81 N
{1.0 kg}
7.85 N
{0.8 kg}
13
Centering spring
(for P1, P2)
42.5 x 15.5
34.0
17.7 N
{1.8 kg}
14.1 N
{1.44 kg}
14
Metering spring
26.5 x 8.2
24.9
16.7 N
{1.7 kg}
13.3 N
{1.36 kg}
PC600-8
Replace
spring if
damaged or
deformed
45
SEN00139-04
Operation
1. At neutral
Ports A and B of the control valve and ports P1
(P3) and P2 (P4) of the PPC valve are connected
to drain chamber D through fine control hole f in
spool (1). (Fig. 1)
2. Fine control (neutral fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed. Spool (1) is also pushed
by metering spring (2) and moves down.
When this happens, fine control hole f is shut off
from drain chamber D. At almost the same time,
it is connected to pump pressure chamber PP,
and the pilot pressure of the control pump is sent
from port A through fine control hole f to port P1.
When the pressure at port P1 rises, spool (1) is
pushed back. Fine control hole f is shut off from
pump pressure chamber PP. At almost the same
time, it is connected to drain chamber D, so the
pressure at port P1 escapes.
As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced with
the pressure of port P1.
The relationship of the positions of spool (1) and
body (10) (fine control hole f is in the middle
between drain chamber D and pump pressure
chamber PP) does not change until retainer (9)
contacts spool (1).
Therefore, metering spring (2) is compressed in
proportion to the travel of the control lever, so the
pressure at port P1 also rises in proportion to the
travel of the control lever.
In this way, the spool of the control valve moves
to a position where the pressure of chamber A
(same as pressure at port P1) and the force of
the return spring of the control valve spool are
balanced. (Fig. 2)
46
5
4
9
D
2
f
T
P
PP
P2
P1
Control valve
10
(Fig. 2)
SBP00276
PC600-8
SEN00139-04
3. Fine control (control lever returned)

When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
Because of this, fine control hole f is connected
to drain chamber D, and the pressurized oil at
port P1 is released.
If the pressure at port P1 drops too much, spool
(1) is pushed down by metering spring (2), so
fine control hole f is shut off from drain chamber
D. At almost the same time, it is connected to
pump pressure chamber PP, so the pressure at
port P1 supplies the pump pressure until the
pressure recovers to a pressure equivalent to the
position of the lever.
When the control valve spool returns, oil in drain
chamber D flows in from fine control hole f of the
valve on the side that is not moving. It passes
through port P2 and goes to chamber B to
charge the oil. (Fig. 3)
5
4
3
D
2
f
T
P
f'
1
PP
P2
P1
Control valve
(Fig. 3)
SBP00277
4. At full stroke
Disc (5) pushes down piston (4), and retainer (9)
pushes down spool (1). Fine control hole f is shut
off from drain chamber D, and is connected to
pump pressure chamber PP.
Therefore, the pilot pressure oil from the control
pump passes through fine control hole f and
flows to chamber A from port P1 to push the control valve spool.
The return oil from chamber B passes from port
P2 through fine control hole f and flows to drain
chamber D. (Fig. 4)
5
4
D
T
P
f'
1
Pp
P2
P1
Control valve
(Fig. 4)
SBP00278
PC600-8
47
SEN00139-04
Travel PPC valve
P : From main pump

T : To tank
P1
P2
P3
P4
: L.H. travel REVERSE

: L.H. travel FORWARD
: R.H. travel REVERSE
: R.H. travel FORWARD
a The travel PPC valve operates similarly to the work equipment and swing PPC valves.
48
PC600-8
SEN00139-04
1. Plate
2. Body
3. Piston
4. Collar
5. Valve
Unit: mm
No.
Check item
Remedy
Criteria
Standard size
Centering spring
Metering spring
PC600-8
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
48.6 x 15.5
32.5
108 N
{11.0 kg}
86.3 N
{8.8 kg}
26.5 x 8.15
24.9
16.7 N
{1.7 kg}
13.7 N
{1.4 kg}
Replace
spring if
damaged or
deformed
49
SEN00139-04
Service PPC valve

1.
2.
3.
4.
5.
6.
7.
8.
Spool
Metering spring
Centering spring
Piston
Lever
Plate
Retainer
Body
T : To tank
P : From main pump
P1 : Port
P2 : Port
a The service PPC valve operates similarly to the work equipment and swing PPC valves.
Unit: mm
No.
Check item
Remedy
Criteria
Standard size
10
50
Centering spring
Metering spring
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
33.9 x 15.3
28.4
124.5 N
{12.7 kg}
100 N
{10.2 kg}
22.7 x 8.1
22
16.7 N
{1.7 kg}
13.7 N
{1.4 kg}
Replace
spring if
damaged or
deformed
PC600-8
SEN00139-04
PPC accumulator
SBP00290
1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
PC600-8
Specifications
Actual gas volume: 500 cc
51
SEN00139-04
PPC shuttle valve

For arm, swing
1. Plug
2. Body
3. Ball
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
Port P1B (right swing)

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

Port P3A (bucket CURL)
Port P4A (boom LOWER)
Port P2A (boom RAISE)
Port P3B (bucket CURL)
Port P1B (bucket DUMP)
Port P2B (boom RAISE)
Port P4B (boom LOWER)
For boom, bucket
52
PC600-8
SEN00139-04
Solenoid valve
For CO cancel, 2-stage relief, boom Hi 2-stage safety valve, swing brake, travel speed solenoid
valve
1.
2.
3.
4.
5.
CO cancel solenoid valve

2-stage relief solenoid valve
Boom Hi 2-stage safety valve solenoid valve
Swing brake solenoid valve
Travel speed solenoid valve
PC600-8
T
A1
A2
A3
A4
A5
P1
ACC
PPC
: To tank
: To No. 1 pump (NC valve)
: To left and right travel motors
: To boom LOWER 2-stage safety valve
: To main valve (relief valve)
: To swing motor
: From control pump
: To accumulator
: To PPC valve
53
SEN00139-04
1.
2.
3.
4.
5.
6.
7.
Connector
Moving core
Solenoid
Cage
Spool
Block
Spring
Operation
When solenoid is de-energized
When the signal current does not flow from the
connector, solenoid (3) is de-energized.
For this reason, spool (5) is pushed fully to the
left by spring (6).
As a result, the circuit between ports P and A
closes and the pressurized oil from the control
pump does not flow to the actuator.
At the same time, the pressurized oil from the
actuator flows from port A to port T, and is then
drained to the tank.
When solenoid is energized

When the signal current flows from the connector
to solenoid (3), solenoid (3) is energized.
For this reason, spool (5) is pushed to the right
in the direction of the arrow.
As a result, the pressurized oil from the control
pump flows from port P through the inside of
spool (5) to port A, and then flows to the actuator. At the same time, port T is closed, and this
stops the oil from flowing to the tank.
54
PC600-8
SEN00139-04
Bucket curl Hi cancel

1.
2.
3.
4.
5.
6.
7.
Connector
Moving core
Solenoid
Spool
Body
Spring
Plug
Operation
The signal current does not flow from the connector, so solenoid (3) is de-energized.
For this reason, spool (4) is returned to the neutral position by spring (6).
As a result, the circuit between ports P and A is
connected, and the pressurized oil from the
PPC valve flows to the control valve.

When the signal current flows from the connector
to solenoid (3), solenoid (3) is energized and
moving core (2) is pushed to the right in the direction of the arrow.
For this reason, spool (4) is also pushed to the
right in the direction of the arrow.
As a result, port P is closed, and the pressurized
oil from the PPC valve does not flow to the control valve.
At the same time, port A and port T are interconnected, and the oil from the control valve is
drained to the tank.
PC600-8
55
SEN00139-04
For safety lock (under cab)
1. Safety lock solenoid valve
56
T : To tank
A : To port P of work equipment PPC valve
To port P of travel PPC valve
P : From control pump
PC600-8
SEN00139-04
1.
2.
3.
4.
5.
6.
Connector
Solenoid
Moving core
Body
Plug
Spring
7.
8.
9.
10.
11.
Spool
Body
Plug
Spring
Spool
Operation
No signal current flows from the PPC hydraulic
lock switch, so solenoid (2) is de-energized.
Accordingly, spool (11) is pushed up by spring
(10) and spool (7) is pushed to the left by spring
(6).
As a result, port P is closed, so pressurized oil
from the control pump does not flow to the actuator.
At the same time, the oil from the actuator flows
from port A2 to port T and is drained to the tank.
When the signal current flows from the PPC hydraulic lock switch to solenoid (2), solenoid (2) is
energized.
Accordingly, spool (11) is pushed down and the
pressurized oil from the control pump flows
through port P to port A1 and spool (7) is pushed
to the right.
As a result, pressurized oil from the control pump
flows from port P to port A2, and then flows to the
actuator.
At the same time, port T is closed, so the oil
does not flow to the tank.
PC600-8
57
SEN00139-04
Boom holding valve
T
V
CY
PI
58
: To tank
: To boom cylinder bottom
: From PPC valve (pilot pressure)
1.
2.
3.
4.
5.
Safety-suction valve
Pilot spring
Pilot spool
Poppet spring
Poppet
PC600-8
SEN00139-04
1. Boom at RAISE
Operation
When the boom is raised, the main pressure
from the control valve pushes poppet (5) up.
Because of this, the main pressurized oil from
the control valve passes through the valve and
flows to the bottom end of the boom cylinder.
PC600-8
59
SEN00139-04
2. Boom at HOLD
Operation
When the boom is raised and the control lever is
returned to NEUTRAL, the circuit for the holding
pressure at the bottom end of the boom cylinder
is closed by poppet (5). At the same time, the oil
flowing into poppet (5) through orifice a of poppet
(5) is closed by pilot spool (3).
As a result, the boom is held in position.
60
PC600-8
SEN00139-04
3. Boom at LOWER
Operation
When the boom is lowered, the pilot pressure
flows to port PI from the PPC valve pushes pilot
spool (3) and the pressurized oil in chamber b inside the poppet is drained.
When the pressure at port CY rises because of
the pressurized oil from the bottom end of the
boom cylinder, the pressure of the pressurized
oil in chamber b is lowered by orifice a.
If the pressure in chamber b drops below the
pressure at port CY, poppet (5) opens, the pressurized oil flows from port CY to port V, and then
flows to the control valve.
If any abnormal pressure is generated in the circuit at the bottom end of the boom cylinder, safety valve (1) is actuated to drain oil from port CY
to port T.
PC600-8
61
SEN00139-04
Boom LOWER regeneration valve
T
PB
PM
PI
62
: To tank
: From boom cylinder bottom
: From boom cylinder head
: From boom LOWER PPC valve
PC600-8
SEN00139-04
1.
2.
3.
4.
Body
Spool
Check valve
Spring
Unit: mm
No.
Check item
Remedy
Criteria
Standard size
Spring (check valve)
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
83.5 x 25.5
22
29.4 N
{3.0 kg}
23.5 N
{2.4 kg}
Spool return spring (small)
41.1 x 9.6
35
58.8 N
{6.0 kg}
47.1 N
{4.8 kg}
Spool return spring (large)
49.4 x 25.7
47
207 N
{21.1 kg}
166 N
{16.9 kg}
PC600-8
Replace
spring if
damaged or
deformed
63
SEN00139-04
Function
When the boom is lowered, some of the oil
drained from the bottom end of the boom cylinder
is circulated to the cylinder head to increase the
lowering speed of the boom.
Operation
When control lever (1) is operated to the LOWER
position, PPC pressure flows and boom Lo spool
(2) moves to the LOWER position. At the same
time, regeneration valve spool (3) is moved by
the PPC pressure from port Pi. As a result, the
head and bottom ends of boom cylinder (4) are
interconnected through ports PB and PM.
When this happens, the oil from the cylinder bottom passes through the control valve and returns
to tank (5). Some of the oil enters port PB of the
regeneration valve and flows from port PM to the
cylinder head to increase the lowering speed of
the boom.
The boom cylinder has a large volume, and during compound operations, the oil flow from the
pump to the cylinder head is insufficient, so this
action prevents any vacuum from forming inside
the circuit.
64
PC600-8
SEN00139-04
Quick return valve

Function
When arm OUT is operated, this valve reduces
the pressure loss of the large amount of oil returning from the cylinder bottom.
PC600-8
Operation
1. Arm at OUT
When arm OUT is operated, the pilot pressure
from the PPC valve pushes pilot spool (1), and
the pressure oil from chamber b inside the poppet is drained through orifice c.
The oil at the bottom end of the arm flows from
orifice a to chamber b to orifice c to drain, so the
oil pressure in chamber b drops.
When the pressure in chamber b drops below the
pressure at port A, the pressure at port A and
acts on ring -shaped area C (= Area of d1
Area of d2) because of the difference in the outside diameter d1 of valve (2) and seat diameter
d2. Valve (2) moves to the top and the pressure
oil from port A goes to port B. From port B, the oil
is drained directly to the tank.
65
SEN00139-04
2. Arm at HOLD
The oil that has flowed through orifice a in valve
(2) is closed by pilot piston (1). At the same
time, the hold pressure at the bottom end of the
arm acts in the bottom direction on ring-shaped
area C (= Area of d1 Area of d2) because
of the difference in the outside diameter d1 of
valve (2) and seat diameter d2. Valve (2) is
closed by the total of this force and the force of
spring (3), so port A and port B are shut off.
66
PC600-8
PC600-8
SEN00139-04
67
SEN00139-04
Hydraulic cylinder
Boom cylinder
Arm cylinder
Bucket cylinder
68
PC600-8
SEN00139-04
Unit: mm
No.
Check item
Name of
cylinder
Clearance
between
piston rod and
bushing
Clearance
between
piston rod
support shaft
and bushing
Clearance
between
cylinder bottom
support shaft
and bushing
PC600-8
Remedy
Criteria
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
Boom
120
0.036
0.090
+0.263
+0.048
0.084
0.353
0.453
Arm
140
0.043
0.106
+0.256
+0.039
0.082
0.362
0.662
Bucket
130
0.043
0.106
+0.256
+0.040
0.083
0.362
0.462
Boom
125
0.043
0.106
+0.495
+0.395
0.438
0.601
1.5
Arm
125
0.043
0.106
+0.495
+0.395
0.438
0.601
1.5
Bucket
110
0.036
0.090
+0.457
+0.370
0.406
0.547
1.5
Boom
110
0.036
0.090
+0.151
+0.074
0.110
0.241
1.5
Arm
120
0.036
0.090
+0.457
+0.370
0.406
0.547
1.5
Bucket
110
0.036
0.090
+0.457
+0.370
0.406
0.547
1.5
Replace
bushing
Replace pin,
bushing
69
SEN00139-04

Boom cylinder
Arm cylinder
Bucket cylinder
Bottom dump cylinder
70
PC600-8
SEN00139-04
Unit: mm
No.
Check item
Name of
cylinder
Clearance
between
piston rod and
bushing
Clearance
between
piston rod
support shaft
and bushing
Clearance
between
cylinder bottom
support shaft
and bushing
PC600-8
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
Boom
130
0.043
0.106
+0.256
+0.040
0.083
0.362
0.662
Arm
140
0.043
0.106
+0.263
+0.047
0.090
0.369
0.662
Bucket
110
0.036
0.090
+0.261
+0.047
0.083
0.351
0.662
Bottom dump
90
0.036
0.090
+0.257
+0.048
0.084
0.347
0.647
Boom
125
0.043
0.083
+0.495
+0.395
0.438
0.578
1.5
Arm
125
0.043
0.106
+0.495
+0.395
0.438
0.601
1.5
Bucket
125
0.043
0.083
+0.495
+0.395
0.438
0.578
1.5
Bottom dump
90
0.036
0.090
+0.457
+0.370
0.406
0.547
1.5
Boom
110
0.036
0.090
+0.161
+0.074
0.110
0.251
1.5
Arm
125
0.043
0.106
+0.495
+0.395
0.438
0.601
1.5
Bucket
115
0.036
0.090
0
0.020
0.016
0.090
1.5
Bottom dump
90
0.036
0.090
+0.457
+0.370
0.406
0.547
1.5
Replace
bushing
Replace pin,
bushing
71
SEN00139-04

2011 KOMATSU
All Rights Reserved
72
SEN00140-03
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

Work equipment
Work equipment
Work equipment.............................................................................................................................................. 2
Dimensions of work equipment ...................................................................................................................... 6
PC600-8
SEN00140-03
Work equipment
Work equipment
PC600-8
SEN00140-03
Unit: mm
No.
Check item
Clearance between bushing

and mounting pin of boom
and revolving frame
Remedy
Criteria
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
140
0.043
0.106
+0.148
+0.057
0.100
0.254
1.5

and mounting pin of boom and
arm
130
0.043
0.106
+0.407
+0.325
0.368
0.513
1.5

and mounting pin of arm and
link
110
0.036
0.090
+0.360
+0.284
0.320
0.450
1.5

bucket
115
0.036
0.090
+0.326
+0.223
0.259
0.416
1.5

and mounting pin of link and
link
110
0.036
0.090
+0.354
+0.275
0.311
0.444
1.5

and mounting pin of link and
bucket
115
0.036
0.090
+0.382
+0.279
0.315
0.472
1.5
Bucket clearance
PC600-8
0.5 1.0
Replace
Adjust
shims
SEN00140-03
PC600-8
SEN00140-03
Unit: mm
No.
Check item

revolving frame
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
140
0.043
0.106
+0.148
+0.057
0.100
0.254
1.5
Standard
size
Clearance
limit

arm
140
0.043
0.106
+0.542
+0.442
0.485
0.648
1.5

bucket
140
0.043
0.106
+0.523
+0.460
0.503
0.629
1.5

and mounting pin of front
bucket and rear bucket
95
0.036
0.090
+0.457
+0.370
0.406
0.547
1.5
PC600-8
Replace
SEN00140-03
Dimensions of work equipment

1. Arm
PC600-8
SEN00140-03
Unit: mm
Model
No.
PC600, PC600LC-8
2.9 m Arm
3.5 m Arm
4.3m Arm
5.2m Arm
125
125
125
125
148
148
148
148
458
458
458
458
130
130
130
130
499
582
627.7
666.9
460.6
321.7
338
352
1,188.9
1,187.2
1,182.7
1,178.6
2,863.2
3,465.2
4,256.6
5,188.1
3,624
3,324.2
3,315.9
3,308.2
10
471.3
497.6
497.6
497.6
11
910
810
810
810
12
700
700
700
700
13
678
608
608
608
14
2,197
2,166
2,166
2,166
15
115
115
115
115
16
456 0.5
456 0.5
456 0.5
456 0.5
17
115
115
115
115
Arm as
individual part
448
0
-0.5
448
0
-0.5
448
0
-0.5
448
0
-0.5
18
When pressfitting bushing
464
464
464
464
Min.
2,380
2,152
2,152
2,152
Max.
3,990
3,577
3,577
3,577
19
PC600-8
SEN00140-03
2. Bucket
PC600-8
SEN00140-03
Unit: mm
Model
2.0 m3, 2.3m3, 2.7m3 Bucket
3.5 m3 Bucket
599.7 0.5
665 0.5
100.1 0.5
132.5 0.5
2,148
2,179
280
280
115 +0.1
0
115 +0.1
0
10
457 +20
457 +20
11
84.5
84.5
12
80.5
80.5
13
135 +0.063
0
135 +0.063
0
14
75.5
75.5
15
16
17
18
19
20
21
488.5 +20
488.5 +20
22
79
79
23
115 +0.1
0
115 +0.1
0
24
No.
Press fit hole

for bushing
PC600, PC600LC-8
PC600-8
SEN00140-03

2008 KOMATSU
All Rights Reserved
10
SEN00141-00
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

Air conditioner piping ...................................................................................................................................... 2
PC600-8
SEN00141-00

Air conditioner piping
For the electric circuit diagram of the air conditioner, see Others.
1.
2.
3.
4.
5.
6.
7.
8.
Air conditioner unit

Duct
Refrigerant piping
Air conditioner compressor
Condenser
Receiver tank
Hot water return piping
Hot water pickup piping
A : Fresh air
B : Recirculated air
C : Hot air/cold air
SEN00141-00

2005 KOMATSU
All Rights Reserved
SEN00142-05
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

Electrical system
Engine control ...................................................................................................................................................... 2
Machine control system diagram ......................................................................................................................... 7
Monitor system................................................................................................................................................... 31
Sensors.............................................................................................................................................................. 46
KOMTRAX system ............................................................................................................................................. 50
PC600-8
SEN00142-05
Engine control
1. Operation of system
Starting engine
When the starting switch is turned to the START
position, the starting signal flows to the starting
motor, and the starting motor turns to start the
engine.
When this happens, the engine controller
checks the signal from the fuel control dial and
sets the engine speed to the speed set by the
fuel control dial.
Engine speed control

The fuel control dial sends signal voltages to the
engine controller according to its angle.
The engine controller sends drive signals to the
supply pump according to the signal voltages
received from the fuel control dial and controls
the fuel injection pump to control the engine
speed.
Stopping engine
When the engine controller detects that the starting switch is at the STOP position, it cuts the signal to the supply pump drive solenoid to stop the
engine.
PC600-8
SEN00142-05
2. Components of system
Fuel control dial
1.
2.
3.
4.
5.
6.
Knob
Dial
Spring
Ball
Potentiometer
Connector
Function
The fuel control dial is installed at the bottom of
the machine monitor. A potentiometer is installed
under the knob, and when the knob is turned, it
rotates the potentiometer shaft.
When the shaft rotates, the resistance of the
variable resistor inside the potentiometer
changes, and the desired throttle signal is sent
to the engine controller.
The hatched area in the graph on the right is the
abnormality detection area and the engine speed
is set at low idling.
PC600-8
SEN00142-05
Engine controller
PC600-8
SEN00142-05
Input and output signals

CN-CE01
Pin No.
Signal name
Input/
Output
Pin No.
48
49
NE sensor ()
NC
Input/
Output
50
51
52
53
54
55
56
57
58
59
60
NC
Injector #2 ()
Injector #3 ()
Injector #1 ()
Injector #2 (+)
Injector #3 (+)
Injector #4 (+)
Injector #6 (+)
Injector #4 ()
Injector #6 ()
Injector #5 ()
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
1
2
NC
NC
3
4
5
Ambient press. sensor

Supply pump #1 (+)
Supply pump #1 ()
CAN ()
NC
CAN (+)
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
Supply pump #2 (+)

Supply pump #2 ()
EGR valve ()
NC
Engine oil press. sensor
NC
Water temp. sensor
Sensor power (+5V)
NC
NC
EGR position sensor
EGR in press. sensor
NC
EGR valve (+)
Boost temp. sensor
NC
Common rail press. sensor
G sensor (+)
NE sensor (+)
NC
Bypass valve position sensor
Fuel temp. sensor
Bypass valve (+)
NC
Sensor power (+5V)
NC
Input
Output
Output
Input/
Output
Input/
Output
Output
Output
Output
Input
Input
Output
Input
Input
Output
Input
Input
Input
Input
Input
Input
Output
Output
35
36
37
38
39
40
41
42
43
44
45
46
47
NC
NC
Sensor power (+5V)
GND
NC
NC
NC
NC
NC
Boost press. sensor
Injector #1 (+)
Injector #5 (+)
G sensor ()
Output
Input
Output
Output
PC600-8
Signal name
CN-CE02
1
2
3
4
5
NC
NC
NC
NC
NC
Input/
Output
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
NC
NC
NC
Fuel dial (+)
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
Fuel dial (+5V)
Fuel dial ()
NC
NC
NC
NC
NC
NC
NC
NC
NC
Input
Output
Pin No.
Signal name
SEN00142-05
Pin No.
Signal name
33
34
35
36
NC
NC
NC
NC
37
38
39
43
44
45
NC
NC
Key switch (ACC)
Electrical intake air heater sub relay
(output)
NC
Electrical intake air heater sub relay
(return)
NC
NC
NC
46
CAN (+)
47
CAN ()
48
49
50
NC
NC
NC
40
41
42
Input/
Output
Input
Output
Output
Input/
Output
Input/
Output
CN-CE03
Pin No.
1
2
3
4
Signal name
GND
NC
Power (+24V)
NC
Input/
Output
PC600-8
SEN00142-05
Machine control system diagram

OFF (Cancel)
Auto deceleration function
ON
E0
P
Electronic OLSS function
3-mode selector type torque control
Cut-off control
Flow control
E1
E2
E3
OFF
Power max. function
ON
ON (low pressure) (Digging improvement mode)
2-stage boom pushing force
selector function
OFF (high pressure) (Machine push-up mode)
(Machine push-up)
Machine control
system
Swing control function
Engine automatic warming-up,

Overheat prevention function,
Turbo protect function
Travel control function

Travel speed
selection function
Travel pressure
increasing function
Fixed to Lo (Low speed)

Automatic travel speed shifting between
Hi (High speed) and Lo (Low speed)
Normal rotation
Fan rotation control

Reverse rotation
PC600-8
SEN00142-05
Machine control system diagram
PC600-8
PC600-8
SEN00142-05
SEN00142-05
1. Auto deceleration system
Function
If all the control levers are at neutral when waiting for work or waiting for a dump truck, the engine speed is automatically reduced to a
midrange speed to reduce fuel consumption and
noise.
If any lever is operated, the engine speed returns
immediately to the set speed.
10
PC600-8
SEN00142-05
Operation
1. When auto-deceleration switch is turned ON
Control levers at neutral
If the engine is running at above the deceleration
actuation speed (approx. 1,400 rpm), and all the
control levers are returned to neutral, the engine
speed drops immediately to approx. 100 rpm below the set speed to the No. 1 deceleration position.
If another 4 seconds passes, the engine speed is
reduced to the No. 2 deceleration position (approx. 1,400 rpm), and is kept at that speed until
a lever is operated.
When control lever is operated

If any control lever is operated when the engine
speed is at No. 2 deceleration, the engine speed
will immediately rise to the speed set by the fuel
control dial.
2. When auto-deceleration switch is turned OFF
Control lever at neutral

If the engine is running at a speed above 1,750
rpm and all the control levers are returned to
neutral, the engine speed drops to approx. 1,750
rpm after 4 seconds and is kept at that speed until a lever is operated.
PC600-8
When control lever is operated

If any control lever is operated under the condition shown at left (after the engine speed drops
to approx. 1,750 rpm), the engine speed will immediately rise to the speed set by the fuel control
dial.
11
SEN00142-05
2. Electronic OLSS function

Pump control system
12
Interconnected control of all pumps is carried out

by one TVC valve.
P mode: Total horsepower control by engine
speed sensing
E mode: Total horsepower control by engine
speed sensing
Emergency pump drive circuit:
Constant torque control
PC600-8
SEN00142-05
1) Control method in each mode

P, E, L mode
Matching point in P, E and L mode: Rated output point

Model
PC600-8R
PC600LC-8R
Cut-off
2-stage relief
Relief pressure
1,800 rpm
31.9 MPa {325 kg/cm2}
E0
1,720 rpm
E1
1,680 rpm
E2
1,640 rpm
31.9 MPa {325 kg/cm2}
E3
1,580 rpm
1,730 rpm
37.3 MPa {380 kg/cm2}
Mode
When the load on the pump rises and the pressure rises, the engine speed goes down.
At this time, by reducing the pump discharge,
set the engine speed at about the rated output
point.
If the pressure lowers, by increasing the pump
discharge, set the engine speed at about the
rated output point.
By repeating this control, the engine can always
be used at near the rated output point.
Compared with the P mode, which provides the
maximum output, the E mode lowers the engine
output to provide matching at a point which gives
better fuel consumption efficiency than the P
mode.
PC600-8
13
SEN00142-05
2) Cut-off function
If the load during operation increases and the
pump discharge pressure rises to near the relief
pressure, the main pump cut-off valve is actuated to reduce the relief loss.
3) Cut-off cancel function

The cut-off cancel function acts to stop the operation of the cut-off function in order to ensure the
pump flow close to the relief pressure, thereby
preventing any drop in speed.
The actuation and cancellation of the cut-off function is set automatically by operating the power
max. switch, or travel lever.
Cut-off function and actuation of each switch

Switch
Function
Cut-off function
Working mode
switch
P
Actuated Actuated
Travel lever
Power max.
switch
Swing lock
switch
ON
OFF
ON
OFF
ON
OFF
Cancel
Cancel
Actuated
Cancel
Actuated
Cancel
Actuated
4) 2-stage relief function

When L mode switch is ON, the pilot pressure of
the 2-stage relief valve raises the set pressure
of the main relief valve from 31.9 MPa {325 kg/
cm2} to 37.2 MPa {380 kg/cm2} to increase the
hydraulic power.
14
PC600-8
SEN00142-05
3. Power max. function
Function
This is a function to increase the power for a
fixed period when the L.H. knob switch is oprerated. It makes it possible to obtain a sudden
burst of power to match the working conditions.
If knob switch on the work equipment control lever is turned ON, the following functions are actuated.
Power max.
switch
Mode,
function
OFF
ON
CO function
Actuated
Canceled
Main relief valve

set pressure
31.9 MPa
{325 kg/cm2}
34.3 MPa
{350 kg/cm2}
Canceled
after 8.5 sec
even when
kept pressed
Operating time
PC600-8
15
SEN00142-05
4. 2-stage boom pushing force selector function
Outline
This function switches the pushing force of the
boom. It is aimed to provide both increased digging efficiency by reducing the digging resistance of the boom, and increased ease of
operation by increasing the thrusting force for excavation, digging square holes, carrying out twist
turns, or escaping from soft ground.
16
PC600-8
SEN00142-05
Operation
This function acts to change the set pressure of the safety valve at the boom cylinder end of the R.H. 4-spool
control valve boom Lo in 2 ways: to low pressure (14.7 MPa {150 kg/cm2}) and high pressure (33.3 MPa {340
kg/cm2}.
Mode
Boom pushing
force
(low mode)
Boom pushing
force
(high mode)
PC600-8
Machine push-up
switch
Machine push-up
solenoid valve
Energized
De-energized
Safety valve set

pressure
Effect
14.7 MPa
{150 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.
28.4 MPa
{290 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.
17
SEN00142-05
5. Swing control function
Function
The system is provided with a swing lock and
swing holding brake function.
18
PC600-8
SEN00142-05
Swing lock, swing holding brake function

The swing lock (manual) can be locked at any
desired position, and the swing lock and swing
holding brake (automatic) are interconnected
with the swing, so they prevent any hydraulic drift
after the swing is stopped.
a Swing brake solenoid valve

For details of the structure and function, see
Solenoid valve.
a Swing motor
For details of the structure and function, see
Swing motor.
Actuation
Mode
Swing lock
switch
Swing lock
monitor
Swing brake
solenoid valve
Actuation
When swing and work equipment levers are placed at
neutral, swing brake is applied after approx. 10 sec;
when any swing or work equipment lever is operated,
brake is canceled and swing can be operated freely.
Swing holding
brake
OFF
OFF
See diagram
on right
Swing brake
ON
ON
De-energized
Operation of swing lock prolix switch

If any abnormality should occur in the controller,
and the swing holding brake is not actuated normally and the swing cannot be operated, the
swing lock prolix switch can be operated to cancel the swing lock and allow the swing to be operated.
a Even when the swing lock prolix switch is turned
ON, the swing lock switch stays ON and the
swing brake is not canceled.
a When the swing brake is canceled, the swing
has only a hydraulic brake operated by the
safety valve, so if the swing is stopped on a
slope, there may be hydraulic drift.
PC600-8
Swing lock is actuated and swing is held in position.

Even when swing lever is operated, swing lock is not
canceled and swing does not move.
Swing lock
prolix
switch
ON
(when controller is
abnormal)
OFF
(when controller is
normal)
Swing lock
switch
ON
OFF
ON
OFF
Swing
brake
Swing
lock
applied
Swing
lock
canceled
Swing
lock
applied
Swing
holding
brake
applied
19
SEN00142-05
6. Engine automatic warming-up, overheat prevention function, turbo protect function
Function
If the coolant temperature is low, this automatically raises the engine speed to warm up the engine after it is started. In addition, if the coolant
temperature rises too high during operations, it
reduces the load of the pump to prevent overheating.
To protect the turbocharger bearing during cold
weather, the engine speed is kept below the
fixed speed when the engine is started. In addition, to improve the starting ability, a small
amount of fuel is injected two or more times before the main injection.
20
PC600-8
SEN00142-05
1) Engine automatic warming-up function

After the engine is started, if the engine coolant
temperature is low, the engine speed is automatically raised to warm up the engine.
2) Engine overheat prevention function

This function protects the engine by lowering the
pump load and engine speed to prevent overheating when the engine coolant temperature
has risen too high.
This system is actuated at 105C and above.
PC600-8
21
SEN00142-05
3) Turbo protection function

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

(sec)
More than +10C
+10C to 10C
Gradually changes
between 0 and 20
Less than 10C
20
Engine speed: 1,000 rpm

Even if the fuel control dial is operated during
the above time, the engine speed will not
change. After the set time passes, the operation
moves to the automatic warming up function in
Step 1).
22
PC600-8
SEN00142-05
7. Travel control function
Outline
The pump absorption torque is increased when
traveling to increase the drawbar pull.
Switching between manual and automatic travel
speed selection is used to improve the travel performance.
PC600-8
23
SEN00142-05
Travel speed selection function

1) Manual selection using travel speed switch
If the travel speed switch is set to Lo, Hi, the
pump controller controls the pump flow and
motor volume at each speed range as shown on
the right to switch the travel speed.
2) Automatic selection according to engine speed
If the engine speed is reduced to below 1,200
rpm by the fuel control dial:
If the machine is traveling in Lo, it will not
shift even if Hi is selected.
If the machine is traveling in Hi, it will automatically shift to Lo.
3) Automatic selection according to pump discharge pressure
If the machine is traveling with the travel speed
switch at Hi, and the load increases, such as
when traveling up a steep hill, if the travel pressure continues at 31.4 MPa {320 kg/cm 2 } for
more than 2.0 sec, the pump volume is automatically switched and the travel speed changes to
Lo.
(The travel speed switch stays at Hi.)
The machine continues to travel in Lo, and when
the load is reduced, such as when the machine
travels again on flat ground or goes downhill,
and the travel pressure stays at 22.6 MPa {230
kg/cm2} or less for more than 1.0 sec, the pump
volume is automatically switched and the travel
speed returns to Hi.
Travel speed
switch
Lo
(Low speed)
Hi
(High speed)
Motor volume
Max.
Min
Travel speed
(km/h)
3.0
4.9
Travel pressure increasing function

Outline
To maintain the drawbar pull when traveling, the
cut-off is canceled and the pressure is raised
from 31.9 MPa {325 kg/cm2} to 34.3 MPa {350
kg/cm2}.
Operation
Pressure increase
solenoid valve
Main relief valve

set pressure
Cut-off cancel
solenoid valve
CO valve
When traveling
De-energized
31.9 MPa
{325 kg/cm2}
Energized
Canceled
When not traveling
De-energized
31.9 MPa
{325 kg/cm2}
De-energized
Actuated
24
PC600-8
SEN00142-05
Components of system
Engine speed sensor
1.
2.
3.
4.
5.
Wire
Magnet
Terminal
Housing
Connector
Function
The engine speed sensor is installed to the ring
gear portion of the engine flywheel. It counts
electrically the number of gear teeth that pass in
front of the sensor, and sends the results to the
engine controller and pump controller.
This detection is carried out by a magnet, and an
electric current is generated every time the gear
tooth passes in front of the magnet.
PPC hydraulic switch

1. Plug
2. Switch
3. Connector
Specifications
Composition of points: N. O. points
Actuation (ON) pressure:
0.5 0.1 MPa {5.0 1.0 kg/cm2}
Reset (OFF) pressure:
0.3 0.5 MPa {3.0 0.5 kg/cm2}
Function
There are 12 switches installed to the PPC block.
The operating condition of each actuator is detected from the PPC pressure, and this is sent to
the engine controller and pump controller.
PC600-8
25
SEN00142-05
TVC resistor
1. Resistor
2. Connector
Specification
Resistance: 20 z
Function
This resistor acts to allow a suitable current to
flow to the TVC solenoid when the TVC emergency pump drive switch is ON.
No current flows when the TVC emergency
pump drive switch is OFF.
Fuel control dial, engine controller

a See Engine control.
Monitor panel
a See Monitor system.
TVC valve
a See Hydraulic pump.
26
PC600-8
SEN00142-05
Pump controller
PC600-8
27
SEN00142-05

CN-CP01
CN-CP02
1
2
NC
R pump pressure sensor
Input/
Output
Input
Input
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
NC
Signal GND
(Auto grease-up error)
NC
NC
F pump pressure sensor
Air temp sensor
Signal GND
Knob switch
NC
NC
NC
NC
NC
Starting switch (C)
NC
NC
NC
Analog GND
Power supply (+5V)
Starting switch (ACC)
Step light switch
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Output
Input
Input
Input
Input
Output
Input
Input
Pin No.
28
Signal name
Pin No.
Signal name
1
2
NC
Swing prolix switch
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
NC
232C_RD
(Overload sensor)
(Overload caution enable switch)
Machine select 4
NC
NC
NC
NC
CAN shield
Machine select 5
232C_TxD
NC
NC
Machine select 3
NC
Step light drive relay
NC
21
NC
22
CAN0_L
23
NC
24
25
26
27
28
29
30
31
Flash memory write enable signal

Horn switch
NC
Machine select 2
NC
NC
NC
NC
32
CAN0_H
33
NC
34
35
36
37
38
GND (232C GND)

Service pressure switch
NC
Machine select 1
Swing lock switch
39
40
NC
NC
Input/
Output
Output
Input
Input
Input
Input
Input
Input
Output
Output
Input
Output
Input
Output
Input
Input
Input
Output
Output
Input
Input/
Output
Input/
Output
Input/
Output
Input
Input
Input
Input
Input
Input
Input/
Output
Input/
Output
Input
Input
Input
Input
Input
PC600-8
SEN00142-05
CN-CP03
1
2
Controller power supply

Solenoid power supply
Input/
Output
Input
Input
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
SOL_COM
Battery relay drive
NC
NC
NC
Travel alarm
Bucket digging pressure switch
Boom raise switch
Controller power supply
SOL_COM
Key signal
NC
TVC solenoid
2-stage relief solenoid
Flash light drive relay
Bucket dump pressure switch
Boom lower pressure switch
GND
SOL_COM
Key signal
Fan reverse solenoid
NC
Travel speed solenoid
Cut-off cancel solenoid
Swing pressure switch
Arm digging pressure switch
GND
GND
GND
NC
Fan pump EPC
NC
Swing parking brake solenoid
Bucket Hi cancel solenoid
Travel pressure switch
Arm dump pressure switch
Output
Output
Output
Output
Output
Input
Input
Input
Input
Input
Output
Output
Output
Output
Input
Input
Input
Input
Output
Output
Output
Output
Input
Input
Output
Output
Output
Output
Input
Input
Pin No.
PC600-8
Signal name
29
SEN00142-05
30
PC600-8
SEN00142-05
Monitor system
The monitor system monitors the condition of the

machine with sensors installed on various parts
of the machine. It processes and immediately
displays the obtained information on the panel
notifying the operator of the condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when the
machine has troubles
2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil
temperature, fuel level, etc.)
The monitor panel also has various mode selector switches and functions to operate the machine control system.
PC600-8
31
SEN00142-05
Monitor panel
Outline
The monitor panel has the functions to display
various items and the functions to select modes
and electric parts.
The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the
information.
The monitor display unit consists of LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
32
PC600-8
SEN00142-05

CN1
CN3
1
2
Key ON
Key ON
Input/
Output
Input
Input
3
4
5
6
7
8
9
10
11
12
Washer
Start
Limit switch (W)
GND
GND
VB+
Wiper (+)
Wiper ()
Buzzer on input
Limit switch (P)
Output
Input
Input
Input
Output
Output
Input
Input
Pin No.
Signal name
CN2
Pin No.
Signal name
1
2
3
4
5
6
7
8
(Coolant temp.)
Fuel level
Coolant level
(Hydraulic oil level)
Air filter
NC
(Engine oil press.)
Engine oil level
N/W signal
10
N/W signal
11
12
13
14
15
16
17
18
19
20
Charge
Hydraulic oil temp. (a)
GND
Buzzer drive
Limit switch (window)
Buzzer cancel
Swing lock
Pre-heating
Light
GND
PC600-8
Input/
Output
Input
Input
Input
Input
Input
Input
Input
Input
Input/
Output
Input/
Output
Input
Input
Input
Input
Input
Input
Input
Input
Pin No.
Signal name
1
2
NC
NC
3
4
5
6
7
8
NC
NC
NC
NC
RS230C CTS
RS232C RD
RS232C RD
10
RS232C RD
11
12
13
14
15
16
Boot switch
NC
GND
CAN (shield)
CAN (+)
CAN ()
Input/
Output
Input
Input
Input
Input
Input
Input
Input
Input
Input/
Output
Input/
Output
Input
Input
Input
Input
Input
33
SEN00142-05
Monitor control, display portion

Monitor portion
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
34
Wiper monitor
Preheating monitor
Swing lock monitor
Engine coolant temperature monitor
Hydraulic oil temperature gauge
Engine coolant temperature gauge
Working mode monitor
Service monitor
Travel speed meter
Fuel gauge
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Fuel level monitor

Hydraulic oil temperature monitor
Power Max. monitor
Auto-deceleration monitor
Radiator coolant level caution
Battery charge caution
Engine oil pressure caution
Engine oil level caution
Air cleaner clogging
Maintenance time warning caution
PC600-8
SEN00142-05
Monitor items and display

Display category
Symbol
Display item
Wiper
Display range
INT
ON
Display method
OFF
Displays set condition
Working mode
Displays set mode
Travel speed
Displays set speed
Monitor
Auto-deceleration
Service meter
PC600-8
Service meter
indicator
ON
OFF
When service meter is working
Displays actuation
status
Lights up when service

meter is working
35
SEN00142-05
Symbol
Display item
Swing lock
SAT00098
Display method
Swing lock switch
Swing holding brake

release switch
Swing lock monitor
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
Flashes
ON
ON
ON
Continuous set time
Preheating monitor status
Up to 30 sec.
ON
From 30 sec. to 40 sec.
Flashes
More than 40 sec.
OFF
Power Max. switch status
Power Max. monitor status
Being pressed
Lights up but goes out after

approx. 9 sec. when kept pressed
Not being pressed
Flashes
Preheating
Power Max.
Engine coolant
temperature
Hydraulic oil
temperature
See gauge display on the next page
Fuel level
36
PC600-8
SEN00142-05
Gauge display
Gauge
Engine coolant
temperature (C)
Hydraulic oil temperature (C)
Range
Temperature, volume
Indicator (Symbol)
A1
105
Red
A2
102
Red
A3
100
Green
A4
80
Green
A5
60
Green
A6
30
White
B1
105
Red
B2
102
Red
B3
100
Green
B4
80
Green
B5
40
Green
B6
20
White
C1
524
Green
C2
382
Green
C3
249
Green
C4
138
Green
C5
101
Green
C6
84
Red
Buzzer sound
Fuel level (l)
PC600-8
37
SEN00142-05
Cautions displayed during checks before starting (caution lamps all light up)
When any of the following items is abnormal or its maintenance interval is reached or exceeded, the monitor
corresponding to it lights up at the center of the screen.
Symbol
Display item
Check before starting

item
When engine is
stopped
When engine is
running
Engine oil pressure
When abnormal,
lights up and buzzer
sounds
Battery charge
Lights up when
abnormal
Radiator coolant
level
Lights up when
abnormal
When abnormal,
lights up and buzzer
sounds
Engine oil level
Lights up when
abnormal
Lights up when
abnormal
SAP00519
SAP00522
SAP00520
SAP00523
SAP00521
Maintenance
Lights up when there is a warning. Lights up for

only 30 sec. after key is turned ON, then goes
out.
The above cautions are displayed at the display positions of the hydraulic oil temperature gauge and hydraulic
oil temperature monitor. Accordingly, if the hydraulic oil temperature is abnormally high or low at this time, only
the hydraulic oil temperature monitor symbol is displayed.
38
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
PC600-8
SEN00142-05
Switches
1.
2.
3.
4.
5.
6.
7.
8.
9.
Working mode selector switch

Buzzer cancel switch
Display brightness, contrast adjustment switch
Control switch
Window washer switch
Wiper switch
Maintenance switch
Travel speed selector switch
Auto-deceleration switch
PC600-8
39
SEN00142-05
Working mode selector switch

The condition of the machine changes according
to the switch that is pressed (Shown in the figure
at right). It is possible to check the condition on
the working mode monitor display. The relationship between each working mode and the monitor display is shown in the table on the right.
Maintenance switch
Check the condition of the maintenance items.
(For details, see Maintenance function.)
Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON/OFF.
Use the auto-deceleration monitor display to
check the present condition.
When the working mode selector switch is operated to switch the working mode, it is automatically set to ON.
Travel speed selector switch

Each time the travel speed selector switch is
pressed, the travel speed changes.
Lo o Hi o Lo
Use the travel speed monitor display to check
the present condition.
The relationship between the set speed and the
monitor display is shown in the table on the right.
Wiper switch
Each time the wiper switch is pressed, the wiper
setting changes OFF o INT o ON o OFF o
Use the wiper monitor display to check the present condition.

The relationship between the wiper setting and
the monitor display is shown in the table on the
right.

While the switch is being pressed, window
washer liquid is sprayed out. There is a time
delay before the wiper starts.
Control switch
This is used for control when using the maintenance function or select function.
(For details, see each function.)
Display brightness, contrast adjustment switch

Use this switch when adjusting the display
brightness and contrast.
(For details, see each function.)
Buzzer cancel switch

Pressing this switch when the alarm buzzer is
making sound stops the alarm buzzer.
If a new abnormality is detected, the alarm
buzzer sounds.
Depending on the alarm buzzer type, it does not
stop even if you press the buzzer cancel switch.
40
Switch that is
pressed
Display
Working mode status

after setting
[P]
P mode (default)
[E]
E mode
[L]
L mode
Display
Setting
Crawler symbol + Lo
Low speed (default)
Crawler symbol + Hi
High speed
Display
Setting
Wiper actuation
status
None
OFF
Stowing stopped or
now stowing
Wiper symbol + INT
INT
Intermittent actuation
Wiper symbol + ON
ON
Continuous actuation
PC600-8
SEN00142-05
Maintenance function
When the maintenance time for replacement,
inspection, or filling has approached for the 11 maintenance items, press maintenance switch (1) and
the caution display (yellow or red) appears on the
monitor display for 30 seconds after the key is
turned ON to remind the operator to carry out lubrication maintenance.
a Maintenance items
No.
Replacement
interval (hours)
Item
01
Engine oil
500
02
Engine oil filter
500
03
Fuel filter
41
Fuel pre-filter
500
04
Hydraulic filter
1,000
05
Hydraulic tank breather
1,000
06
Corrosion resistor
1,000
07
PTO case oil
1,000
08
Final case oil
2,000
09
Machinery case oil
1,000
10
Hydraulic oil
5,000
1,000
a The above replacement intervals are set for

each item, and the time remaining to maintenance is reduced as the machine is operated.
The content of the caution display differs
according to the remaining time. The relationship is as shown in the table below.
Display
Condition
None
Remaining time for maintenance for all items is more

than 30 hours
Notice display (black symbol displayed on yellow

background)
There is one or more items

with less than 30 hours
remaining time for
maintenance
Warning display (white

symbol displayed on red
background)
There is one or more items

with less than 0 hours
remaining time for
maintenance
PC600-8
41
SEN00142-05
Method of checking status

Maintenance items
a Operate as follows when on the operator
screen.
1. Press maintenance switch (1) and switch to the
maintenance list display screen.
a The maintenance items are displayed as
symbols on the screen.
2. Press control switch (2), or use the 10-key pad
to input the number (01 to 10, 30, 31) of the
maintenance item to select the item.
a The cursor moves and the item is highlighted.
a The display method is the same as described on the previous page (relationship
between remaining time and caution display). If the remaining time is less than 30
hours, the item is displayed in yellow, and if
it is less than 0 hours, it is displayed in red.
Maintenance operation
1. After completing the selection, press input confirmation switch (3).
The screen will change to the maintenance
reset screen.
2. Use the maintenance reset screen to check the
content, and if there is any problem, press input
confirmation switch (3) to move to the check
screen.
If the wrong item is selected, press return switch
(4) to return to the maintenance list screen.
3. Check the content on the check screen, and if
there is no problem, press input confirmation
switch (3) to reset the maintenance time.
After the reset is completed, the screen returns
to the maintenance list display screen. To check
the remaining time, or if the wrong item is
selected, press return switch (4) to return to the
maintenance list screen.
a The check screen shows the symbol for the
maintenance item and the set time in large
letters.
a The background color of the symbol for the
item where the maintenance hour was reset
is the same as the background of the screen,
so it is possible to check that it has been reset.
42
PC600-8
SEN00142-05
Brightness, contrast adjustment function

This function is used to adjust the brightness and
contrast of the display.
Adjustment method
a Operate as follows when on the operator
screen.
1. Press display brightness, contrast adjustment
switch (1) and switch to the adjustment screen.
a Relationship between menu symbol and content.
No.
Symbol
Content
00
Return mark
Return
01
Contrast
02
Brightness
2. Press control switch (2), or use the 10-key pad

to input the number (00 to 02) to select either
contrast or brightness.
After completing the selection, press input confirmation switch (3) and return to the adjustment
screen.
Then press return switch (4) or use the 10-key
pad to set to [00] and press input confirmation
switch (3) to return to the normal screen.
3. Press control switch (2) and adjust the brightness and contrast as desired.
Control switch
Actuation
Flow level bar graph
extends to the right
Flow level bar graph

retracts to the left
PC600-8
43
SEN00142-05
Service meter check function
When the starting switch is at the OFF position,

keep return switch (1) and control switch (2) of
the monitor pressed at the same time, and the
service meter is shown on the display.
This display is shown only while the two switches
are being pressed. When the switches are released, the display goes out.
Note that it takes 3 5 seconds after the
switches are pressed for the service meter display to appear.
Display LCD check function
On the password input screen or on the normal

screen, if monitor return switch (1) and working
mode (A) switch are kept pressed at the same
time, all the LCD display will light up and the
whole screen will become white, so the display
can be checked.
If any part of the display is black, the LCD is broken.
User code display function
44
If there is any problem in operating the machine,

the user code is displayed on the monitor to advise the operator of the steps to take.
This code display appears on the operator
screen.
On the operator screen, the user code is displayed on the portion for the hydraulic oil temperature gauge.
If more than one user code is generated at the

same time, the user codes are displayed in turn
for 2 seconds each to display all the user codes.
PC600-8
While the user code is being displayed, if the input confirmation switch is pressed, the service
code and failure code can be displayed.
If there is mode than one service code or failure

code, the display switches every 2 seconds and
displays all the service codes/failure codes that
caused the user code to be displayed.
Even if service codes/failure codes have
occurred, if they did not cause the user code to
be displayed, this function does not display
them.
If the telephone number has been set using the

telephone number input on the service menu, it
is possible to switch on the service code/failure
code and display the telephone symbol and telephone number.
For details of inputting and setting the telephone
number, see Special functions of monitor panel
in the Testing and adjusting section.
PC600-8
SEN00142-05
45
SEN00142-05
Sensors
The signals from the sensors are input directly to

the engine controller and the pump controller
monitor.
Name of sensor
The contact type sensors are always connected

at one end to the chassis GND.
Type of sensor
When normal
When abnormal
Input controller
Coolant level
Contact type
ON (closed)
OFF (open)
Monitor
Engine oil level
Contact type
ON (closed)
OFF (open)
Monitor
Engine oil pressure
Contact type
ON (closed)
OFF (open)
Engine controller
Coolant temperature
Resistance type
Engine controller
Fuel level
Resistance type
Monitor
Contact type
OFF (open)
ON (closed)
Monitor
Resistance type
Monitor
Analog
Pump controller

Hydraulic oil temperature
Main pump oil pressure
Coolant level sensor
1.
2.
3.
4.
46
Sub-tank
Float
Sensor
Connector
PC600-8
SEN00142-05
Engine oil level sensor
1.
2.
3.
4.
Connector
Bracket
Float
Switch
1.
2.
3.
4.
5.
6.
Plug
Contact ring
Contact
Diaphragm
Spring
Terminal
Engine oil pressure sensor
Air cleaner clogging sensor
PC600-8
47
SEN00142-05
Fuel level sensor

1.
2.
3.
4.
Float
Connector
Cover
Variable resistor
Coolant temperature sensor

Hydraulic oil temperature sensor
1. Thermistor
2. Body
3. Tube
48
4. Tube
5. Wire
6. Connector
PC600-8
SEN00142-05
Main pump oil pressure sensor (0 49.0 MPa {0 500 kg/cm2})
1.
2.
3.
4.
Sensor
Nut
Case
Connector
Function
The pump pressure sensor is installed to the inlet
circuit of the control valve. It converts the pump
discharge pressure into a voltage and transmits
it to the pump controller.
Operation
The oil pressure applied from the pressure intake
part presses the diaphragm of the oil pressure
sensor, the diaphragm is deformed.
The gauge layer facing the diaphragm measures
the deformation of the diaphragm by the change
of its resistance, then converts the change of the
resistance into a voltage and transmits it to the
amplifier (voltage amplifier).
The amplifier amplifies the received voltage and
transmits it to the pump controller.
Relationship between pressure P (MPa {kg/cm2})
and output voltage (V) is as follows.
V = 0.08 {0.008} x P + 0.5
PC600-8
49
SEN00142-05
KOMTRAX system
(if equipped)
The KOMTRAX terminal sends various information on the machine by a wireless communication.The KOMTRAX operator refers to this information in the office, and various services can be provided for the customer.
a To be provided with the KOMTRAX service, it is necessary to sign up separately.
Information that can be sent from the KOMTRAX terminal is as follows:
1. Traveling map
2. Service meter
3. Location information
4. Error history
50
PC600-8
SEN00142-05
KOMTRAX terminal
Model name: TC301
The KOMTRAX system uses satellite communication technology.
1.
2.
3.
Communication antenna connector

GPS antenna connector
Machine harness connector (DEUTSCH-40P)

DEUTSCH-40P [CN-G01]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Signal name
NC
NC
NC
NC
NC
NC
CAN signal (L)
CAN signal (H)
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
Relay output
Input/Output
signal
Input/Output
Input/Output
Output
Outline
The KOMTRAX terminal can send information
via wireless communication antenna, acquiring
various information of the machine from the network signal in the machine and the input signal.
Also, the controller incorporates CPU (Central
Processing Unit) and provide the wireless communication function and the GPS function.
Use of KOMTRAX terminal must be limited for
the countries in which such communication is allowed.
PC600-8
Pin No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Signal name
Operation mode selection 1
Operation mode selection 2
NC
NC
NC
NC
Starting switch (C)
Alternator (R)
NC
NC
NC
NC
NC
NC
NC
Starting switch (ACC)
Power source GND
Power source GND
Constant power source (24V)
Constant power source (24V)
Input/Output
signal
Input
Input
Input
Input
Input
Input
Input
There are the LED lamp and the 7-segment indicator lamp in the display area, and these lamps
are used for the testing and the troubleshooting.
When using TC301 in other countries, the satellite communication company to contract is different. So, part numbers of TC301 are different in
other countries. Also, when using TC301 in other
countries, you must notify the name of the country.
51
SEN00142-05

2010 KOMATSU
All Rights Reserved
52
SEN00395-04
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

Standard value table for engine ........................................................................................................................... 2
Standard value table for chassis .......................................................................................................................... 3
PC600-8
SEN00395-04
Standard value table for engine
Item
Machine model
PC600, 600LC-8
Engine
SAA6D140E-5
Measurement condition
Unit
Standard value
Permissible value
1,950 50
1,950 50
800 25
800 25
1,800
1,800
kPa
{mmHg}
Min 147 {Min. 1,100}
125 {940}
High idle
Engine speed
Low idle
rpm
Rated speed
Intake air pressure
At rated output
Exhaust gas
pressure
All speed range

(intake air temp: 20C)
Max. 650
700
Exhaust gas color
At sudden acceleration
(low o high idle)
At high idle
%
Bosch
index
Max. 25
(Max. 2.5)
(Max. 1.0)
35
(3.5)
(2.0)
0.35
0.57
Min. 1.18 {Min. 12}
Min. 1.18 {Min. 12}
Valve clearance
(at cold)
Intake valve
mm
Exhaust valve
MPa
EGR valve and bypass High idle

valve drive oil pressure
Low idle
{kg/cm2}
Min. 1.43 {Min. 14.6}
Min. 1.43 {Min. 14.6}
Compression
pressure
MPa
{kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
kPa
{mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
Min. 0.10 {Min. 1.0}
0.08 {0.8}
MPa
{kg/cm2}
Min. 1.43 {Min. 14.6}
Min. 1.43 {Min. 14.6}
Min. 1.18 {Min. 12}
Min. 1.18 {Min. 12}
Oil temperature: 40 60C

Engine speed: 200 250 rpm
(Coolant temperature: Min. 70C)
Blow-by pressure
At rated output
Oil temperature:
Min. 80C
Rated output
(At high idle)
Oil pressure
Oil temperature:
Min. 80C
Rated output
(At low idle)
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
EGR valve and bypass High idle

valve drive oil presLow idle
sure
MPa
{kg/cm2}
Oil temperature
All speed range (inside oil pan)
90 110
120
Alternator belt tension
Deflection when pressed with finger

force of approx. 58.8 N {6 kg}
mm
13 16
13 16
Air conditioner
compressor belt
tension
Deflection when pressed with finger

force of approx. 58.8 N {6 kg}
mm
10 15
10 15
PC600-8
SEN00395-04
Standard value table for chassis

Applicable model
Engine speed
Category
Item
PC600, 600LC-8
Measurement conditions
Unit
Standard value
Permissible value
Min. 1,780
Min. 1,780
Min. 1,730
Min. 1,730
All pumps at relief
Engine coolant temperature:

Within operating range
Hydraulic oil temperature:
Engine at high idle
Working mode: P
Boom RAISE relief
Power max. ON
+
All pumps at relief

Engine at high idle
Working mode: P
Boom RAISE relief + power
max. switch ON
High idle-cut ON
Engine at high idle

Auto-deceleration switch OFF
All control levers at neutral
1,750 100
1,750 100
Auto-deceleration
ON
Engine at high idle

Auto-deceleration switch ON
1,400 100
1,400 100
16 0.5
16 0.5
85 10
85 10
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
N o F, R
(L.H., R.H.)
115 12
115 12
Work equipment,
swing, travel
Max. 10
Max. 15
rpm
Boom Lo control valve
Spool stroke
Boom Hi control valve

Arm Lo control valve
Arm Hi control valve
Stroke of each side
Bucket Lo control valve
Bucket Hi control valve
Swing control valve
Travel control valve
N o RAISE,
LOWER
Travel of control levers
Boom control lever

Arm control lever
Bucket control lever
Swing control lever
Travel control lever
Play of control levers
PC600-8
Center of
lever knob
Read max.
value to end
of travel
(Exclude play
at neutral.)
Engine
stopped
mm
SEN00395-04
Applicable model
Category
Item
PC600, 600LC-8
Unit
Standard value
Permissible value
15.7 3.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
15.7 3.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
12.7 2.9
{1.3 0.3}
Max. 21.6
{Max. 2.2}
12.7 2.9
{1.3 0.3}
Max. 21.6
{Max. 2.2}
Lever
24.5 5.9
{2.5 0.6}
Max. 39.2
{Max. 4.0}
Pedal
74.5 18.6
{7.6 1.9}
Max. 107.6
{Max. 11}
31.87 +1.47
31.87 +1.47
Operating effort of control levers
Boom control lever

Arm control lever
Engine at high idle

Center of lever knob
Measure max. value to end of
travel
N {kg}
Swing control lever
Travel control lever,

pedal
0.98
+15
{325 10 }
34.32 +1.47
0.98
+15
{350 10 }
37.2 +1.5
2.0
+15
{380 20 }
RAISE
Normal
Boom relief pressure
At power
max.
L mode
Hydraulic pressure
LOWER
Hydraulic oil
temperature:
Normal
At machine
Engine at high
push-up
idle
Working
Normal
mode: P
Pump outlet
pressure
when meaAt power max.
sured circuit is
relieved
Relieve either
Normal
travel circuit.
Arm relief pressure
Bucket relief pressure

At power max.
0.98
+15
{350 10 }
37.2 +1.5
2.0
+15
15.69 1.96
{160 20}
27.95 1.96
{285 20}
27.95 1.96
{285 20}
0.98
+15
{325 10 }
34.32 +1.47
0.98
+15
{350 10 }
31.87 +1.47
0.98
+15
{325 10 }
34.32 +1.47
0.98
+15
{350 10 }
31.87 +1.47
0.98
+15
{325 10 }
34.32 +1.47
0.98
+15
{350 10 }
31.87 +1.47
0.98
+15
{325 10 }
34.32 +1.47
0.98
+15
Swing relief pressure
29.91 0.98
{305 10}
{350 10 }
29.91 0.98
{305 10}
Travel relief pressure
35.30 1.47
{360 15}
35.30 1.47
{360 15}
3.14 +0.39
3.14 +0.39
Control pressure
34.32 +1.47
{380 20 }
15.69 1.96
{160 20}
31.87 +1.47
MPa
{kg/cm2}
0.98
+15
{325 10 }

Engine at high idle
+0
+4
{32 +0 }
+0
+4
{32 +0 }
PC600-8
SEN00395-04
Applicable model
Category
Item
Hydraulic pressure
TVC valve output

pressure
CO-NC valve output

pressure
Swing
Jet sensor output

differential pressure
PC600, 600LC-8
Hydraulic oil
temperature:
Engine at high
idle
Working
mode: P
Hydraulic oil
temperature:
Engine at high
idle
Working
mode: P
When track
runs idle,
measure oil
pressure on
idle side.
Hydraulic oil
temperature:
Engine at high
idle
Working
mode: P
All control
levers at
neutral
Boom RAISE
relief (Normal)
Power max. +
Boom RAISE
relief
All control
levers at
neutral
Boom RAISE
relief (Normal)
Standard value
Permissible value
2.25 0.2
{23 2}
Min. 1.76
{Min. 18}
1.10 +0.20
1.05 +0.20
0.53
+2.0
{11.2 5.4 }
{10.7 5.4 }
0.53
+2.0
1.02 0.2
{10.4 2.0}
0.97 0.2
{9.9 2.0}
Max. 0.4
{Max. 4}
Max. 0.55
{Max. 5.5}
1.10 +0.20
1.05 +0.20
0.53
+2.0
{11.2 5.4 }
{10.7 5.4 }
Min. 1.7
{Min. 17}
Min. 1.7
{Min. 17}
1.02 0.2
{10.4 2.0}
0.97 0.2
{9.9 2.0}
All control
levers at neutral
1.76 0.2
{18 2}
Min. 1.5
{Min. 15}
Travel under no
load (Lever at
stroke end)
Max. 0.2
{Max. 2}
Max. 0.2
{Max. 2}
2.9 +0.54
2.9 +0.54
Travel under no
load (Lever at
stroke end)
Power max. +
Boom RAISE
relief
PPC valve output

pressure

Engine at high idle
Control lever at stroke end
Oil pressure drop

Difference between relief pressure at high idle and that at low
idle
Overrun when stopping Hydraulic oil temperature:

swing
Bucket: No load
Engine at high idle
Working mode: P
Stop after swinging one turn
and measure distance that
swing circle moves
PC600-8
Unit
MPa
{kg/cm2}
0.15
+5.5
{30 1.5 }
deg.
(mm)
0.53
+2.0
0.15
+5.5
{30 1.5 }
Max. 2.0
{Max. 20}
Max. 2.9
{Max. 30}
Max. 45
(Max. 775)
Max. 60
(Max. 1,040)
SEN00395-04
Applicable model
Category
Item
PC600, 600LC-8
Unit
Standard value
Permissible value
4.0 0.5
Max. 4.9
5.8 0.7
Max. 7.2
sec.
34 38
Max. 40
mm
l/min
Max. 5
Max. 10
90
Time taken to start

swing
Swing
Time taken to swing
Hydraulic oil temperature: Within operating

range
Bucket: No load
Engine at high idle
Working mode: P
Time taken to swing 90
and 180 from starting
position
sec.
180

Bucket: No load
Engine at high idle
Working mode: P
Swing one turn, then measure
time taken to swing next 5 turns

Hydraulic drift of swing Engine stopped
Set machine on 15 slope, and
set upper structure at 90 to the
side.
Make match marks on inner
race and outer race of circle.
Measure distance that match
marks move apart after 5 minutes.
Leakage from swing

motor

Engine at high idle
Swing lock switch: ON
Leakage in 1 minute during
swing relief
PC600-8
SEN00395-04
Applicable model
Category
Item
PC600, 600LC-8
Unit
Standard value
Permissible value
STD: 54 66
LC: 57 70
STD: 54 66
LC: 57 70
Hi
STD: 35 43
LC: 37 46
STD: 35 43
LC: 37 46
Lo
23 31
23 31
15 19
15 19
Max. 200
Max. 220
Lo
Travel speed
(Free rotation)
Travel
Travel speed
(Actual travel)
Travel deviation
PC600-8

range
Engine at high idle
Working mode: P
Raise track on one side
at a time, rotate one turn,
then measure time taken
for next 5 turns with no
load.

range
Engine at high idle
Working mode: P
On flat place
Run up for at least 10 m,
and measure time taken
to travel next 20 m on flat
ground.
sec.
sec.
Hi

Engine at high idle
Working mode: P
Travel speed: Lo
On hard and flat place
Measure travel deviation (x) in
travel of 20 m after running up
10 m.
mm
SEN00395-04
Applicable model
Category
Item
Travel
Hydraulic drift of travel
Leakage of travel
motor

Engine stopped
Stop machine on 12 slope with
sprocket at uphill end of
machine.
Measure the distance the
machine moves in 5 minutes.
Engine at high idle
Travel: Lock sprocket.
Measure leakage in 1 minute
during travel relief.
PC600, 600LC-8
Unit
Standard value
Permissible value
mm
l/min
Max. 10
Max. 20
Max. 1,200
Max. 1,800
Max. 60
Max. 90
Max. 165
Max. 250
Max. 50
Max. 75
Hydraulic drift of work equipment
Work equipment
Total work equipment

(hydraulic drift at
tip of bucket teeth)
Boom cylinder
(amout of retraction of cylinder)
Arm cylinder
(amount of extension of cylinder)
Bucket cylinder
(amount of retraction of cylinder)

On level and flat place
Work equipment: In above measuring posture with rated load
44 kN {4,500 kg}
Engine: Stopped
Work equipment control lever:
Neutral
Start measuring just after setting machine and measure
every 5 minutes for 15 minutes.
mm
PC600-8
SEN00395-04
PC600-8

Engine: High idle
Working mode: P
Measure time taken to
move bucket between
DUMP stroke end and
CURL stroke end (including
operating time of cylinder
cushion).
RAISE
Bucket speed

Engine: High idle
Working mode: P
move arm between OUT
stroke end and IN stroke
end (including operating
time of cylinder cushion).
5.1 0.5
Max. 5.9
LOWER
Arm speed
Permissible value
3.6 0.4
Max. 4.4
IN
Work equipment speed
Work equipment
Boom speed

Engine: High idle
Working mode: P
move bucket between
RAISE stroke end and
ground touch point of
bucket (including operating
Standard value
5.3 0.5
Max. 6.3
OUT
Item
3.9 0.4
Max. 4.7
CURL
Category
PC600, 600LC-8
3.2 0.4
Max. 4.0
DUMP
Applicable model
Unit
3.2 0.4
Max. 4.1
sec.
SEN00395-04
Applicable model
Category
Item
Time lag
Work equipment
Boom time lag
Arm time lag
Pump
performance
Oil leakage
Bucket time lag
10
PC600, 600LC-8
Unit

Engine: Low idle
Working mode: P
Lower boom from RAISE stroke
end and measure time taken to
lift up front side of machine after
bucket touches ground.

Engine: Low idle
Working mode: P
Move in arm from OUT stroke
start moving arm again after it is
stopped.
sec.

Engine: Low idle
Working mode: P
Curl bucket from DUMP stroke
start moving bucket again after
it is stopped.

Engine: High idle
Relieve cylinder to be measured or travel circuit and meaCenter swivel joint
sure leakage in 1 minute.
Cylinder
Hydraulic pump
discharge amount
See following page.
Standard value
Permissible value
Max. 3
Max. 3
Max. 3
Max. 3
Max. 3
Max. 3
Max. 5
Max. 20
Max. 10
Max. 100
cc/min
l/min
See following page.
PC600-8
SEN00395-04
Applicable model
Category
Item
Unit
Standard value
Permissible value
Hydraulic oil temperature: 45

55C
Engine: High idle
Fan: 100% speed mode
rpm
1,450 50
1,450 50

55C
Fan circuit oil pressure
Engine: High idle
MPa
{kg/cm2}
13.2 18.1
{135 185}
13.2 18.1
{135 185}

55C
Fan pump EPC current
Engine: High idle
mA
490 50
490 50
Fan speed
Fan
PC600, 600LC-8
PC600-8
11
SEN00395-04
Applicable model
Category
Item
PC600, 600LC-8
Unit
Standard value
Permissible value
Performance of hydraulic pump
Discharge amount of one hydraulic pump
TVC current : 400 mA

Pump speed: At 2,000 rpm (Engine rated speed at 1,800 rpm)
Check point
Test pump
discharge
pressure
(MPa {kg/cm2}
Discharge
pressure of
other pump
(MPa {kg/cm2})
As desired
P1
P2
Average
pressure
(MPa {kg/cm2})
Standard value
for discharge
amount Q
(l/min)
Judgement
standard lower
limit Q
(l/min)
P1 + P2
2
See graph
See graph
P=
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when
measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
12
PC600-8
SEN00395-04

Applicable model
Engine speed
Category
Item
PC600, 600LC-8
Unit
Standard value
Permissible value
Min. 1,780
Min. 1,780
All pumps at relief

Engine at high idle
Working mode: P
Boom RAISE relief
High idle-cut ON
Engine at high idle

Auto-deceleration switch OFF
1,750 100
1,750 100
Auto-deceleration
ON
Engine at high idle

Auto-deceleration switch ON
1,400 100
1,400 100
16 0.5
16 0.5
79 10
85 10
N o IN, OUT
79 10
85 10
N o CURL,
DUMP
79 10
85 10
N o R.H., L.H.
79 10
85 10
N o F, R
(L.H., R.H.)
115 12
115 12
Work equipment,
swing, travel
Max. 10
Max. 15
16.7 3.9
{1.7 0.4}
Max. 25.5
{Max. 2.6}
16.7 3.9
{1.7 0.4}
Max. 25.5
{Max. 2.6}
13.7 2.9
{1.4 0.3}
Max. 22.6
{Max. 2.3}
13.7 2.9
{1.4 0.3}
Max. 22.6
{Max. 2.3}
Lever
24.5 5.9
{2.5 0.6}
Max. 39.2
{Max. 4.0}
Pedal
74.5 18.6
{7.6 1.9}
Max. 107.6
{Max. 11}
rpm
Boom Lo control valve
Spool stroke
Boom Hi control valve

Arm Lo control valve
Arm Hi control valve
Stroke of each side
Bucket Lo control valve
Bucket Hi control valve
Swing control valve
Travel control valve
N o RAISE,
LOWER
Travel of control levers
Boom control lever

Arm control lever
Swing control lever
Play of control levers
Center of
lever knob
Read max.
value to end
of travel
(Exclude play
at neutral.)
Engine
stopped
mm
Operating effort of control levers
Boom control lever

Arm control lever
Engine at high idle

Center of lever knob
Measure max. value to end of
travel
Swing control lever
Travel control lever,

pedal
PC600-8
N {kg}
13
SEN00395-04
Applicable model
Category
Item
PC600, 600LC-8
Unit
RAISE
Normal
29.42 +1.47
0.98
29.42 +1.47
0.98
{300 +15
10 }
{300 +15
10 }
34.32 +1.47
0.98
34.32 +1.47
0.98
{350 +15
10 }
(When Boom Raise
is single)
Normal
15.69 1.96
{160 20}
15.69 1.96
{160 20}
At machine
push-up
27.95 1.96
{285 20}
27.95 1.96
{285 20}
29.42 +1.47
0.98
29.42 +1.47
0.98
{300 +15
10 }
{300 +15
10 }
29.42 +1.47
0.98
29.42 +1.47
0.98
{300 +15
10 }
{300 +15
10 }
28.42 +1.47
0.98
28.42 +1.47
0.98
{290 +15
10 }
{290 +15
10 }
24.52 0.98
+1.47
24.52 +1.47
0.98
{250 +15
10 }
{250 +15
10 }
29.91 0.98
{305 10}
29.91 0.98
{305 10}
35.3 1.47
{360 15}
35.3 1.47
{360 15}
Bucket relief pressure
Bottom dump relief

pressure
Control pressure
LOWER
Hydraulic oil
temperature:
Engine at high
idle
Working
mode: P
Pump outlet
pressure
when measured circuit is
relieved
Relieve either
travel circuit.
Normal
At power max.
Normal
At power max.
Open
Arm relief pressure
L mode
Normal
Close
Hydraulic pressure
Permissible value
{350 +15
10 }
(When Boom Raise
is single)
Boom relief pressure
14
At power
max.
Standard value
Normal

Engine at high idle
MPa
{kg/cm2}
+0.39
3.14 0
{32 +4
0}
+0.39
3.14 0
{32 +4
0}
PC600-8
SEN00395-04
Applicable model
Category
Item
TVC valve output

pressure
Hydraulic pressure
CO-NC valve output

pressure
Swing
Jet sensor output

differential pressure
PC600, 600LC-8
Hydraulic oil
temperature:
Engine at high
idle
Working
mode: P
Hydraulic oil
temperature:
Engine at high
idle
Working
mode: P
When track
runs idle,
measure oil
pressure on
idle side.
Hydraulic oil
temperature:
Engine at high
idle
Working
mode: P
All control
levers at
neutral
Standard value
Permissible value
2.25 0.2
{23 2}
Min. 1.76
{Min. 18}
+0.20
1.05 0.53
{11.2 5.4 }
+2.0
{10.7 5.4 }
Max. 0.4
{Max. 4}
Max. 0.55
{Max. 5.5}
1.10 0.53
Boom RAISE
relief (Normal)
All control
levers at
neutral
+0.20
+2.0
+0.20
1.05 0.53
{11.2 5.4 }
+2.0
{10.7 5.4 }
Min. 1.7
{Min. 17}
Min. 1.7
{Min. 17}
All control
levers at neutral
1.76 0.2
{18 2}
Min. 1.5
{Min. 15}
Travel under no
load (Lever at
stroke end)
Max. 0.2
{Max. 2}
Max. 0.2
{Max. 2}
+0.54
2.9 0.15
{30 1.5 }
+5.5
{30 1.5 }
Max. 2.0
{Max. 20}
Max. 2.9
{Max. 30}
Max. 45
(Max. 775)
Max. 60
(Max. 1,040)
1.10 0.53
Boom RAISE
relief (Normal)
Travel under no
load (Lever at
stroke end)
PPC valve output

pressure

Engine at high idle
Control lever at stroke end
Oil pressure drop

Difference between relief pressure at high idle and that at low
idle
Overrun when stopping Hydraulic oil temperature:

swing
Bucket: No load
Engine at high idle
Working mode: P
Stop after swinging one turn
and measure distance that
swing circle moves
PC600-8
Unit
MPa
{kg/cm2}
2.9 0.15
deg.
(mm)
+0.20
+2.0
+0.54
+5.5
15
SEN00395-04
Applicable model
Category
Item
PC600, 600LC-8
Unit
Standard value
Permissible value
4.0 0.5
Max. 4.9
5.8 0.7
Max. 7.2
sec.
34 38
Max. 40
mm
l/min
Max. 5
Max. 10
90
Time taken to start

swing
Swing
Time taken to swing

range
Bucket: No load
Engine at high idle
Working mode: P
Time taken to swing 90
and 180 from starting
position
sec.
180

Bucket: No load
Engine at high idle
Working mode: P
Swing one turn, then measure
time taken to swing next 5 turns

Hydraulic drift of swing
Engine stopped
Set machine on 15 slope, and
set upper structure at 90 to the
side.
Make match marks on inner
race and outer race of circle.
Measure distance that match
marks move apart after 5 minutes.
Leakage from swing

motor
16

Engine at high idle
Swing lock switch: ON
Leakage in 1 minute during
swing relief
PC600-8
SEN00395-04
Applicable model
Category
Item
PC600, 600LC-8
Unit
Standard value
Permissible value
STD: 54 66
LC: 57 70
STD: 54 66
LC: 57 70
Hi
STD: 35 43
LC: 37 46
STD: 35 43
LC: 37 46
Lo
23 31
23 31
15 19
15 19
Max. 200
Max. 220
Lo
Travel speed
(Free rotation)
Travel
Travel speed
(Actual travel)
Travel deviation
PC600-8

range
Engine at high idle
Working mode: P
Raise track on one side
at a time, rotate one turn,
then measure time taken
for next 5 turns with no
load.

Engine at high idle
Working mode: P
On flat place
Run up for at least 10 m,
and measure time taken
to travel next 20 m on flat
ground.
sec.
sec.
Hi

Engine at high idle
Working mode: P
Travel speed: Lo
On hard and flat place
Measure travel deviation (x) in
travel of 20 m after running up
10 m.
mm
17
SEN00395-04
Applicable model
Category
PC600, 600LC-8
Unit
Standard value
Permissible value
Hydraulic drift of travel

Engine stopped
Stop machine on 12 slope with
sprocket at uphill end of
machine.
Measure the distance the
machine moves in 5 minutes.
mm
l/min
Max. 10
Max. 20
Max. 1,500
Max. 1,800
Max. 150
Max. 230
Max. 30
Max. 45
Max. 8
Max. 12
Travel
Item
Leakage of travel
motor

Engine at high idle
Travel: Lock sprocket.
Measure leakage in 1 minute
during travel relief.
Hydraulic drift of work equipment
Work equipment
Total work equipment

(hydraulic drift at
tip of bucket teeth)
Boom cylinder
(amout of retraction of cylinder)
Arm cylinder
(amount of extension of cylinder)
Bucket cylinder
(amount of retraction of cylinder)
18

On level and flat place
Work equipment: In above measuring posture with rated load
70 kN {7,200 kg}
Engine: Stopped
Work equipment control lever:
Neutral
Start measuring just after setting machine and measure
every 5 minutes for 15 minutes.
mm
PC600-8
SEN00395-04
RAISE
5.5 0.6
Max. 6.8
LOWER
4.0 0.4
Max. 5.2
IN
Engine: High idle
Working mode: P
move arm between OUT
stroke end and IN stroke
end (including operating
Unit
4.5 0.5
Max. 5.9
2.7 0.3
Max. 3.6
2.2 0.2
Max. 2.8
2.5 0.3
Max. 3.4
4.0 0.4
Max. 5.0
4.0 0.4
Max. 2.8
OUT
Work equipment speed
Work equipment
Arm speed
Permissible value
OPEN
Boom speed

Engine: High idle
Working mode: P
move bucket between
RAISE stroke end and
ground touch point of
bucket (including operating
Standard value
CLOSE
Item
CURL
Category
PC600, 600LC-8
DUMP
Applicable model
sec.
Bottom speed
Engine: High idle
Bucket speed
PC600-8

Engine: High idle
Working mode: P
move bucket between
DUMP stroke end and
CURL stroke end (including
operating time of cylinder
cushion).
19
SEN00395-04
Applicable model
Category
Item
PC600, 600LC-8
Unit
Boom time lag
Standard value
Permissible value
Max. 3
Max. 3
Max. 3
Max. 3
Max. 3
Max. 3
Time lag
Work equipment

Engine: Low idle
Working mode: P
Lower boom from RAISE stroke
lift up front side of machine after
bucket touches ground.
Arm time lag

Engine: Low idle
Working mode: P
Move in arm from OUT stroke
start moving arm again after it is
stopped.
Bucket time lag
sec.

Engine: Low idle
Working mode: P
Curl bucket from DUMP stroke
start moving bucket again after
it is stopped.
20
PC600-8
SEN00395-04
Applicable model
Time lag
Item
Fan
Pump
performance
Oil leakage
Work equipment
Category
Bottom time lag
PC600, 600LC-8
Unit
Standard value
Permissible value
sec.
Max. 3
Max. 3
Max. 5
Max. 20
Max. 10
Max. 100

Engine: Low idle
Close bottom in full open state
and measure time taken to start
moving bottom again after it is
stopped.
Engine: High idle
Relieve cylinder to be measured or travel circuit and meaCenter swivel joint
sure leakage in 1 minute.
Cylinder
Hydraulic pump
discharge amount
See following page.
Fan speed

55C
Engine: High idle
cc/min
l/min
See following page.
rpm
1,450 50
1,450 50

55C
Fan circuit oil pressure
Engine: High idle
MPa
{kg/cm2}
13.2 18.1
{135 185}
13.2 18.1
{135 185}

55C
Fan pump EPC current
Engine: High idle
mA
490 50
490 50
PC600-8
21
SEN00395-04
Applicable model
Category
Item
PC600, 600LC-8
Unit
Standard value
Permissible value
Performance of hydraulic pump
Discharge amount of one hydraulic pump
TVC current : 400 mA

Pump speed: At 2,000 rpm (Engine rated speed at 1,800 rpm)
Check point
Test pump
discharge
pressure
(MPa {kg/cm2}
Discharge
pressure of
other pump
(MPa {kg/cm2})
As desired
P1
P2
Average
pressure
(MPa {kg/cm2})
Standard value
for discharge
amount Q
(l/min)
Judgement
standard lower
limit Q
(l/min)
P1 + P2
2
See graph
See graph
P=
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when
measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
22
PC600-8
PC600-8
SEN00395-04
23
SEN00395-04

2009 KOMATSU
All Rights Reserved
24
SEN00444-04
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

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

Test, measurement item
Symbol
Measuring intake air

pressure (boost
pressure)
Measuring exhaust
temperature
Measuring exhaust gas

color
Qty
799-201-2220
Hose
799-101-1502
Digital thermometer
1 99.9 1,299 C
799-201-9001
Handy smoke checker
Commercially
available
Smoke meter
Commercially
available
Clearance gauge
1 (Intake: 0.35 mm, Exhaust: 0.57 mm)
795-502-1590
Compression gauge
1 0 7 MPa {0 70 kg/cm2}
795-471-1330
Adapter
1 For 140E-5 engine
6261-71-615A
Gasket
1 For 140E-5 engine
799-201-1504
Blow-by checker
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
1 Pressure gauge: 60 MPa {600 kg/cm2}
799-401-2320
Gauge
Pressure gauge: 1 MPa {10 kg/cm2}
799-101-5002
Hydraulic tester
Pressure gauge: 2.5, 6, 40, 60 MPa

{25, 60, 400, 600 kg/cm2}
790-261-1204
799-401-2320
Gauge
795-471-1450
Adapter
1 8 1.25 o R1/8
07005-00812
Seal washer
6151-51-8490
Spacer
1 Inside diameter: 14 mm
6206-71-1770
Joint
1 Inside diameter of joint: 10 mm
Commercially
available
Hose
1 5mm 2 3 m
J 4
Commercially
available
Hose
1 15mm 2 3 m
Commercially
available
Measuring cylinder
Commercially
available
Stopwatch
Commercially
available
Dial gauge
1 With magnet
799-101-5002
Hydraulic tester
790-261-1204
799-101-5002
Hydraulic tester
790-261-1204
1 101 200 kPa {760 1,500 mmHg}
Bosch index: 0 9
Measuring blow-by
pressure
1
G
2
1
Measuring fuel pressure
2
3
Testing leakage from

pressure limiter and
return rate from injector
Measuring clearance of
swing circle bearing
Testing and adjusting in

work equipment, swing,
and travel circuit oil
pressures
Testing and adjusting

control circuit oil pressure
Remarks
Boost gauge kit
Measuring engine oil

pressure
Testing EGR valve and
bypass valve drive oil
pressure
Part name
799-201-2202
Adjusting valve
clearance
Measuring compression
pressure
Part No.

{25, 60, 400, 600 kg/cm2}

{25, 60, 400, 600 kg/cm2}

{25, 60, 400, 600 kg/cm2}
PC600-8
SEN00444-04
Symbol
Part No.
Part name
Qty
Remarks
799-101-5002
Hydraulic tester

{25, 60, 400, 600 kg/cm2}
790-261-1204
799-401-2701
Differential pressure
gauge
799-101-5220
Nipple
07002-11023
O-ring
799-401-3200
Adapter
2 Size: 03
708-25-14140
Cap
07000-B2065
O-ring
566-98-41120
Disc gauge
799-101-5002
Hydraulic tester

{25, 60, 400, 600 kg/cm2}
790-261-1204
799-401-3200
Adapter
1 Size: 03
799-101-5002
Hydraulic tester

{25, 60, 400, 600 kg/cm2}
790-261-1204
799-401-3200
Adapter
1 Size: 03
799-205-1100
Multiple tachometer
799-101-5002
Hydraulic tester

{25, 60, 400, 600 kg/cm2}
799-261-1204
1
Testing and adjusting
piston pump control oil
pressure
N 2
3
4
Testing servo piston

stroke
1
P
2
Measuring PPC valve

output pressure
2
Measuring outlet
pressure of solenoid
valve and PPC shuttle
valve
For HPV95 + 95 pump
1
Q
1
R
2
Measuring fan speed
Measuring fan circuit oil

pressure
Size: 10 1.25 mm
Measuring oil leakage
Commercially
available
Measuring cylinder
Measuring wear of
sprocket
796-627-1140
Wear gauge
1 Same as PC600, 600LC-7
Measuring water
temperature and oil
temperature
799-101-1502
Digital thermometer
1 99.9 1,299 C
Measuring operating
effort and pressing force
79A-264-0021
Push-pull scale
1 0 294 N {0 30 kg}
79A-264-0091
Push-pull scale
1 0 490 N {0 50 kg}
Measuring stroke and

hydraulic drift
Commercially
available
Scale
Measuring work
equipment speed
Commercially
available
Stopwatch
Measuring voltage and

resistance
Commercially
available
Multimeter
PC600-8
SEN00444-04
Symbol
Part No.
799-601-4101
or
799-601-4201
T-adapter
799-601-4211
T-adapter
1 Engine controller
799-601-4220
T-adapter
1 Engine controller
799-601-9020
T-adapter
1 Ambient pressure sensor
799-601-4240
Socket
1 For 16 A
Commercially
available
Deep socket (21mm)

(MITOLOY 4ML-21 or
equivalent)
Applicable engine serial
No.:
530001-534132
Deep socket (19mm)

(MITOLOY 4ML-19 or
795T-981-1010 equivalent)
Applicable engine serial
No.: 534133 and up
799-601-4101
or
799-601-4201
or
799-601-9000
or
799-601-9100
or
799-601-9200
T-adapter assembly
799-601-9020
Adapter for DT
For DT2P
(Does not include 799-601-9100)
799-601-9030
Adapter for DT
For DT3P (Does not include 799-6014101, 799-601-4201 and 799-601-9100)
799-601-9050
Adapter for DT
For DT6P (Does not include 799-6014101, 799-601-4201 and 799-601-9100)
799-601-9110
Adapter for DT (GR)
For DT12GRP
(Does not include 799-601-4101,
799-601-4201 and 799-601-9100)
799-601-9120
Adapter for DT (B)
For DT12BP
1 (Does not include 799-601-4101,
799-601-4201 and 799-601-9100)
799-601-9130
Adapter for DT (G)
For DT12GP
1 (Does not include 799-601-4101,
799-601-4201 and 799-601-9100)
799-601-9240
T-adapter for HD30
799-601-7000
or
799-601-7100
or
799-601-7400
or
799-601-8000
T-adapter assembly
Troubleshooting for
engine controller /
sensors / actuators
Troubleshooting for
chassis / sensors / wiring
harnesses
Part name
Qty
Remarks
For coolant temperature sensor
For HD30 (Does not include 799-6014101,

799-601-4201 and 799-601-9200)
PC600-8
SEN00444-04
Troubleshooting for
chassis / sensors / wiring
harnesses
PC600-8
Symbol
Part No.
799-601-7010
Part name
Qty
Remarks
Adapter for X
For X1P (Does not include 799-601-7000

and 799-601-7100)
799-601-7020
Adapter for X
1 For X2P
799-601-7040
Adapter for X
1 For X4P
799-601-7060
Adapter for SWP
799-601-7210
Adapter for 040
1 For A16P
799-601-7080
Adapter for M
799-601-7090
Adapter for M
1 For M2P
799-601-7110
Adapter for M
1 For M3P
799-601-7120
Adapter for M
1 For M4P
799-601-7130
Adapter for M
1 For M6P
799-601-7140
Adapter for S
1 For S8P
799-601-7160
Adapter for S
799-601-7170
Adapter for S
1 For S16P
799-601-7520
T-adapter assembly
799-601-8000
Adapter for 070
1 For 070-12P
For SW8P
(Does not include 799-601-8000)
For M1P (Does not include 799-601-7000

and 799-601-7100)
For S12P (Does not include 799-6018000)
SEN00444-04
Socket
PC600-8
Measuring engine speed

a Measure the engine speed under the following
condition.
Engine coolant temperature: Within operating range
range
1. Preparation work
Turn the starting switch ON and set the machine
monitor to Monitoring.
a For the operating method, see Special function of machine monitor.
a Monitoring code: 01002 Engine speed
01006 Engine speed
a Code 01002 is information of the engine controller and code 01006 is information of the
pump controller. The engine speed can be
measured with either of those codes.
a The engine speed is displayed in rpm.
SEN00444-04
4. Measuring all-pump relief speed
1) Start the engine and set the fuel control dial
in the high idle position (MAX).
2) Set the working mode switch in the P mode
position.
3) Relieve the boom circuit by raising the boom
and measure the engine speed.
5. Measuring power max. ON + all-pump relief
speed
position.
3) While relieving the boom circuit by raising
the boom and holding the power max.
switch, measure the engine speed.
a The power max. function is reset automatically in about 8.5 seconds even if the switch
is kept held. Accordingly, measure the engine speed in that period.
6. Measuring high idle-cut ON speed
2) Turn the auto-deceleration switch OFF.
3) Set the work equipment control, swing control, and travel levers in neutral and measure the engine speed when the high idle-cut
function is turned ON.
a The engine speed lowers to a certain level
approx. 4 seconds after all the control levers
are set in neutral. This level is the high idlecut ON speed.
2. Measuring low idle speed

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
2) Set the working mode switch to the P mode
position.
3) Turn the auto-deceleration switch OFF.
4) Turn the swing lock switch ON, release the
lock lever, and measure the engine speed
while operating the swing control lever
finely.
a Operate the swing control lever to a degree that the PPC oil pressure switch is
turned ON. Do not relieve the swing.
PC600-8
7. Measuring auto-deceleration ON speed

2) Turn the auto-deceleration switch ON.
3) Set the work equipment control, swing control, and travel levers in neutral. When the
auto-deceleration operates, measure the
engine speed.
a The engine speed lowers to a certain level
about 6 seconds after all the levers are set in
neutral. This level is the auto-deceleration
speed.
SEN00444-04
Measuring intake air pressure

(boost pressure)
a Tools for measuring intake air pressure (boost
pressure)
Symbol
Part No.
799-201-2202
Part name
Boost gauge kit
a When installing and removing the measuring

tools, take care not to touch a hot part of the
engine.
a Measure the intake air pressure (boost pressure) under the following condition.
range
4. Run the engine at a medium or higher speed

and drain the oil from the hose.
a Insert the connecting parts of the gauge and
hose about a half and open the self-seal on
the hose side repeatedly, and the oil will be
drained.
a If Pm kit A is available, the air bleed coupling
(790-261-1130) inside the kit can also be
used.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
5. Set the working mode switch to P mode and turn
the power max. switch ON.
6. Run the engine at high idle and measure the
intake air pressure (boost pressure) when the
boom RAISE circuit is relieved.
1. Open the engine hood.

2. Remove intake air pressure measurement plug
(1) at turbocharger outlet tube.
7. After completing the measurement, remove the

measuring tools and set to the original condition.
3. Install nipple [1] of boost gauge kit A and connect gauge [2].
10
PC600-8
SEN00444-04
Measuring exhaust gas

temperature
a Tools for measuring exhaust gas temperature
Symbol
Part No.
799-101-1502
4. Install sensor [1] of digital thermometer B and

connect them to meter [2].
a Clamp the wiring harness of the digital thermometer so that it does not touch any high
temperature part during the measurement.
Part name
Digital thermometer
k Wait for the temperature of the exhaust manifold

to go down before installing and removing the
measuring tools.
a Measure the exhaust gas temperature under the
following conditions.
range
1. Open the engine hood.
2. Remove heat insulation cover (1).
5. Procedure for measuring maximum exhaust gas

temperature for troubleshooting
Operate the machine actually and measure the
maximum exhaust gas temperature.
a Set the digital thermometer in the PEAK
mode.
6. Procedure for measuring exhaust gas temperature periodically for preventive maintenance (Pm
Clinic), etc.
position and turn the power max. switch ON.
2) Run the engine at high idle and measure the
exhaust gas temperature when boom
RAISE circuit is relieved.
a Measure the exhaust gas temperature
after it is stabilized.
3. Remove exhaust gas temperature measurement plug (2).

PC600-8
11
SEN00444-04
Measuring exhaust gas color

a Tools for measuring exhaust gas color
Symbol
Part Number
799-201-9001
Handy smoke checker
Commercially
available
Smoke meter
Part name
k Be careful not to touch hot areas when installing

and removing the measuring tools.
a When air source or electric power supply is not
available in field, use C1 handy smoke checker,
but use C2 smoke meter, when recording official
data.
a Measure exhaust gas color under the following
conditions:
Engine coolant temperature: Within the operating range.
1. Measurement with C1, Handy Smoke Checker
1) Set a filter paper in the handy smoke
checker C1.
2) Insert the exhaust gas suction port in the
exhaust pipe (1).
3) Start the engine.
4) Operate the handle of the smoke checker
C1, and adhere exhaust gas to the filter
paper when accelerating the engine quickly
or at a high idle.
5) Remove the filter paper and compare the

color on the filter paper with the accessory
scale.
6) After the measurement, remove the measuring tools and return the engine to the original state.
2. Measurement with Smoke Meter C2
1) Insert the probe [1] of the smoke meter C2,
in the outlet of the exhaust pipe (1) and fix it
to the exhaust pipe with clip.
12
2) Connect the probe hose, the receptacle of

the accelerator switch and the air hose to
the smoke meter C2.
a The supply air pressure shall be less
than 1.5 MPa {15 kg/cm2}
3) Connect the power cord to power receptacle.
a Before connecting the power cord, make
sure that the power switch of the smoke
meter is turned off.
4) Loosen the cap nut of the suction pump and
set a filter paper there.
a Set the filter paper accurately so that exhaust gas does not leak out.
5) Turn on the power switch of the smoke
meter C2.
6) Start the engine.

7) When accelerating the engine quickly or at a
high idle, step down the accelerator pedal of
the smoke meter C2, and collect exhaust
gas in the filter paper.
8) Place the filter paper contaminated with
exhaust gas on new filter papers (more than
10 sheets) in the filter paper holder and read
the indicated value.
9) After completing the measurement, remove
the measuring tools and set to the original
condition.
PC600-8
SEN00444-04
Adjusting valve clearance

a Tools for adjusting valve clearance
Symbol
Part No.
Commercially
available
Part name
Clearance gauge
1. Open the engine hood and remove all the heat

insulation covers.
2. Remove all the cylinder head covers (1).
3. Rotate the crankshaft in the normal direction to

align [1.6 TOP] line (a) on the damper with
pointer (2), and set the No.1 cylinder to the compression top dead center.
a Check the pointer from the alternator side.
a Crank the engine with the hexagonal part at
the water pump drive shaft on the alternator
side.
a At the compression top dead center, the
rocker arm of the No. 1 cylinder can be
moved by hand an amount equal to the valve
clearance. If the rocker arm does not move,
it is not at the compression top dead center,
so rotate the crankshaft one more turn.
PC600-8
4. Insert clearance gauge D in the clearance

between rocker arm (5) and crosshead (6), and
turn adjustment screw (3) to adjust the valve
clearance.
a With clearance gauge D inserted, turn the
adjustment screw and adjust until the clearance is a sliding fit.
a Valve clearance
Intake valve : 0.35 mm
Exhaust valve : 0.57 mm
5. Fix adjustment screw (3) and tighten locknut (4).
3 Locknut:
45.1 51.0 Nm {4.6 5.2 kgm}
a After tightening the locknut, check the valve
clearance again.
6. Rotate the crankshaft 120 each time in the normal direction and repeat Steps 2 4 to adjust
the valve clearance of each cylinder according
to the firing order.
a Firing order: 1 5 3 6 2 4
7. After completing the adjustment, set to the original condition.
3 Cylinder head cover mounting bolt:
29.4 34.3 Nm {3.0 3.5 kgm}
13
SEN00444-04
Measuring compression
pressure
a Pass a wire, etc. under the fuel path projected sideways and pull up the injector (Do not
pry the injector top up).
a Tools for measuring compression pressure

Symbol
1
E
Part No.
Part name
795-502-1590
Compression gauge
795-471-1330
Adapter
6261-71-615A
Gasket
a When measuring the compression pressure,

take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating
part.
a Measure the compression pressure under the
following condition.
Engine oil temperature: 40 60C
1. Open the engine hood and remove all the heat
insulation covers.
2. Remove head cover (1) of the cylinder to measure the compression pressure.
5. Install adapter E2 and connect it to compression

gauge E1.
a Install gasket to the tip of adapter E2.
a Secure the adapter with the injector holder.
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so
that air will not leak easily.
6. Install rocker arm assembly (2) and adjust the
valve clearance.
3 Mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a See Adjusting valve clearance.
3. Remove rocker arm assembly (2).

a Referring to Adjusting valve clearance, set
the cylinder to be measured at the compression top dead center so that you can work
easily.
4. Disconnect fuel high-pressure tube (3) and
remove the injector wiring harness and injector
(4).
a Use a high-pressure pipe ring wrench (on
the market) to disconnect and connect the
fuel high-pressure tube. At this time, loosen
the clamps on the common rail side and at
the intermediate part.
a Disconnect the terminal of the injector wiring
harness on the injector side and the plate on
the rocker housing side and remove the injector wiring harness (Loosen the terminal
nuts alternately).
14
PC600-8
SEN00444-04
5) Tighten sleeve nut (15) of the fuel high-pressure tube securely.
3 Sleeve nut:
39.2 49.0 Nm {4 5 kgm}
6) Tighten the intermediate clamp of the fuel
high-pressure tube.
7) Install the injector wiring harness.
a Tighten the terminal nuts at the injector
top alternately.
3 Nut: 2 0.2 Nm {0.2 0.02 kgm}
7. Operate the machine monitor to set it to the noinjection cranking function.

a See No-injection cranking.
8. Turn the starting switch ON and prepare for
measuring the engine speed with the machine
monitor.
a See Measuring engine speed.
9. Crank the engine with the starting motor and
measure the compression pressure.
a Read the pressure gauge pointer when it is
stabilized.
a When measuring the compression pressure,
measure the engine speed, too, and check
that it is in the measurement condition range.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Assemble injector (11) and holder (12)
together and set them to the mounting position of the cylinder head.
a When setting the injector, pull the fuel
high-pressure tube to outside of the cylinder head so that the threads of the injector will not interfere with the taper seal
of the fuel high-pressure tube.
2) Tighten mounting bolt (13) temporarily.
a Tighten the mounting bolt to a degree
that you can move the injector.
3) Tighten sleeve nut (15) of the fuel high-pressure tube to injector (11) lightly.
a Use a high-pressure pipe ring wrench
(on the market) to disconnect and connect the fuel high-pressure tube.
a Tighten the sleeve nut lightly until it is
stopped by the injector.
4) Tighten mounting bolt (13) securely.
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
PC600-8
a After installing the rocker arm assembly, adjust the valve clearance. For details, see
Adjusting valve clearance.
3 Rocker arm assembly mounting bolt:
93 103 Nm {9.5 10.5 kgm}
29.4 34.3 Nm {3.0 3.5 kgm}
15
SEN00444-04
Measuring blow-by pressure
Measuring engine oil pressure
a Tools for measuring blow-by pressure
a Tools for measuring engine oil pressure
Symbol
Part No.
799-201-1504
Part name
Symbol
Blow-by checker
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Gauge
a Measure the blow-by pressure under the following conditions.

range
G
2
a Measure the engine oil pressure under the following conditions.

1. Remover the engine under cover (front side).

2. Install the nozzle [1] of blow-by checker F to
blow-by hose (1).
1. Remove the engine room cover (control valve

side) or under cover (front side).
3. Connect the hose [2] and gauge [3].
2. Install hose [1] of hydraulic tester G1 and connect them to gauge G2.
4. Start the engine and set the working mode

switch to the P mode position.
3. Start the engine and measure the oil pressure

with the engine at low idle and high idle.

blow-by pressure when arm IN circuit is relieved.
6. After finishing measurement, remove the measuring tools and set to the original condition.
16

3 Oil pressure switch:
2.9 5.9 Nm {0.3 0.6 kgm}
PC600-8
SEN00444-04
Testing EGR valve and bypass

a Testing instrument for EGR valve and bypass
Symbol
G
Part No.
3. Connect hydraulic testers [2] and [3] (Component part of tool G1) to the nipple [1].
4. Start the engine and measure the oil pressure at
low idle and high idle.
Part name
799-101-5002
Hydraulic tester
790-261-1204
1. Remove oil pressure pickup plug (2) from the

left side of timing gear cover (1).
2. Install nipple [1] of hydraulic tester G1 to the
hole from which the oil pressure pickup plug was
removed.
5. After finishing measurement, remove the measuring instruments and return the removed parts.
a Remove the gasket sealant remaining on the
threads of the removed plug with a wire
brush and apply new adhesive or gasket
sealant to the plug before installing.
2 Plug: LT2 or LG-5
3 Plug: 9.8 19.6 Nm {1.0 2.0 kgm}
PC600-8
17
SEN00444-04
Handling equipment in fuel

circuit
Releasing remaining pressure

in fuel system
a Precautions in inspection and maintenance of

fuel system equipment
The common rail type fuel injection system
(CRI) is composed of more precise components
than the usual fuel injection pump and nozzle
and will probably get out of order when foreign
matters enter the system.
During inspection and maintenance of the fuel
system, pay more attention to foreign matters
than in case of usual fuel injection pumps and
wash the system carefully with clean fuel if dusts
enter the system.
a While the engine is rotating, pressures occur in

the low pressure circuit and the high pressure
circuit of the fuel system.
Low pressure circuit : feed pump fuel filter
fuel supply pump
High pressure circuit : fuel supply pump common rail fuel injector
a When 30 seconds elapse after the engine
stopped, pressures in both the low pressure circuit and the high pressure circuit drop to the
safe level automatically.
a Since pressure remaining in the fuel system
should be released certainly before inspection of
the fuel system and mounting and removing of
equipment, be sure to observe the following precautions:
k Inspect the fuel system or mount or remove
equipment more than 30 seconds after the engine stopped and after pressure remaining in the
fuel system is released. (Pressure remains in the
fuel system right after the engine stopped, so do
not start any work until 30 seconds elapse.)
a Precautions in replacement of fuel filter cartridge

Be sure to use genuine fuel filter cartridge of
Komatsu.
The common rail type fuel injection system
(CRI) is composed of more precise components
than the usual fuel injection pump and nozzle
and is equipped with special filter with highly
efficient filtration performance to prevent foreign
matters from entering the system.
Therefore, be sure to use genuine filters only.
Otherwise, the fuel system will possibly get out
of order.
18
PC600-8
SEN00444-04
Measuring fuel pressure

a Tools for measuring fuel pressure
Symbol
Part No.

fuel pressure.
a If the fuel pressure is in the following range,
it is normal.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Gauge
795-471-1450
Adapter
(8 1.25 o R1/8)
07005-00812
Seal washer
Engine speed
Fuel pressure
High idle
0.15 0.3 MPa

{1.5 3 kg/cm2}
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the engine
controller cooler and fuel filter to the supply
pump.
k Since the pressure in the high-pressure circuit
from the supply pump through the common rail to
the injector is very high, it cannot be measured.
1. Remove fuel pressure measuring plug (1) on
fuel filter head.
4. After finishing testing, remove the testing tools
and return the removed parts.
2. Install adapter H3, hydraulic tester H1 (elbow)

[1] and nipple [2], and connect gauge H2.
PC600-8
19
SEN00444-04
Reduced cylinder mode operation
No-injection cranking
a Reduced cylinder mode operation means to run

the engine with the fuel injectors of 1 or more
cylinders disabled electrically to reduce the
number of effective cylinders. The purposes and
effects of this operation are as follows.
1. This operation is used to find out a cylinder
which does not output power normally (or, combustion in it is abnormal).
a No-injection cranking means to crank the engine

with the starting motor while all the injections are
stopped electrically. The purpose and effect of
this operation are as follows.
Before the engine is started after it or the machine has been stored for a long period, the noinjection cranking is performed to lubricate the
engine parts and protect them from seizure.
a See Special functions of machine monitor, noinjection cranking.
2. When a cylinder is selected for the reduced cylinder mode operation, if the engine speed and
output do not change from the normal operation
(all-cylinder operation), that cylinder has 1 or
more defects. The possible defects are as follows.
Leakage through cylinder head gasket
Defective injection
Defective piston, piston ring, or cylinder liner
Defective valve mechanism (Moving valve
system)
Defect in electrical system
3. Since the common rail fuel injection system controls the injector of each cylinder electronically,
the operator can perform the reduced cylinder
mode operation easily with switches to find out a
defective cylinder.
a See Special functions of machine monitor,
no-injection cranking.
20
PC600-8
SEN00444-04
Testing leakage from pressure limiter and return rate from injector
a Testing tools for measuring leakage and return

rate of fuel
Symbol
Part No.
Part name
6151-51-8490
Spacer
6206-71-1770
Joint
Commercially
available
Hose
Commercially
available
Hose
Commercially
available
Measuring cylinder
Commercially
available
Stopwatch
1. Preparation work
1) Remove tube (3) between common rail (1)
and supply pump (2).
2) Insert spacer J1 on supply pump (2) side
and tighten the removed joint bolt again.
a Connect the return pipe to the fuel tank
again, too.
a Be sure to fit the gaskets to both ends of
the spacer.
a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
PC600-8
21
SEN00444-04
3) Insert joint J2 on common rail (1) side and

tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends of
the joint.
4) Connect test hose J3 to the end of joint J2.
a Bind the connecting part of the test hose
with a wire, etc. to prevent it from coming
off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5) After finishing testing, stop the engine.
2. Testing leakage from pressure limiter

1) Lay test hose J3 so that it will not slacken
and put its end in the oil pan.
2) Operate machine monitor to set it so that it
can check the engine speed.
3) Start the engine and keep its speed equivalent to the rated load.
4) After the engine speed is stabilized, test the
leakage in 1 minute with measuring cylinder
J5.
a You may test for 20 seconds and judge
by multiplying the result by 3.
a If the leakage from the pressure limiter is
in the following range, it is normal.
22
Engine speed
(rpm)
Leakage
(cc/min)
Operation with
rated outout
Max. 10
3. Testing return rate from injector

a Keep the hose on the pressure limiter side
connected and keep its end in the oil pan
while testing the return rate from the injector.
1) Disconnect return hose (5) of return block
(4) and connect test hose J4.
a Stop the return hose with a plug, etc. and
fix it to the fuel tank.
Plug: 07376-70315
a Bind the connecting part of the test hose
with a wire, etc. to prevent it from coming
off.
2) Lay test hose J4 so that it will not slacken
and put its end in the oil pan.
3) Operate machine monitor to set it so that it

can check the engine speed.
4) Start the engine and keep its speed equivalent to the rated load.
PC600-8
SEN00444-04
5) After the engine speed is stabilized, test the

return rate in 1 minute with measuring cylinder J5.
a You may test for 20 seconds and judge
by multiplying the result by 3.
a If the supply pump is not supplying fuel,
the engine speed may not rise. In this
case, record the engine speed, too, during the test.
a If the return rate (spill) from the injector
is in the following range, it is normal.
Rated output
speed (rpm)
Limit of return rate

(spill) (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
Bleeding air from fuel circuit

a If fuel is used up or if a fuel circuit part is
removed and installed, bleed air from the fuel
circuit according to the following procedure.
1. Remove fuel prefilter (1) and fill it with fuel.
a Fill the fuel prefilter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a) (central
hole) of the fuel prefilter, and then add fuel
through part (b) (holes around the central
hole).
a After filling the fuel prefilter with fuel, remove
the cap from part (a).
a If clean fuel is not available, do not remove
the prefilter but fill it with the fuel by operating
priming pump (4).
a Do not add fuel to fuel main filter (2) from outside.
6) After finishing testing, stop the engine.

4. Work after finishing testing
After finishing all testing, remove the testing
tools and return the removed parts.
PC600-8
23
SEN00444-04
2. Install fuel prefilter (1) to the filter head.
a Thinly apply engine oil to the packing surface
on the fuel prefilter.
a After the packing surface on the fuel prefilter
side touches the seal surface of the filter
head, tighten the fuel prefilter by 3/4 turns.
6. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled automatically if the engine is rotated.
a If the engine does not start, there may be still
air in the low-pressure circuit. In this case,
repeat the above procedure from step 3.
3. Remove air bleeding plug (3) of the main fuel filter and operate priming pump (4).
a Operate the priming pump until fuel flows out
of the plug hole. After fuel starts flowing out,
install plug (3).
3 Air bleeding plug:
7.8 9.8 Nm {0.8 1.0 kgm}
4. Loosen air bleeding plug (5) of the main fuel filter and operate priming pump (4).
of the plug hole. After fuel starts flowing out,
install plug (5).
3 Air bleeding plug:
7.8 9.8 Nm {0.8 1.0 kgm}
5. Loosen air bleeder (6) of the fuel supply pump

and operate priming pump (4) 90 100 times.
of the bleeder. After fuel starts flowing out,
tighten the bleeder and operate the priming
pump several times until it becomes heavy.
3 Air bleeder:
4.9 6.9 Nm {0.5 0.7 kgm}
24
PC600-8
Testing fuel system for leakage
k Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel leaks while
the engine is running, it is dangerous since it can
catch fire.
After testing the fuel system or removing its
parts, test it for fuel leakage according to the following procedure.
a Clean and degrease the engine and the parts
around it in advance so that you can test it easily
for fuel leakage.
SEN00444-04
9. Inspect the fuel piping and devices for fuel leakage.
a Inspect mainly around the high-pressure circuit parts coated with the color checker for
fuel leakage.
a If any fuel leakage is detected, repair it and
inspect again from step 1.
a If no fuel leakage is detected, inspection is
completed.
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.
fuel leakage.
4. Run the engine at low idle.
fuel leakage.
6. Run the engine at high idle.
fuel leakage.
8. Run the engine at high idle and load it, and
relieve the oil from the hydraulic pump.
PC600-8
25
SEN00444-04
Testing and adjusting alternator

belt tension
Testing
Press the intermediate point of the belt between
alternator pulley and drive pulley with a finger and
measure deflection (a) of the belt.
a Pressing force: Approx. 98 N {Approx. 10 kg}
a Deflection (a): 13 16 mm (1 piece)
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
1. Loosen mounting bolts (2) and (3) of alternator
(1), and then loosen locknut (4).
2. Move alternator (1) with adjustment nut (5) to
adjust the tension of belt (6).
3. Tighten locknut (4), and then tighten mounting
bolts (3) and (2).
a After adjusting, test the belt tension again.
26
PC600-8
Testing and adjusting air

conditioner compressor belt
tension
SEN00444-04
3. Tighten nuts and bolts (4), (3), (2) and (1) in this
order.
a When the belt was replaced, readjust it after
1 hour operation.
Testing
1. Open the engine hood and remove the insulation cover on the air conditioner compressor
side.
2. Measure the belt deflection (a) when pushing a
point midway between the air conditioner compressor pulley and drive pulley with a finger.
a Deflection (a) when pressing force is approx.
58.8 N {approx. 6 kg}: 10 15 mm
Adjusting
a Adjust the belt tension according to the following
procedure when the belt deflection is not normal.
1. Loosen the mounting bolts (1) and (2), locknut
(3).
2. Turn adjusting nut (4) to move compressor (5)
and adjust the belt tension.
a If nut (4) is:
Tightened clockwise, the belt is loosened.
Loosened counterclockwise, the belt is
tensed.
a Check each pulley for breakage, check the
V-grooves and V-belts for wear, and check
that the V-grooves and V-belts are in good
contact with each other.
a If the belts are so lengthened that their tension cannot be adjusted any more or they
have a cut or a crack, replace them.
PC600-8
27
SEN00444-04
Testing clearance of swing

circle bearing
a Tools for testing clearance of swing circle bearing
Symbol
Part No.
Commercially
available
Part name
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.
Dial gauge
(with magnet)
a When measuring swing circle bearing clearance

on a machine, follow the procedures below:
a For the standard values, see Structure, function
and maintenance standard, Swing circle.
1. Fix the dial gauge K to the track frame (center
frame) and bring the stylus to the outer race end
face.
a Set the dial gauge to the front or to the rear.
5. At the time, read the value on the dial gauge K.

This value on the dial gauge indicates the swing
circle bearing clearance.
k During the measurement, never place hands

and legs below the undercarriage.
6. Return the work equipment to the state in Paragraph 2 and make sure that the dial gauge K
has returned to the zero point. If not, repeat
Steps 2 to 5.
2. Set the work equipment to the maximum reach
and set the bucket tip to the height of the revolving frame lower face.
a At the time, the front of the upper structure
lowers and its rear rises.
28
PC600-8
SEN00444-04
Testing and adjusting track

shoe tension
Adjusting
a If the track shoe tension is not proper, adjust it in
the following manner.
Testing
1. Travel the machine forward by the length of
track on ground, keeping the engine at low idle,
and stop the machine slowly.
1. When the tension is too strong

Discharge grease by loosening valve (3).
2. Place steel bar [1] on the track shoe between

second carrier roller (1) and third carrier roller
(2).
a L beam is recommended for bar [1], because
of its deflection-free nature.
3. Measure max. clearance (a) between bar [1]
and the track shoe.
Max. standard clearance (a): 10 30 mm
PC600-8
k Do not loosen valve (3) more than one turn,

because grease will spurt due to its internal
high pressure.
2. When the tension is too weak

Add grease through grease fitting (4).
a If the normal track shoe tension is not restored even after greasing, move the machine slowly back and forth.
29
SEN00444-04
Testing and adjusting work

equipment, swing, and travel
circuit oil pressures
a Tools for testing and adjusting work equipment,
swing, and travel circuit oil pressures
Symbol
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Measuring
a Measure the work equipment, swing and travel
circuit oil pressures under the following conditions:
range
a The work equipment, swing, and travel circuit oil
pressures can be checked in the monitoring
function of the machine monitor, too. (For the
operating method, see Special function of
machine monitor panel.)
Monitoring code: 01100 F pump pressure
01101 R pump pressure
The pump oil pressure is displayed in
0.1 MPa (1 kg/cm2, 1 PSI).
1. Preparation work
k Lower the work equipment to the ground and

stop the engine. Operate the control levers
several times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release
the internal pressure of the hydraulic tank.
1) Open the pump compartment cover (both
front and rear end).
2) Connect oil pressure gauges [1] of hydraulic
tester L to quick couplers (1) and (2)
installed to the outlet of each pump of the
circuit to be measured.
30
a Use quick coupler (2) to measure the

rear pump (No. 1 R + No. 2 R) circuit oil
pressure.
a Use quick coupler (1) to measure the
front pump (No.1F + No.2F) circuit oil
pressure.
a The relief pressure of the boom LOWER
circuit can be measured only in the front
pump circuit.
a The relief pressure of the bucket DUMP
circuit can be measured only in the rear
pump circuit.
a The relief pressure of the swing circuit
can be measured only in the front pump
circuit.
a Use the oil pressure gauges of 60 MPa
{600 kg/cm2}.
2. Measuring work equipment circuit oil pressure

1) Measuring normal relief pressure
i) Start the engine and set the working
mode switch to the A mode position.
ii) Run the engine at high idle, relieve each
cylinder singly at the stroke end, and
measure the oil pressure.
a The main relief valves of the control
valve (left and right) relieve on the lowpressure setting side.
a If the boom cylinder is relieved at the
LOWER stroke end, the safety-suction
valve on the boom head side of the right
side 4-spool control valve relieves on the
low-pressure setting side (The set pressure of the safety-suction valve is lower
than that of the main relief valve).
PC600-8
2) Measuring relief pressure during L mode

mode switch in the L mode position.
ii) Run the engine at high idle, relieve the
boom cylinder singly at the RAISE stroke
end, and measure the oil pressure.
a The main relief valves of the control
valve (left and right) relieve on the highpressure setting side.
3) Measuring relief pressure during machine
push-up operation
mode switch in the P mode position.
ii) Turn the machine push-up switch ON.
iii) Run the engine at high idle, relieve the
boom cylinder singly at the LOWER
stroke end, and measure the oil pressure.
a Since the set pressure of the safety-suction valve on the boom head side of the
right side 4-spool valve rises higher than
the set pressure of the main relief valve,
the main relief valve relieves on the lowpressure setting side.
4) Measuring relief pressure during one-touch
power max. operation
mode switch in the P mode position.
ii) Run the engine at high idle, relieve each
work equipment cylinder singly at the following stroke end, press the one-touch
power max. switch, and measure the oil
pressure.
Boom: RAISE stroke end
Arm: IN stroke end
Bucket: CURL stroke end
a The one-touch power max. function is reset
automatically in about 8.5 seconds even if
the switch is kept held. Accordingly, measure the engine speed in that period.
PC600-8
SEN00444-04
3. Measuring swing circuit oil pressure
1) Start the engine and set the working mode
switch in the P mode position.
2) Turn the swing lock switch ON.
3) Run the engine at high idle, relieve the
swing motor, and measure the oil pressure.
a The safety valves of the front and rear swing
motors relieve. (The set pressure of the
safety valves is lower than that of the main
relief valve.)
4. Measuring travel circuit oil pressure

1) Start the engine and lock the travel mechanism.
k Put pin [2] between the sprocket and

track frame to lock the travel mechanism securely.
31
SEN00444-04
2) Run the engine at high idle, relieve the
travel motor, and measure the oil pressure.
a The main relief valves of the control valve
(left and right) relieve on the high-pressure
setting side.
4) Turn holder (7) to adjust the pressure.

a If the holder is:
Turned to the right, the pressure rises.
Turned to the left, the pressure lowers.
a Pressure changed by 1 turn of holder:
12.5 MPa {128 kg/cm2}
5) Fix holder (7) and tighten locknut (8).
3 Locknut:
93.2 122.6 Nm {9.5 12.5 kgm}
a If the high-pressure setting side is adjusted, the low-pressure setting side
changes. Accordingly, adjust the lowpressure setting side, too.
Adjusting
a Do not adjust any safety valve other than the
swing motor safety valve.
a When adjusting the main relief valves of the left
side 4-spool valve and right side 5-spool valve,
remove the control valve top cover.
1. Adjusting main relief valve (high-pressure
setting) of right side 5-spool control valve
a If the work equipment oil pressure in the front
pump circuit (during L mode) and the L.H.
travel oil pressure are abnormal, adjust the
high-pressure setting side of main relief
valve (3) of the right side 5-spool control
valve according to the following procedure.
a The high pressure setting is the state in

which the 2-stage relief solenoid valve is
turned ON and the pilot pressure is applied
to the changeover port.
1) Disconnect hose (4).
2) Loosen locknut (5) and set elbow (6) free.
3) Fix holder (7) and loosen locknut (8).
32
6) Fix elbow (6) and tighten locknut (5).

7) Connect hose (4).
8) After completing the adjustment, check the
oil pressure again according to the above
described measurement procedure.
2. Adjusting main relief valve (low-pressure setting) of right side 5-spool control valve
If the work equipment oil pressure in the front
pump circuit (during normal relief operation)
is abnormal or the high-pressure setting side
was adjusted, adjust the low-pressure setting side of main relief valve (3) of the right
side 5-spool control valve according to the
If the left travel oil pressure and power maximizing oil pressure are abnormal, adjust the
low-pressure setting of main relief valve (3)
of the right side 5-spool control valve according to the following procedure.
a The low-pressure setting is the state in which
the 2-stage relief solenoid valve is turned
OFF and the pilot pressure is not applied to
the changeover port.
2) Loosen locknut (5) and set elbow (6) free.
3) Fix union (9) and loosen locknut (10).
4) Turn union (9) to adjust the pressure.
a If the union is:
PC600-8
SEN00444-04
a Pressure changed by 1 turn of union:

12.5 MPa {128 kg/cm2}
5) Fix union (9) and tighten locknut (10).
3 Locknut:
39.2 49.0 Nm {4.0 5.0 kgm}
4. Adjusting main relief valve (low-pressure setting) of left side 4-spool control valve
1) If the work equipment oil pressure in the
rear pump circuit (during normal relief operation) is abnormal or the high-pressure setting side was adjusted, adjust the lowpressure setting side of main relief valve
(11) of the left 4-spool control valve according to the following procedure.
a Adjust the left side 4-spool control valve similarly to the right side 5-spool control valve.
2) If the right travel oil pressure and power
maximizing oil pressure are abnormal,
adjust the low-pressure setting of main relief
valve (11) of the left side 4-spool control
valve according to the following procedure.
a Adjust the left side 4-spool control valve
similarly to the right side 5-spool control
valve.
6) Fix elbow (6) and tighten locknut (5).

7) Connect hose (4).
5. Adjusting swing motor safety valve

a If the relief pressure of the swing motor is abnormal, adjust safety valves (12) and (13) of
the swing motor according to the following
procedure.
(12): Safety valve of left swing motor
3. Adjusting main relief valve (high-pressure

setting) of left side 4-spool control valve
a If the work equipment oil pressure in the rear
pump circuit (during L mode) oil pressure are
abnormal, adjust the high-pressure setting
side of main relief valve (11) of the left side
4-spool control valve according to the following procedure.
(13): Safety valve of right swing motor
a Adjust the left side 4-spool control valve similarly to the right side 5-spool control valve.
PC600-8
33
SEN00444-04
1) Fix adjustment screw (14) and loosen locknut (15).

2) Turn adjustment screw (14) to adjust the
pressure.
a If the adjustment screw is:
a Pressure changed by 1 turn of adjustment screw: 3.87 MPa {39.5 kg/cm2}
3) Fix adjustment nut (14) and tighten locknut
(15).
3 Locknut:
118 147 Nm {12 15 kgm}

34
PC600-8
SEN00444-04
Testing and adjusting control

circuit oil pressure
3. Run the engine at high idle, set the work

equipment swing lever and travel lever in neutral, and measure the oil pressure.
a Tools for testing and adjusting control circuit oil

pressure
Symbol
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Measuring
a Measure the control circuit oil pressure under
the following condition.
range
stop the engine. Operate the control levers several times to release the remaining pressure in
the piping, and then loosen the oil filler cap of
the hydraulic tank slowly to release the internal
pressure of the hydraulic tank.
1. Open the pump compartment cover (front side)
and remove oil pressure measurement plug (1).
Adjusting
a If the control circuit oil pressure is abnormal,
adjust control relief valve (2) according to the
1. Remove cap (3).

2. Fix adjustment screw (4) and loosen locknut (5).
2. Install nipple [1] of hydraulic tester M and connect
it to oil pressure gauge [2].
a Use the oil pressure gauges of 6 MPa{60 kg/
cm2}
3. Turn adjustment screw (4) to adjust the pressure.

4. Fix adjustment screw (4) and tighten locknut (5).
3 Locknut: 9.8 Nm {1 kgm}
PC600-8
35
SEN00444-04
5. After completing the adjustment, repeat the procedure in above to check the set pressure
again.
36
PC600-8
SEN00444-04
Testing and adjusting piston

pump control oil pressure
a Tools for testing and adjusting piston pump control oil pressure
Symbol
Part No.
3) Install nipple N3 and connect oil pressure

gauge [1] of hydraulic tester N1.
{60 kg/cm2}.
a Fig. shows the view from the pump room
under cover side.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2701
Differential pressure
gauge
799-101-5220
Nipple (10 1.5 mm)
07002-11023
O-ring
799-401-3200
Adapter (Size: 03)
2
N
3
4
Measuring
a Measure the piston pump control oil pressure
under the following conditions:
Hydraulic oil temperature: Within the operating range
1. Measuring TVC valve output pressure
a Since the TVC valve output pressure varies
with the discharge pressure of each pump,
check that the work equipment, swing, and
travel circuit oil pressure is normal before
starting measurement.
a Since the basic pressure of the TVC valve
output pressure is the control circuit pressure, check that the control circuit oil pressure is normal before starting measurement.
1) Open the pump compartment cover (front
side)
2) Remove oil pressure measurement plug (1)
of the No. 1 front pump.

5) Set all the control levers in neutral and
measure the TVC valve output pressure
under the following condition.
i) Set all the control levers in neutral.
ii) Run the engine at high idle and measure
the output pressure.
(normally), and measure the TVC valve output pressure under the following condition.
Run the engine at high idle, relieve the
boom circuit by raising the boom, and
measure the output pressure.
7) Set the working mode switch in the L mode
position, relieve the boom circuit by raising
the boom, and measure the TVC valve output pressure under the following condition.
i) Select L mode.

condition.
PC600-8
37
SEN00444-04
2. Measuring CO NC valve output pressure
1) Open the undercover of the No. 2 pump.
2) Remove oil pressure measurement plugs
(2) and (3) of the No. 2 pump.
(2): For front pump circuit
(3): For rear pump circuit
7) Drive the travel motor under no load and

measure the CO NC valve output pressure
i) Raise the track shoe to be measured by
using the boom and arm.
ii) Run the engine at high idle, drive the
travel motor under no load (with the lever
at the stroke end), and measure the output pressure.
8) Set the working mode switch in the L mode
position, relieve the boom circuit by raising
the boom, and measure the output pressure
i) Select L mode.
3) Install nipple N3 and connect oil pressure

gauge [1] of hydraulic tester N1.
{60 kg/cm2}.

measure the CO NC valve output pressure
the output pressure.
(P mode) and measure the CO NC valve
output pressure under the following condition.
i) Run the engine at high idle, relieve the
38

condition.
PC600-8
3. Measuring jet sensor output differential pressure of right side 5-spool control valve and
left side 4-spool control valve
1) Remove oil pressure measurement plugs
(4) and (5) under the right side 5-spool control valve and oil pressure measurement
plugs (6) and (7) under the left side 4-spool
control valve.
(4): High pressure side (Pt) of right side
5-spool control valve (F pump)
(5): Low pressure side (Pd) of right side
5-spool control valve (F pump)
(6): High pressure side (Pt) of left side
4-spool control valve (R pump)
(7): Low pressure side (Pd) of left side
4-spool control valve (R pump)
a The jet sensor output differential pressure may be measured at the inlet hose
of the No. 1 pump by using adapter N4
and nipple N3.
SEN00444-04

measure the jet sensor output differential
pressure under the following condition.
the output differential pressure.
a Jet sensor output differential pressure =
High pressure (Pt) Low pressure (Pd)
5) Drive the travel motor under no load and
measure the jet sensor output differential
pressure under the following condition.
i) Raise the track shoe to be measured by
using the boom and arm.
ii) Run the engine at high idle, drive the
travel motor under no load, and measure
the output differential pressure.
a Jet sensor output differential pressure =
High pressure (Pt) Low pressure (Pd)
2) Install nipple [2] of hydraulic tester N1 and

connect it to differential pressure gauge N2
or oil pressure gauge [1] of N1.
a When using differential pressure gauge:
Connect the high pressure (Pt) to the
high pressure side (back side) of the differential pressure gauge and connect
the low pressure (Pd) to the low pressure side (lower side). Since the differential pressure gauge needs DC 12 V,
connect 1 battery to it.
a When using pressure gauge:
Connect the pressure gauge of 6 MPa
{60 kg/cm 2 } to the high pressure side
(Pt) and connect the pressure gauge of
2.5 MPa {25 kg/cm2} to the low pressure
side (Pd).
PC600-8
39
SEN00444-04
3) Fix adjustment screw (9) and tighten locknut

(10).
3 Locknut:
5.9 9.8 Nm {0.6 1.0 kgm}

condition.
Adjusting
1. Adjusting TVC valve
a When adjusting the TVC valve, open the
pump compartment cover.
a If the TVC valve output pressure is abnormal, adjust TVC valve (8) of the No. 1 pump
according to the following procedure.

2. Adjusting CO NC valve
a When adjusting the CO valve side of the
CO NC valve, remove the No. 1 pump undercover. When adjusting the NC valve
side, open the pump compartment cover.
a If the CO NC valve output pressure is abnormal, adjust CO valves (11) and (12) and
NC valves (13) and (14) of the No. 1 pump
(11): Front CO valve of No. 1 pump
(12): Rear CO valve of No. 1 pump
1) Fix adjustment screw (9) and loosen locknut

(10).
pressure.
40
PC600-8
(13): Front NC valve of No. 1 pump

(14): Rear NC valve of No. 1 pump
1) Adjusting CO valve side

i) Fix adjustment screw (15) and loosen
locknut (16).
ii) Turn adjustment screw (15) to adjust the
pressure.
a Pressure changed by 1 turn of adjustment screw: 4.05 MPa {41.25 kg/cm2} (at
pump pressure)
iii) Fix adjustment screw (15) and tighten
locknut (16).
3 Locknut:
5.9 9.8 Nm {0.6 1.0 kgm}
SEN00444-04
a Pressure changed by 1 turn of adjustment screw: 0.39 MPa {4.0 kg/cm2} (at
J/S difference pressure)
iii) Fix adjustment screw (17) and tighten
locknut (18).
3 Locknut:
5.9 9.8 Nm {0.6 1.0 kgm}
iv) After completing the adjustment, check

the oil pressure again according to the
above described measurement procedure.
3. Adjusting jet sensors of right side 5-spool
control valve and left side 4-spool control
valve
a If the jet sensor output differential pressure
of the right side 5-spool control valve or left
side 4-spool control valve is abnormal, adjust jet sensor relief valves (19) and (20) according to the following procedure.
(19): Jet sensor relief valve of right side 5spool control valve
(20): Jet sensor relief valve of left side 4spool control valve
iv) After finishing adjustment, check the oil

pressure again according to the above
2) Adjusting NC valve side
i) Fix adjustment screw (17) and loosen
locknut (18).
ii) Turn adjustment screw (17) to adjust the
pressure.
PC600-8
41
SEN00444-04
1) Fix adjustment screw (21) and loosen locknut (22).

pressure.
3) Fix adjustment screw (21) and tighten locknut (22).
3 Locknut: 59 78 Nm {6 8 kgm}

42
PC600-8
SEN00444-04
Testing servo piston stroke

a Tools for testing servo piston stroke
Symbol
Part No.
Part name
708-25-14140
Cap
07000-B2065
O-ring
566-98-41120
Disc gauge
1
P
2
a After checking that the rod moves

smoothly, keep it at the position where it
is most protruded.
5) Stop the engine and measure the size of the
rod protrusion (a2).
6) Calculate the servo piston stroke (b) from
the measured size.
a Servo piston stroke (b) = (a2) (a1)
a Standard stroke (b): 9.37 mm
a When the NC valve output pressure is normal

but the pump performance is considered inappropriate, inspect the acceptability of the servo
valve and piston according to the following procedures:
1. Preparation of tool
Drill a through hole PT1/4 in the center of the
cap P1 and screw the disc gauge P2 in the hole.
a Prepare the cap for the side where the spring
of the hydraulic pump servo piston is fitted.
7) After completing the testing, remove the

testing tools and set to the original condition.
2. Measurement of stroke
1) Remove the cap and the shim of the servo
valve on the measuring side.
a Since the cap is pressed with the spring,
remove the cap carefully with the long
bolt (01016-31070, etc.) and the nut so
that the cap does not jump out.
2) Mount the measuring tools P, on the servo
piston together with the removed shim.
a Be careful so that the shim is not caught
in the bolt threads.
3) Push in the rods of the measuring tools P,
fully and measure the size of the protrusion
(a1).
4) Start the engine, keep it at full throttle and
move the track shoe under no load.
a Operate the lever to the full stroke.
a During the measurement, press the rod
with hand and check at the same time
that the rod moves smoothly as the control lever changes the stroke.
PC600-8
3. Judgment of servo valve

a If the servo piston stroke is abnormal, remove the servo valve, servo piston cap, and
spring, and check that you can move the servo piston smoothly before judging the condition of the servo valve.
1) When servo piston stroke is normal:
Servo valve is normal.
2) When servo piston stroke is abnormal:
Servo piston moves smoothly;
Servo valve is abnormal.
Servo piston does not move smoothly;
Servo valve is normal.
43
SEN00444-04
Measuring PPC valve output

pressure
(3) : For boom LOWER circuit

(4) : For arm IN circuit
(5) : For arm OUT circuit

(6) : For bucket CURL circuit
(7) : For swing circuit (left and right)
a Tools for measuring PPC valve output pressure

Symbol
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3200
Adapter (Size: 03)
1
Q
2
a Measure the PPC valve output pressure under

the following conditions:
range
1. Remove the control valve top cover or operator's cab undercover (front side).
2. Remove the PPC oil pressure switches (1) - (8)
of the circuits to be measured.
(1) : For boom RAISE circuit
(2) : For bucket DUMP circuit
44
PC600-8
SEN00444-04
(8) : For travel circuit (left and right, forward,

and reverse)
3. Install nipple [1] of hydraulic tester Q1 and connect it to oil pressure gauge [2].
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.
a The measuring tools installed to the swing
circuit are shown in the figure.

a The PPC valve output pressure may be
measured at the PPC hose joint, using
adapter Q2 (For the hose to be measured,
see the connection diagram on the next
page).
4. Run the engine at high idle and operate the control lever of the PPC circuit to be measured and
measure the oil pressure.
a Measure the oil pressure with the lever at a
stroke end.
a Set the actuators to be measured as shown
below.
When measuring the work equipment
circuit, set each cylinder to the stroke
end.
When measuring the swing circuit, turn
the swing lock switch ON.
When measuring the travel circuit, put
pin [3] between the sprocket and track
frame to lock the travel system.
PC600-8
45
SEN00444-04
Connection diagram of pilot piping (PPC, Solenoid, OLSS circuit)
46
PC600-8
SEN00444-04
a The colors in ( ) in the figure are the colors of the tapes wound onto the hoses.
PC600-8
47
SEN00444-04
Measuring outlet pressures of

solenoid valve and PPC shuttle
valve
a Tools for measuring outlet pressures of solenoid
valve and PPC shuttle valve
Symbol
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3200
Adapter (Size: 03)
1
R
2
a Measure the outlet pressures of solenoid valve

and PPC shuttle valve under the following condition.
range
(7): Bucket CURL Hi cancel solenoid

valve
1. Measuring outlet pressure of solenoid valve

1) Remove operators cab under cover (rear
side) or control valve upper cover.
2) Disconnect outlet hoses (1) (7) of the solenoid valves to be measured, and install
adapter R2 and connect the hoses again.
(1): PPC lock solenoid valve
48
3) Install nipple [1] of hydraulic tester R1 and

connect it to oil pressure gauge [2].
a Use a pressure gauge of 6 MPa {60 kg/
cm2}.
a The following figure shows the measuring devices installed to the outlet hose of
the safety lock solenoid valve.
(2): CO cancel solenoid valve

(3): 2-stage relief solenoid valve
(4): Machine push-up solenoid valve
(5): Travel speed select solenoid valve
(6): Swing holding brake solenoid valve
PC600-8
SEN00444-04
4) Run the engine at high idle, set the condition

or operate the control levers as shown in the
table, and measure the output pressure.
a When operating the work equipmentswing or travel control lever, operate it
finely to a degree that the PPC oil pressure switch is turned ON.
a If the solenoid valve outlet pressure is as
shown in the table, the solenoid valve is
normal.

condition.
PC600-8
49
SEN00444-04
Measurement conditions for solenoid valve

a The measurement conditions in the following table are for measuring the solenoid valve outlet pressure and
they are a part of the operating condition of each solenoid valve.
No.
Note:
50
Solenoid valve
Operation of machine
Operation
Oil pressure
of
(MPa {kg/cm2})
solenoid
Set lock lever in LOCK

position.
Basic pressure circuit to

PPC valve is closed.
OFF
0 {0}
Set lock lever in FREE

position.
Basic pressure circuit to

PPC valve is opened.
ON
Min. 2.74
{Min. 28}
Set working mode switch in L

mode.
Pump CO function is turned

ON.
OFF
0 {0}
Power max. switch ON (only

8.5 sec.).
Turn heavy lift switch ON and
raise boom singly.
Swing lock switch ON
Operate travel lever.
Pump CO function is turned

OFF.
ON
Min. 2.74
{Min. 28}
Set working mode switch in L

mode.
Main relief valve is set to

high pressure.
ON
Min. 2.74
{Min. 28}
Turn machine push-up switch

ON.
Boom LOWER safety valve

is set to high pressure.
OFF
0 {0}
Turn machine push-up switch

OFF.
Boom LOWER safety valve

is set to low pressure.
ON
Min. 2.74
{Min. 28}
Set travel speed switch in Lo

position.
Swash plate angle of travel

motor is set to maximum.
OFF
0 {0}
Set travel speed switch in Hi

position.
Swash plate angle of travel

motor is set to minimum.
ON
Min. 2.74
{Min. 28}
Turn swing lock switch ON.

About 10 seconds after work
equipment swing control lever
is set in NEUTRAL position.
Swing holding brake is

applied.
OFF
0 {0}
Turn swing lock switch OFF

and operate work equipment
swing control lever.
Swing holding brake is

released.
ON
Min. 2.74
{Min. 28}
OFF
Min. 2.35
{Min. 24}
ON
0 {0}
PPC lock
CO cancel
2-stage relief
Machine push-up
Travel speed select
Swing holding brake
Bucket CURL operated singly. Bucket Hi spool is operated

Bucket CURL Hi cancel (see Note)
Bucket CURL operated other
Bucket Hi spool is stopped.
than above.
The inlet pressure of the bucket CURL Hi cancel solenoid valve is the boom RAISE PPC circuit pressure. Accordingly, when measuring the outlet pressure, move the bucket control lever to the CURL
stroke end (The bucket cylinder may be at the CURL stroke end).
PC600-8
SEN00444-04
2. Measuring outlet pressures of boom bucket

PPC shuttle valves
1) Remove the control valve top cover.
2) Disconnect control valve inlet hose (8),
install adapter R2, and connect the hose
again.

condition.
3) Install nipple [1] of hydraulic tester Q1 and

a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.

as shown in the following table, and measure the output pressure.
a If the outlet pressures of the boom and
bucket PPC shuttle valve are as shown
in the following table, the boom bucket
PPC shuttle valve are normal.
Neutral
Operated to
boom RAISE
PC600-8
3. Measuring outlet pressures of arm swing

PPC shuttle valves (arm side)
2) Disconnect control valve inlet hose (9),
install adapter R2, and connect the hose
again.

kg/cm2}.
Oil pressure
(MPa {kg/cm2})
0 {0}
Min. 2.35
{Min. 24}
Right work
Operated to
equipment
boom LOWER
control lever Operated to
bucket CURL
Min. 2.35
{Min. 24}
Operated to
bucket DUMP
Min. 2.35
{Min. 24}
Min. 2.35
{Min. 24}
51
SEN00444-04

a If the outlet pressures of the arm swing
PPC shuttle valve are as shown in the
following table, the arm swing PPC
shuttle valve (arm side) are normal.
Neutral
Right work
Operated to
equipment
arm IN
control lever
Operated to
arm OUT
4. Measuring outlet pressures of arm and swing

PPC shuttle valves (swing side)
2) Remove swing PPC oil pressure switch
(10).
Oil pressure
(MPa {kg/cm2})
0 {0}
Min. 2.35
{Min. 24}
Min. 2.35
{Min. 24}

kg/cm2}.

condition.

a If the outlet pressures of the arm swing
PPC shuttle valve are as shown in the
following table, the arm swing PPC
shuttle valve (swing side) are normal.
Neutral
Right work
Operated to
equipment
swing LEFT
control lever
Operated to
swing RIGHT
52
Oil pressure
(MPa {kg/cm2})
0 {0}
Min. 2.35
{Min. 24}
Min. 2.35
{Min. 24}
PC600-8
SEN00444-04

condition.
PC600-8
53
SEN00444-04
Adjusting work equipment,

swing PPC valve
a If there is excessive play at the tip of the work
equipment, swing lever, adjust as follows.
1. Remove work equipment, swing PPC valve
assembly.
2. Take off boot (1).
3. Loosen lock nut (2) and screw in disc (3) until it
contacts the heads of four pistons (4).
a Do not move the piston while doing this work.
4. Keep disc (3) in place and tighten lock nut (2) to
the specified tightening torque.
3 Lock nut: 98 127 Nm {10 13kgm}
5. Install boot (1).
6. Install work equipment, swing PPC valve
assembly.
54
PC600-8
SEN00444-04
Testing and adjusting travel

deviation
Testing
a Measure on a hard and flat place.
1. Start the engine and set the work equipment in
the travel position.
a To set the work equipment in the travel position, extend the bucket and arm cylinders fully and set the boom angle to 45 degrees.
2. Set the working mode switch to the P mode
position and set the travel speed switch to the
Lo position.
3. Run up for 10 m with the engine speed at high
idle and continue travel under the same condition for 20 m and measure the deviation (a).
a At this time, install an oil pressure gauge and
measure the pump discharge pressure, too,
(or monitor the pump discharge pressure
with the machine monitor).
PC600-8
55
SEN00444-04
Adjusting
a If the travel deviation is abnormal, adjust the
thickness of the shim at the servo piston according to the following procedure.
No. 1 pump
No. 2 pump
1. Determine where to add a shim from the direction of the travel deviation.
a Adjustment method
When machine
deviates to left
Add shim on rear pump
side (c).
When machine
deviates to right
Add shim on front pump
side (b).
No. 1 pump
No. 2 pump
3. Add shim (2) according to the deviation and
tighten bolt (1).
a Limit the thickness of the added shim to 3
mm for each pump.
3 Bolt: 59 74 Nm {6.0 7.5 kgm}
a Travel deviation and thickness of added
shim.
2. Loosen 4 bolts (1) on the side to adjust the shim.

a Since the shim is of split type, you do not
need to remove the cap.
a Since the cap is pressed by the spring, loosen the bolt to a degree that you can insert the
shim.
4. After completing the adjustment, check the
travel deviation again according to the above
described procedure.
56
PC600-8
SEN00444-04
Measuring fan speed
Measuring fan circuit oil pressure
a Tools for measuring fan speed
a Tools for measuring fan circuit oil pressure
Symbol
Part No.
799-203-8001
Part name
Symbol
Multitachometer
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
1. Remove the covers until the fan blade end is seen.

2. Stick a reflection tape to the fan.
3. Set probe [1] of multitachometer S with stand
[2], match it to the reflection tape, and connect it
to meter [3].
a Take care that the probe will not interfere
with the fan.
a Measure the fan circuit oil pressure under the

following condition.
Hydraulic oil temperature: Within operating range
stop the engine. Operate the control levers several times to release the residual pressure in the
piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank.
1. Connect gauge [2] of hydraulic tester T to oil pressure measurement nipple [1] of the fan pump.
a Use the gauge of 40 MPa {400 kg/cm2}.
4. Run the engine at low idle and high idle and

measure the fan speed.
2. Run the engine in the fan 100% speed mode at

high idle and measure the fan circuit oil pressure.
PC600-8
57
SEN00444-04
Inspection of locations of
hydraulic drift of work equipment
a If there is any hydraulic drift in the work equipment (cylinders), check in the following manner
to determine if the cause is in the cylinder packing or in the control valve.
2. Inspection of arm cylinder

1) Operate the arm cylinder to move the arm to
the position 100 mm before the digging
stroke end, and stop the engine.
1. Inspection of boom and bucket cylinders

1) Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
a Fill the bucket with earth or apply the rated load to the bucket.
2) Operate the control lever to the RAISE position or the bucket control lever to the CURL
position.
If the lowering speed increases, the cylinder packing is defective.
If there is no change, the control valve is
defective.
a Operate the control lever with the engine
starting switch in the ON position.
a If pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator
again.
58
2) Operate the control lever to the CURL position.

If the lowering speed increases, the cylinder packing is defective.
If there is no change, the control valve is
defective.
a Operate the control lever with the engine
starting switch in the ON position.
a If pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator again.
[Reference]If the cause of the hydraulic drift is in the
defective packing, and the above operation is carried out, downward movement
is accelerated for the following reasons.
1) If the work equipment is set to the above posture (holding pressure applied to the bottom
end), the oil at the bottom end leaks to the head
end. However, the volume at the head end is
smaller than the volume at the bottom end by
the volume of the rod end, so the internal pressure at the head end increases because of the
oil flowing in from the bottom end.
2) When the internal pressure at the head end
increases, the pressure at the bottom end also
rises in proportion to this. The balance is maintained at a certain pressure (this differs according to the amount of leakage) by repeating this
procedure.
3) When the pressure is balanced, the downward
movement becomes slower. If the lever is then
operated according to the procedure given
above, the circuit at the head end is opened to
the drain circuit (the bottom end is closed by the
check valve), so the oil at the head end flows to
the drain circuit and the downward movement
becomes faster.
PC600-8
SEN00444-04
Measuring oil leakage

a Tools for measuring oil leakage
Symbol
Part No.
Commercially
available
Part name
Measuring cylinder
a Measure the oil leakage under the following

condition.
range
1. Measuring leakage from boom cylinder
1) Run the engine and raise the boom to the
stroke end.
k Referring to Releasing remaining pressure in hydraulic circuit, release the remaining pressure from the piping on the
boom cylinder head side (Operate the
lever only in the RAISE direction, however).
2) Disconnect hoses (1) on the cylinder head
side and block it with a flange.
2. Measuring leakage from arm cylinder

1) Run the engine and move in the arm to the
stroke end.
arm cylinder head side (Operate the lever only in the CURL direction, however).
2) Disconnect hose (2) on the cylinder head
k Take care not to disconnect the hose on
the cylinder bottom side.
a Use the following part to block the hose.
07379-01044 (Flange #10)

07379-01044 (Flange #10)
3) Run the engine at high idle and relieve the

arm cylinder by operating the arm control
lever in the CURL direction.
k Take care not to operate the arm control lever in the DUMP direction.
4) Start measuring the oil leakage 30 seconds
after the arm cylinder is relieved and measure for 1 minute.
5) After completing the measurement, set to
the original condition.

boom cylinder by operating the boom control lever in the RAISE direction.
k Take care not to operate the boom control lever in the LOWER direction.
after the boom cylinder is relieved and
measure for 1 minute.
PC600-8
59
SEN00444-04
3. Measuring leakage from bucket cylinder
1) Run the engine and curl the bucket to the
stroke end.
bucket cylinder head side (Operate the
lever only in the CURL direction, however).
2) Disconnect hose (3) on the cylinder head
4. Measuring leakage from swing motor

1) Disconnect drain hoses (4) and plug them.
a Use the following parts to block the hoses.
07376-70522 (Plug #05)

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

swing circuit and measure the oil leakage.
a Start measuring the oil leakage 30 seconds after the swing motor circuit is relieved and measure for 1 minute.
a After measuring 1 time, swing the upper
structure 180 and measure again.

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

control lever in the DUMP direction.
after the bucket cylinder is relieved and
60
PC600-8
SEN00444-04
5. Measuring leakage from travel motor

1) Remove the travel motor cover.
4 Travel motor cover: 35 kg

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

track frame to lock the travel mechanism securely.
6. Measuring leakage from center swivel joint

1) Put pin [1] between the sprocket and track
frame to lock the travel motor of the port to
be inspected, and then stop the engine.
k Loosen the oil filler cap of the hydraulic

tank slowly to release the internal pressure of the tank.
a Inspection ports, travel directions, and
measurement ports (See figure on following parts)
Inspection
port
Travel
direction
Measurement
ports
R.H. reverse
T and B
L.H. reverse
A and C
R.H. forward
B and D
L.H. forward
C and E
Speed select
D and T
Drain
3) Disconnect drain hose (5) of the travel

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

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

cause an accident, make signs and
confirmation securely.
a Start measuring the oil leakage 30 seconds after the travel motor circuit is relieved and measure for 1 minute.
a Measure the oil leakage several times,
moving the motor little by little (changing
the positions of the valve plate and cylinder and those of the cylinder and piston).
PC600-8
61
SEN00444-04
2) Disconnect the hoses of the upper and
lower measurement ports of the inspection
port from the top of the swivel joint and
block them.
a For combination of the inspection port
and measurement ports, see the above
table.
a Use the following parts to block the hoses.
Ports A, B, C, D:
07379-01044 (Flange #10)
Port E: 07376-70315 (Plug #03)
Port T: 07376-70522 (Plug #05)
62
3) Run the engine at high idle and measure the

oil leakage through the measurement ports.
a When measuring ports A, B, C, and D,
relieve the travel motor slowly in the revolving direction (See the table on the
last page).
a When measuring port E, set the travel
speed select switch in the Hi position.
4) Start measuring the oil leakage 1 minute
after the center swivel joint is relieved and
PC600-8
Releasing remaining pressure

in hydraulic circuit
1. Release of remaining pressure from hydraulic tank
The hydraulic tank is enclosed and pressurized.
When removing a hose or a plug connected
to the hydraulic tank, release the remaining
pressure from the hydraulic tank according
to the following procedure.
1) Lower the work equipment to the ground in
a stable posture and stop the engine.
2) Slowly loosen oil filler cap (1) of the hydraulic tank to release the air from the tank.
SEN00444-04
3. Release of remaining pressure from swing
motor circuit
a Release the remaining pressure from the
swing motor circuit by performing the procedure for 2. Release of remaining pressure
from hydraulic cylinder circuit.
4. Release of remaining pressure from travel
motor circuit
a Since the control valve spool of the travel
motor is open, release the remaining pressure from the travel motor circuit by performing the procedure for 1. Release of
remaining pressure from hydraulic tank.
2. Release of remaining pressure from hydraulic cylinder circuit
k When disconnecting the piping between a

hydraulic cylinder and the control valve, release the remaining pressure from the piping
1) Referring to 1. Release of remaining pressure from hydraulic tank, release the
remaining pressure from the hydraulic tank.
a Leave the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch to the ON position
and set the lock lever in the FREE position,
and then operate the work equipment control levers on both sides forward, backward,
to the right, and to the left.
a The control valve is driven with the pressure in the accumulator. If it is operated
2 3 times, the pressure lowers.
3) Start the engine and run it at low idle for 5
seconds to heighten the pressure in the
accumulator.
4) Repeat above steps 2) and 3) 2 3 times,
and all residual pressure is released from
the piping.
PC600-8
63
SEN00444-04
Bleeding air from each part
1
Air bleeding item
Bleeding
air from
Contents of work
hydraulic
pump
Replacement of hydraulic oil
q
Cleaning of strainer
Replacement of return filter element
Replacement or repair of
hydraulic pump
q
Removal of suction piping
Replacement or repair of control
valve
Removal of control valve piping
Replacement or repair of cylinder
Removal of cylinder piping
Replacement or repair of swing
motor
Removal of swing motor piping
Replacement or repair of travel
motor
Removal of travel motor piping
Replacement or repair of swivel
joint
Removal of swivel joint piping
Note:
Starting
engine
q
Air bleeding procedure

3
4
5
6
Bleeding
Bleeding Checking
Bleeding
air from
air from
oil level
air from
swing
travel
and startcylinder
motor
motor
ing work
q
q
q
q
(see Note) (see Note)
Bleed air from the swing motor and travel motor only when the oil was drained from the motor cases.
1. Bleeding air from hydraulic pump

1) Loosen air bleeders (1) and (2) by 4 turns
and remove the oil filler cap of the hydraulic
tank.
a Leave the machine under the above
condition for 10 minutes or more.
2) After oil flows out of bleeders (1) and (2),
run the engine at low idle.
a If the engine coolant temperature is low
and the automatic warm-up operation is
started, stop the engine temporarily and
reset the automatic warm-up operation
with the fuel control dial (Set the starting
switch in the ON position and hold the
fuel control dial in the MAX position for 3
seconds, and the automatic warm-up
operation is reset).
a Set the lock lever in the LOCK position
so that you will not operate a lever by
mistake.
64
3) After clear oil flows out of bleeders (1) and

(2), tighten the bleeders.
3 Bleeder:
7.8 9.8 Nm {0.8 1.0 kgm}
PC600-8
2. Starting engine
When running the engine after performing step
1, keep its speed at low idle for 10 minutes.
3. Bleeding air from cylinder
a If a cylinder was replaced, bleed air from it
before connecting the work equipment. In
particular, the boom cylinder does not move
to the lowering stroke end, if it is installed to
the work equipment.
1) Run the engine at low idle for about 5 minutes.
2) Running the engine at low idle, raise and
lower the boom 4 5 times.
a Stop the piston rod about 100 mm before
each stroke end. Do not relieve the oil.
3) Running the engine at high idle, perform
step 2).
4) Running the engine at low idle, move the
piston rod to the stroke end and relieve the
oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) 4).
SEN00444-04
5. Bleeding air from travel motor
1) Remove the travel motor cover.
4 Travel motor cover: 35 kg

2) Loosen bleeder (4) by 1 turn and start the
engine.
a Do not loosen the bleeder more than 1
turn.
3) Run the engine at low idle and repeat the
forward and reverse travel operations 4 - 5
times. After clear oil flows out, tighten the
bleeder.
a Limit the operation of the lever to a degree that the machine starts traveling.
3 Bleeder:
27.4 35.3 Nm {2.8 3.6 kgm}
4. Bleeding air from swing motor

1) Motor unit
a Bleed air from the motor unit according
i) Run the engine at low idle.
ii) Swing to the right and left slowly to bleed
air.
2) Parking brake circuit
a Normally, air in the parking brake circuit
is bled by swinging the machine in step
1). If you feel dragging of the brake during swinging operation, however, bleed
air from the parking brake circuit according to the following procedure.
i) Loosen the adapter of brake hose (3)
and start the engine.
ii) Run the engine at low idle and set the
swing holding brake release switch to the
RELEASE and NORMAL positions
repeatedly. After clear oil oozes out,
tighten the adapters.
PC600-8
65
SEN00444-04
6. Checking oil level and refill

1) Run the engine, retract the arm cylinder and
bucket cylinder to the stroke ends, lower the
work equipment to the ground, and stop the
engine.
2) Check the oil level by the sight gauge at the

back of the hydraulic tank.
a If the oil level is between lines H and L, it
is normal.
a If the oil level is below line L, add new oil.

2009 KOMATSU
All Rights Reserved
66
Inspection procedures for diode

a Check an assembled-type diode (8 pins) and
single diode (2 pins) in the following manner.
a The continuity direction of an assembled-type
diode is as shown in the diagram below.
a The continuity direction of a single diode is

shown on the diode surface.
1. When using digital type circuit tester

1) Switch the testing mode to diode range and
confirm the indicated value.
a Voltage of the battery inside is displayed
with conventional circuit testers.
2) Put the red probe (+) of the test lead to the
anode (P) and the black probe () to the
cathode (N) of diode, and confirm the displayed value.
PC600-8
SEN00444-04
3) Determine if a specific diode is good or no
good with the indicated value.
No change in the indicated value: No
continuity (defective).
Change in the indicated value: Continuity established (normal) (Note)
Note: A silicon diode shows a value between
400 and 600.
2. When using analog type circuit tester

1) Switch the testing mode to resistance range.
2) Check the needle swing in case of the following connections.
i) Put the red probe (+) of the test lead to
the anode (P) and the black probe () to
the cathode (N) of diode.
ii) Put the red probe (+) of the test lead to
the cathode (N) and the black probe ()
to the anode (P) of diode.
3) Determine if a specific diode is good or no
good by the way the needle swings.
If the needle does not swing in Case i),
but swings in Case ii): Normal (but the
breadth of swing (i.e. resistance value)
will differ depending on a circuit tester
type or a selected measurement range)
If the needle swings in either case of i)
and ii): Defective (short-circuited internally)
If the needle does not swing in any case
of i) and ii): Defective (short-circuited internally)
67
SEN00444-04

2009 KOMATSU
All Rights Reserved
68
SEN00445-03
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

Special function of machine monitor .................................................................................................................... 2
Handling controller voltage circuit ...................................................................................................................... 36
Procedure for turning on KOMTRAX terminal.................................................................................................... 37
KOMTRAX terminal lamp indications................................................................................................................. 40
Preparation work for troubleshooting electrical system...................................................................................... 43
Adjusting mirrors ................................................................................................................................................ 45
Pm-clinic service ................................................................................................................................................ 46
Undercarriage inspection ................................................................................................................................... 52
PC600-8
SEN00445-03
Special function of machine monitor
[1] Figure input switch 1


[
[
[
[
] Return switch
] Upward move switch
] Downward move switch
] Input confirmation switch
PC600-8
SEN00445-03
Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary function and special functions and displays information of various types
on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the others
are displayed according to the operation of the switches.
1. Ordinary functions: Operator menu
The items in this menu are displayed ordinarily. The operator can display and set them by operating the
switches.
2. Special functions: Service menu
The items in this menu are not displayed ordinarily. Each serviceman can display them by operating the
switches specially. This menu is used for special setting, testing, adjusting, or troubleshooting.
Operator menu
1
Function of inputting and setting password
Function for showing KOMATSU logo
Function for check before starting
Service Menu
16
Function of Monitoring [01]
17
Function for Abnormality

Record [02]
Function for machine maintenance
18
Function for Maintenance Record [03]
Function for showing caution items
19
Function for Maintenance Mode Change [04]
Function for confirming working mode and travel

speed
20
Function for Phone Number Entry [05]
Function for display of ordinary items
Function for adjusting display luminance and

contrast
Function for confirming maintenance information
10
Function for showing service meter reading
11
Function for checking display LCD
12
Function for showing occurrence of caution item
13
Function for showing action code No.
14
Function for showing failure code No.
15
Function of reversing fan rotation and adjusting

economy mode value
PC600-8
Electrical system
Mechanical system
Key-ON mode
21
Function for AAAA/

Default [06]
Language
Unit
Setting of wiper
22
Function for Adjustment [07]
23
Function of Cylinder Cut Out [08]
24
Function of no injection [09]
SEN00445-03
Operation of operator's menu

and display (outline)
a This section introduces only the outline of the
operator's menu. For details on the contents and
operation steps of each menu, refer to the
OPERATION AND MAINTENANCE MANUAL or
the chapter of Structure, function and maintenance standard in this shop manual.
1. Function of inputting and setting password
When the starting switch is turned ON, the
screen to input a password is displayed.
a This screen is displayed only if the password
function has been set.
4. Function for machine maintenance
Following the display of machine check before
starting, the maintenance mark appears for 30
seconds, if there are oils and filters whose maintenance time is approaching or has just passed.
a This display appears only when the maintenance function is set.
2. Function for showing KOMATSU logo

When the engine starting switch is turned ON,
KOMATSU logo is shown for two seconds.
5. Function for showing caution items

If there is any item of machine check before
starting day's work that indicates some abnormality, a corresponding symbol mark is shown
after the display of machine check before starting day's work.
3. Function for check before starting

Following the KOMATSU logo, the display of
machine check before starting day's work is
shown for 2 seconds.
PC600-8
6. Function for confirming working mode and

travel speed
After the display of machine check before starting day's work, amplified symbol marks for working mode and travel speed are shown for 2
seconds to urge an operator to confirm the setting.
7. Function for display of ordinary items

The display of confirming working mode and
travel speed is switched to this display of ordinary items.
a If the working mode setting or travel speed
setting is changed, or auto-deceleration or
windshield wiper setting is activated while
this is in display, an amplified corresponding
symbol mark is shown for 2 seconds.
a In this display, a symbol mark for preheat
monitor is shown only when preheating is
carried out.
PC600-8
SEN00445-03
8. Function for adjusting display luminance and
contrast
Luminance as well as contrast of the display can
be adjusted by operating the display adjusting
switch.
9. Function for confirming maintenance information

Detailed information on maintenance items (set
time and elapse of time) can be confirmed and
resetting after the confirmation is feasible by
operating the maintenance switch.
a Use service menu for setting or releasing
maintenance items and setting maintenance
time.
SEN00445-03
10. Function for showing service meter reading
Only the service meter reading can be shown by
the following switching operation, when the
engine starting switch is turned OFF.
Switching operation:
[ ] + [ ] (synchronized switching operation)
12. Function for showing occurrence of caution

item
If any of the caution items occurs, the magnified
corresponding symbol mark is shown for 2 seconds and thereafter stays on the display as a
small symbol mark until it is dissolved.
11. Function for checking display LCD

Display of the Display LCD can be confirmed by
the following switching operation in the display
of ordinary items
Switching operation:
[ ] + [A] (synchronized switching operation)
a All the LCD light up, turning the entire screen
white. If there is no showing in black, the display is normal.
a This display returns to the immediately preceding one, if making any other switching
operation.
PC600-8
SEN00445-03
13. Function for showing action code No.

When a trouble occurs on the machine, the
action code is automatically displayed depending on the magnitude of the trouble to call attention of the operator for a proper action.
a This display turns to the display of failure
code, if operating the switch (Refer to Item
No. 14).
a Action codes and instructions given to operator

Action
code
Failure mode
Instructions given to operator
E02
Error in pump control system
If the emergency pump drive switch is set to the upper (emergency) position,
the machine can operate normally. Have the machine inspected immediately, however.
E03
Error in swing brake system
Have the machine inspected immediately.
E10
Error in engine controller power

supply system
Abnormality in engine controller
drive system circuit (engine stop)
Have the machine inspected immediately.
E11
Error in engine controller system

(Engine protection output down)
Set the machine in a safe position and have the machine inspected immediately.
E14
Error in throttle system
E15
Error in engine sensor

(water temperature, fuel temperature and oil pressure)
Ordinary operation is possible. Have the machine inspected immediately,

however.
E0E
Error in network
PC600-8
SEN00445-03
14. Function for showing failure code No.

If the following switching operation is made
while the action code No. is shown, a phone
symbol (if registered), phone numbers (if registered), failure code No. is shown in turn.
Switching operation: [ ]
a The following display is repeated in order according to the operation of the switch.
[1] Telephone symbol mark
[2] Telephone No.
[3] Failure code No.
a The telephone symbol mark and telephone
No. are shown only when they are registered
in the machine monitor.
For registration, correction and deletion of
telephone No., use Service Menu.
a For details on the displayed failure code No.,
refer to the Table for failure code No.
PC600-8
SEN00445-03
Failure code table

Action
code
Failure
code
A000N1
AA10NX Aircleaner Clogging
MON
AB00KE Charge Voltage Low
MON
B@BAZG Eng. Oil Press. Low
MON
B@BAZK Eng. Oil Level Low
MON
B@BCNS Eng. Water Overheat
MON
B@BCZK Eng. Water Lvl Low
MON
B@HANS Hydr. Oil Overheat
MON
Trouble (Displayed on screen)
Alarm
buzzer
Eng. Hi Out of Std
Component Category of
in charge
record
MON
E10
CA111
ECM Critical Internal Failure
E10
CA115
Eng Ne and Bkup Speed Sens Error
ENG
E11
CA122
Chg Air Press Sensor High Error
ENG
E11
CA123
Chg Air Press Sensor Low Error
ENG
E14
CA131
Throttle Sensor High Error
ENG
E14
CA132
Throttle Sensor Low Error
ENG
E15
CA135
Eng Oil Press Sensor High Error
ENG
E15
CA141
Eng Oil Press Sensor Low Error
ENG
E15
CA144
Coolant Temp Sens High Error
ENG
E15
CA145
Coolant Temp Sens Low Error
ENG
E15
CA153
Chg Air Temp Sensor High Error
ENG
E15
CA154
Chg Air Temp Sensor Low Error
ENG
E15
CA187
Sens Supply 2 Volt Low Error
ENG
E15
CA221
Ambient Press Sens High Error
ENG
E15
CA222
Ambient Press Sens Low Error
ENG
E15
CA227
Sens Supply 2 Volt High Error
ENG
CA234
Eng Overspeed
E03
CA238
Ne Speed Sens Supply Volt Error
ENG
E15
CA263
Fuel Temp Sensor High Error
ENG
E15
CA265
Fuel Temp Sensor Low Error
ENG
E11
CA271
IMV/PCV1 Short Error
ENG
PC600-8
ENG
ENG
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
SEN00445-03
Action
code
Failure
code
E11
CA272
IMV/PCV1 Open Error
ENG
E11
CA273
PCV2 Short Error
ENG
E11
CA274
PCV2 Open Error
ENG
E11
CA322
Inj #1(L#1) Open/Short Error
ENG
E11
CA323
ENG
E11
CA324
ENG
E11
CA325
ENG
E11
CA331
ENG
E11
CA332
ENG
E10
CA342
Calibration Code Incompatibility
E10
CA351
Injectors Drive Circuit Error
ENG
E15
CA352
ENG
E15
CA386
ENG
E10
CA441
Battery Voltage low error
ENG
E10
CA442
Battery Voltage high error
ENG
E11
CA449
Rail Press Very High Error
ENG
E11
CA451
Rail Press Sensor High Error
ENG
E11
CA452
Rail Press Sensor Low Error
ENG
E15
CA553
Rail Press High Error
ENG
CA554
Rail Press Sensor In Range Error
E15
CA559
Rail Press Low Error
ENG
E11
CA689
Eng Ne Speed Sensor Error
ENG
E11
CA731
Eng Bkup Speed Sens Phase Error
ENG
E10
CA757
All Persistent Data Lost Error
ENG
E11
CA778
Eng Bkup Speed Sensor Error
ENG
E15
CA1228
EGR Valve Servo Error 1
ENG
E11
CA1625
ENG
E11
CA1626
BP Valve Sol Current High Error
ENG
E11
CA1627
BP Valve Sol Current Low Error
ENG
E15
CA1628
Bypass Valve Servo Error 1
ENG
10
Alarm
buzzer
in charge
record
ENG
ENG
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Mechanical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
PC600-8
SEN00445-03
Action
code
Failure
code
E11
CA1629
ENG
E11
CA1631
BP Valve Pos Sens High Error
ENG
E11
CA1632
BP Valve Pos Sens Low Error
ENG
E0E
CA1633
KOMNET Datalink Timeout Error
ENG
E11
CA1642
EGR Inlet Press Sens Low Error
ENG
E11
CA1653
EGR Inlet Press Sens High Error
ENG
E14
CA2185
Throt Sens Sup Volt High Error
ENG
E14
CA2186
Throt Sens Sup Volt Low Error
ENG
E11
CA2249
Rail Press Very Low Error
ENG
E11
CA2271
EGR Valve Pos Sens High Error
ENG
E11
CA2272
EGR Valve Pos Sens Low Error
ENG
E11
CA2351
EGR Valve Sol Current High Error
ENG
E11
CA2352
EGR Valve Sol Current Low Error
ENG
E15
CA2555
Grid Htr relay Volt Low Error
ENG
E15
CA2556
Grid Htr relay Volt High Error
ENG
D110KB
Battery Relay Drive S/C
PUMP
D163KB
Flash Light Relay S/C
PUMP
D195KB
Step Light Relay S/C
PUMP
DA25KP Press. Sensor Power Abnormality
PUMP
DA2SKQ Model selection Abnormality
PUMP
DA80MA Auto. Lub. Abnormal
PUMP
Alarm
buzzer
in charge
record
E0E
DA2RMC Pump Comm. Abnormality
PUMP
E0E
DAFRMC Monitor Comm. Abnormality
PUMP
DGE5KY Ambi. Temp. Sensor S/C
PUMP
DGH2KB Hydr. Oil Temp. Sensor S/C
PUMP
DHPAMA F Pump P.Sensor Abnormality
PUMP
DHPBMA R Pump P.Sensor Abnormality
PUMP
DV20KB Travel Alarm S/C
PUMP
DW43KA Travel Speed Sol. Disc.
PUMP
DW43KB Travel Speed Sol. S/C
PUMP
PC600-8
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Mechanical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
11
SEN00445-03
Action
code
Failure
code
Alarm
buzzer
in charge
record
E03
DW45KA Swing Brake Sol. Disc.
PUMP
E03
DW45KB Swing Brake Sol. S/C
PUMP
DW48KA CO Cancel Sol. Disc.
PUMP
DW48KB CO Cancel Sol. S/C
PUMP
DW7BKA Fan Reverse Sol. Disc.
PUMP
DW7BKB Fan Reverse Sol. S/C
PUMP
DW4XKA Bucket Curl Hi Cancel Sol. Disc.
PUMP
DW4XKB Bucket Curl Hi Cancel Sol. S/C
PUMP
DWK0KA 2-stage Relief Sol. Disc.
PUMP
DWK0KB 2-stage Relief Sol. S/C
PUMP
E11
DX16KA Fan Pump EPC Sol. Disc.
PUMP
E11
DX16KB Fan Pump EPC Sol. S/C
PUMP
E02
DXA0KA TVC Sol. Disc.
PUMP
E02
DXA0KB TVC Sol. S/C
PUMP
DY20KA Wiper Working Abnormality
PUMP
DY20MA Wiper Parking Abnormality
PUMP
DY2CKB Washer Drive S/C
PUMP
DY2DKB Wiper Drive (For) S/C
PUMP
DY2EKB Wiper Drive (Rev) S/C
PUMP
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
a The items in this table are arranged in the order of the failure codes.
a The action codes having no numbers in the action code column are not displayed on the normal screen,
even if abnormality related to them occurs. They are simply recorded in the abnormality record of the service menu (Electrical system or mechanical system).
a The history division column shows in which division each failure is classified, the electrical system or
mechanical system, when it is recorded in the abnormality record.
a Letter "E" at the head of each action code indicates the following condition.
With E
: The failure has not been repaired yet.
Without E : The failure has been repaired.
12
PC600-8
15. Function of reversing fan rotation and adjusting economy mode value
1) Reversing fan rotation
1] Press switch [5] of the monitor, and the
following screen appears.
"01": Fan rotation reversing menu
"02": Economy mode value adjusting menu
SEN00445-03
4] If the [ ] switch is pressed, the screen
to wait for change of the fan rotation
direction appears and the engine speed
is lowered to low idle automatically.
After about 15 seconds, the fan rotation
is reversed. After 4 seconds, the engine
speed returns to the level before the
[ ] switch was pressed.
a The fan speed is in proportion to the engine speed. If the engine speed is low
idle, the fan speed is MIN.
To increase the fan speed, increase the
engine speed with the fuel control dial.
a When reversing the fan rotation while
the engine is stopped, turn the starting
switch to the START position after the
above screen appears. (This screen
does not change until the engine is started. When stopping reversing the fan rotation, turn the starting switch to the OFF
position.)
2] Select "1" Fan rotation reversing and
press the [ ] switch, and the following
screen appears.
a The fan mark is green.
3] When reversing the fan rotation, press
the [ ] switch.
a When not reversing the fan rotation,
press the return switch [ ], and the
previous screen appears.
PC600-8
5] If the fan rotation is reversed, the following screen appears automatically and is
maintained as long as the fan rotation is
in reverse.
a The fan mark is yellow.
13
SEN00445-03
6] If any trouble occurs while the fan is
rotating in reverse, the following warning monitor is displayed. In this case,
see the page of explanation of the monitoring items and take necessary remedy.
3] If the [ ] switch is pressed, the screen to

wait for change of the fan rotation direction appears and the engine speed is lowered to low idle automatically. After about
15 seconds, the fan rotation is returned to
the normal direction. After 4 seconds, the
engine speed returns to the level before
the [ ] switch was pressed.
2) Returning fan rotation to normal direction

1] Press switch [5] of the panel.
4] If the fan rotation is returned to the normal direction, the initial screen appears
automatically.
2] The following screen appears. When

returning the fan rotation to the normal
direction, press the [ ] switch.
a If the [ ] switch is pressed, the previous screen appears.
14
Remarks
1) The screen in 2)-1] may not change to
the screen in 2)-2] but the following
screen may appear and the fan rotation
may not be reversed.
a The fan mark is blue.
PC600-8
SEN00445-03
2) This state shows that reversing of the

fan rotation is prohibited to protect the
components under some conditions of
coolant temperature and hydraulic oil
temperature.
a To reverse the fan rotation in this
state, press the [ ] switch to return
the screen to the normal screen and
lower the engine speed to low idle or
stop the engine to warm up (cool
down) the engine.
If the coolant temperature and hydraulic oil temperature gauges are in
the range shown below, the fan rotation can be reversed.
Perform the procedure from 2)-1].
a: Coolant temperature
b: Hydraulic oil temperature
3) Adjusting economy mode value

1] In the screen of 2)-1], select "2" E mode
and press the [ ] switch, and the following screen appears.
a The economy mode can be set to 4 levels of E0, E1, E2, and E3 as shown
above.
(It is set to E0 when delivered.)
2] While watching the economy mode
adjusting menu, press the [ ] or [ ]
switch of the panel to select E0 E3
and press the [ ] switch.
3] The relationship between the value and

production is as follows.
Fuel
consumption
Production
Good
Little
E0 Initial value
E1 Economy adjustment 1
a As the value is increased to [E3

side], the fuel consumption is reduced and the production is also reduced.
PC600-8
15
SEN00445-03
Operation and display of service menu

Way of switching to Service Menu
a When using Service Menu, change the display
to Service Menu display through the following
special operation.
1) Confirmation of display
Confirm that the display of ordinary items is
shown.
a Changing to Service Menu cannot be made
from displays other than this.
3) Showing Service Menu display

The display is changed to the initial display of
service menu program. Select an appropriate
item from among the menu.
No.
2) Switch operation
Operate the switch as instructed below.
Switch operation: [ ] + [1] o [2] o [3]
(Enter a figure, depressing [
])
Service Menu
00
Return (Termination of Service Menu)
01
Monitoring
02
Abnormality Record
03
Maintenance Record
04
Maintenance Mode Change
05
Phone Number Entry
06
AAAA / Default
07
Adjustment
08
Cylinder cut out
09
No-injection
4) Termination of Service Menu function

When terminating the initial display or any subsequent display of Service Menu, do that
through any one of the following methods.
[1] Depress [ ] switch. (This method may be
used for terminating any display)
[2] If "Return" switch is shown, depress it.
[3] If "Return" menu is shown, call that menu
and depress [ ] switch.
16
PC600-8
16. Function of Monitoring [01]

The machine monitor monitors signals from an
assortment of switches, sensors and actuators
installed in various parts of the machine. Monitored information can be put in display or confirmed on a real time basis through the following
operations.
1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.
SEN00445-03
any of the following switch operations, after
the registration work has been completed.
Keep [ ] switch depressed. (For about
3 seconds)
Select Menu 99999 and depress [ ]
switch.
a The display automatically moves to the display of monitored information, when all of the
registrable items have been duly registered.
a Monitored information are transmitted via
communication circuits. Thus the number of
selected items can impact the communication speed. If truly real time monitoring is required, reduce the selected items to the
minimum.
a For details on the monitoring items, display
unit, etc., refer to the Table for monitoring
items.
3) Monitoring operation
Call the monitoring information display and
confirm the monitored information, while
operating the machine.
2) Setting of monitoring item

i) Select or register an item to be monitored through the following switch operation.
[ ] switch: Selection
[ ] switch: Selection
[ ] switch: Registration
ii) Selection with numeral keys:
Input a 5-digit code to select the item of
that code directly and depress [ ]
switch.
a A monitoring item can be set in any number

between the min. one to the max. four. (Depending upon the selected item, the max.
number is less than four)
a In case of monitoring 1 to 3 items, move to
the monitored information display through
PC600-8
17
SEN00445-03
4) Monitored information holding function

If [ ] switch is depressed while monitoring,
all the monitored information are put on
hold. If [ ] switch is depressed in this condition, information holding is released.
5) Machine setting mode switching function

If it becomes necessary to change settings
of working mode, travel speed and autodeceleration while monitoring, depress the
corresponding switch, then the mode confirmation display is shown.
a When a specific setting is confirmed, depress [ ] switch, then the display returns to that of monitoring.
a In case a specific setting has been
changed while monitoring, the new setting is still maintained when returning
from Service Menu to Operator's Menu
after the monitoring is finished.
18
PC600-8
SEN00445-03
Monitoring items list

Code
No.
Monitoring item
Unit (Default: ISO)

ISO
meter
inch
Remarks
00000 Return
(Not displayed)
Ending menu
99999 To Display Screen
(Not displayed)
Display execution menu
00200 Controller Model Select
Numeral
00201 Machine ID
Numeral
01002 Engine Speed
r/min
rpm
rpm
01601 2nd Eng Speed Command
r/min
rpm
rpm
01100 F Pump Pressure
MPa
kg/cm2
Psi
01101 R Pump Pressure
MPa
kg/cm2
Psi
04107 Coolant Temperature
14200 Fuel Temperature
04401 Hydr. Oil Temperature
37502 Ambient Temperature
01300 TVC Sol. Curr
mA
mA
mA
31623 Fan Pump EPC Sol. Curr
mA
mA
mA
03200 Battery Voltage
03203 Battery Power Supply
04300 Battery Charge Vol.
01006 Engine Speed
r/min
rpm
rpm
37200 Engine Oil Pressure
MPa
kg/cm2
Psi
36400 Rail Pressure
MPa
kg/cm2
Psi
37400 Ambient Pressure
kPa
kg/cm
Psi
18400 Intake Temperature
18500 Charge Temperature
36500 Boost Pressure
kPa
kg/cm2
Psi
18000 EGR Inlet Pressure
kPa
kg/cm
Psi
18100 EGR Valve Position
mm
mm
in
18200 BPS Valve Position
mm
mm
in
36700 Engine Torque Ratio
Nm
Nm
kgfm
01112 F Pump Pres. Sensor Vol.
01113 R Pump Pres. Sensor Vol.
03000 Fuel Dial Pos Sens Volt
04200 Fuel Level Sensor Vol.
04105 Coolant Temp Sens Volt
14201 Fuel Temp. Sensor Vol.
04402 Hydr. Temp. Sensor Vol.
37503 Ambi. Temp. Sensor Vol.
37201 Eng Oil Press Sens Volt
18700 Engine Output Torque
PC600-8
19
SEN00445-03
Code
No.
Monitoring item
Unit (Default: ISO)

ISO
meter
inch
37401 Ambient Press Sens Volt
18401 Intake Temp Sens Volt
18501 Charge Temp Sens Volt
36501 Charge Press Sens Volt
36401 Rail Pressure Sens Volt
18001 EGR In Press Sens Volt
18101 EGR Valve Pos Sens Volt
18201 BPS Valve Pos Sens Volt
17201 PCV Close Timing
CA
CA
CA
17500 Engine Power Mode
31701 Throttle Position
31706 Final Throttle Position
18600 Inject Fueling Command
mg/st
mg/st
mg/st
36200 Rail Press Command
MPa
kg/cm
PSi
36300 Injection Timing Command
CA
CA
CA
37300 Fuel Rate (Note 1)
L/h
L/h
L/h
01602 2nd Eng. Speed Command
13113 Main Pump Absorb Torque
Nm
kgm
Ibft
13114 Fan Pump Absorb Torque
Nm
kgm
Ibft
13112 Total Pump Absorb Torque
Nm
kgm
Ibft
01900 Pressure Switch 1
01901 Pressure Switch 2
02300 Solenoid 1
02200 Switch Input 1
20
Swing
Display of ON/OFF
Travel
Display of ON/OFF
Boom Lower
Display of ON/OFF
Boom Raise
Display of ON/OFF
Arm Curl
Display of ON/OFF
Arm Dump
Display of ON/OFF
Bucket Curl
Display of ON/OFF
Bucket Dump
Display of ON/OFF
Service
Display of ON/OFF
Travel Steering
Display of ON/OFF
Bucket Hi Cancel
Display of ON/OFF
Swing Brake
Display of ON/OFF
2-Stage Relief
Display of ON/OFF
Travel Speed
Display of ON/OFF
Fan Reverse
Display of ON/OFF
CO Cancel
Display of ON/OFF
Lever SW
Display of ON/OFF
Swing Release SW
Display of ON/OFF
Swing Brake S
Display of ON/OFF
Remarks
PC600-8
SEN00445-03
Code
No.
Monitoring item

05500 Sensor Input 1

03700 Controller Output 1
03701 Controller Output 2
04500 Monitor Input 1
Unit (Default: ISO)

ISO
meter
inch
Model Select 1
Display of ON/OFF
Model Select 2
Display of ON/OFF
Model Select 3
Display of ON/OFF
Model Select 4
Display of ON/OFF
Model Select 5
Display of ON/OFF
Key Switch (AAC)
Display of ON/OFF
Step Light SW
Display of ON/OFF
Horn SW
Display of ON/OFF
Over Load Sensor
Display of ON/OFF
Auto Greasing
Display of ON/OFF
Batt. Relay Dr.
Display of ON/OFF
Step L. Relay
Display of ON/OFF
Flush L. Relay
Display of ON/OFF
Travel Alarm
Display of ON/OFF
Key Switch
Display of ON/OFF
Start
Display of ON/OFF
Preheat
Display of ON/OFF
Light
Display of ON/OFF
Rad. Level
Display of ON/OFF
Aircleaner
Display of ON/OFF
Eng. Oil Level
Display of ON/OFF
Battery Charge
Display of ON/OFF
Swing Brake SW.
Display of ON/OFF
Bzzr Cancel SW.
Display of ON/OFF
Window Limit SW.
Display of ON/OFF
W Limit SW.
Display of ON/OFF
Upper P Limit SW.
Display of ON/OFF
Lower P Limit SW.
Display of ON/OFF
20216 ECM Build Version
20217 ECM CAL Data Ver.
18900 ECM Internal Temp
20400 ECM Serial No.
20200 Monitor Prog. Version
20212 Pump Con. Prog. Version
Remarks
a As the unit of display, one of "SI unit system", "Metric unit system", and "Inch unit system" can be selected.
a The unit of display can be changed with "Unit" in the "AAAA/ Default" function of the Service Menu.
a "CA" of the unit of display denotes the crankshaft angle.
Note 1: The momentary fuel consumption (Code No.: 37300) is the theoretical fuel consumption ratio (Since it is
a theoretical value, it is a little different from the actual fuel consumption ratio).
PC600-8
21
SEN00445-03
17. Function for Abnormality Record [02]

The machine monitor records failures that
occurred on the machines in the past after classifying them into failures in the electric system
and those in the mechanical system. Information
on them can be displayed through the following
operation.
Select 02 Abnormality Record in the initial
display of Service Menu and depress [ ]
switch.
2) Selection of Submenu
Select an appropriate item from Submenu in
the Abnormality Record display and depress
[ ] switch.
22
No.
Abnormality Record Submenu
00
Return
(termination of Abnormality Record)
01
Electrical Systems
02
Mechanical Systems
3) Information shown in display of Abnormality

Record in the electrical system
[1]: The numerator expresses sequence of
failure occurrence, counting from the
latest one. The denominator expresses
the total number of a specific failure
recorded.
[2]: "E" is displayed as long as the failure is
not repaired.
Failure Code (section in 4 digits and
phenomenon in 2 digits)
[3]: Time elapsed since the occurrence of
the first failure
[4]: Contents of failure
a Refer to "Table for failure code No." in
Operator's Menu.
4) Information shown in display of Abnormality

Record in the mechanical systems
[1]: Record No.
[2]: Contents of Abnormality
[3]: Failure Code (section in 4 digits and
phenomenon in 2 digits)
[4]: Total number of occurrence
[5]: Service meter reading at the initial
occurrence
a Refer to "Table for failure code No." in
Operator's Menu.
PC600-8
SEN00445-03
5) Resetting Electrical Systems

a Resetting the Abnormality Record (deletion) is possible only with the electrical
system. The Abnormality Record in the
mechanical system cannot be reset.
a For resetting any specific or all information in the Electrical Systems, follow the
operation explained below.
i)
ii)
Through the following switch operation,

call the resetting display in the display of
Electrical Systems.
Switch operation:
[ ] +[1] o [2] o [3]
a This is the same switch operation in
changing the display to Service
Menu.
Operate the switch, following the instructions shown in the resetting display.
a When resetting specific information

only, call the display of that specific
information and reset it with either
[ ] switch or [ ] switch.
a When resetting all the information, a
display of any information will do.
PC600-8
23
SEN00445-03
18. Function for Maintenance Record [03]
The machine monitor panel records information
on the maintenance of filters and oils. The
stored information can be displayed through the
following switch operation.
Select 03 Maintenance Record in Service
Menu and depress [ ] switch.
2) Information to be displayed
[1]: Name of oils and filters
[2]: Times of replacement to date
[3]: Service meter reading at the latest
replacement
24
19. Function for Maintenance Mode Change [04]

Conditions set for controlling maintenance display function can be changed in the following
manner.
Turn the function effectual or ineffectual.
Change the set interval for replacement.
Select 04 Maintenance Mode Change in
the initial display of Service Menu, and
depress [ ] switch.
2) Selection of item to be changed

Select an item to be changed in the display
of Maintenance Mode Change menu.
PC600-8
No.
Maintenance mode change item
00
Return (Termination of maintenance

mode change)
01
Maintenance Mode On/Off
02
Engine Oil Exch. Int.
03
Engine Oil Filter Exch. Int.
04
Main Fuel Filter Exch. Int.
41
Pre Fuel Filter Exch. Int.
05
Hydr. Oil Filter Exch. Int.
06
H/Tank Breather Exch. Int.
07
Corro. Resis. Exch. Int.
08
PTO Oil Service Int.
09
Final Drive Oil Exch. Int.
10
S/Machinery Oil Exch. Int.
11
Hydraulic Oil Exch. Int.
12
Use Default Values
SEN00445-03
4) Set contents of individual items
[1]: Default: The maintenance time set in
the monitor (recommended by the manufacturer and cannot be changed).
[2]: Set: Maintenance time that can be
freely set. The maintenance mode program functions based on this maintenance time. (The maintenance time can
be increased or decreased by 50 hours
with [ ] or [ ] switch)
[3]: On: Maintenance display function with
this instruction becomes effectual.
[4]: Off: Maintenance display with this
instruction becomes ineffectual.
a The lowest maintenance time is 50 h.
a 01 and 12 menus are provided for setting the

whole maintenance mode, while those from
02 through 11 are for setting individual items.
3) Contents of Maintenance Mode On/Off
On: The maintenance display function of
all oil and filter related items are turned
effectual. (Irrespective of whether "On"
or "Off" set for individual items, this setting prevails)
Off: The maintenance display function of
all oil and filter related items are turned
ineffectual. (Irrespective of whether "On"
or "Off" set for individual items, this setting prevails)
PC600-8
5) Set contents of "Use Default Values"

When selecting this menu and depressing
the switch [ ], all individual time settings
are reduced to the initial settings.
25
SEN00445-03
20. Function for Phone Number Entry [05]
In the display of Action Code, a telephone number and Failure Code are shown alternately.
Phone number can be inputted or modified in
the following manner.
a If there is no Phone number registered, the
display for Phone numbers does not appear.
Select 05 Phone Number Entry menu in
the display of Service Menu, and depress
[ ] switch.
3) Entry and setting phone number

Following the method explained below,
entry a phone number in the Phone Number
Entry display (Entry automatically begins
with a cursor at the left end).
i) Enter a number into a cursor at the left
end with a ten-key.
ii) Depress [ ] switch when all the numbers have been entered.
a Numbers can be entered up to the max.
12 digits, but omit unnecessary digits.
a When entering a wrong number, depress [left bottom (blank)] switch, then
the cursor goes back by one digit.
a When input is finished, the display
changes to Entry display shown above.
If the inputted Phone number is shown in
this display, the input is normal.
2) Changing the display

Select Entry next to change the display to
the Phone Number Entry display.
a Even if a Phone number is already inputted, it is deleted, upon switching to the
Phone Number Entry display.
26
PC600-8
21. Function for AAAA/Default [06]

It is possible to change the following settings for
the machine monitor as well as the machine.
Make a change as is required.
Working mode when the engine starting
switch is in the ON position.
Display language in Service Menu
Display unit in the monitoring function
Setting of double wiper or single wiper
Select 06 "AAAA/Default menu" in the initial display of Service Menu, and depress
[ ] switch.
SEN00445-03
3) Function for Key-on Mode
When the engine starting switch is turned
ON, a working mode can be set that is
shown in the machine monitor.
P Mode, E Mode, L Mode, B Mode: If
any of them is set, the machine always
ramps up with that working mode, when
turning the engine starting switch ON.
Mode at Previous Key-off: If this mode is
set, the machine ramps up with the
working mode that was last used in the
previous machine operation.
Default Value: If this mode is set, the
machine ramps up with the default mode
(P mode only) that was originally set at
the time of delivery from the factory.
2) Selection of submenu
Select an item to change from the submenu,
and depress [ ] switch.
AAAA/Default submenu
No.
PC600-8
00
Return
01
Key-on Mode
02
Language
03
Unit
04
Wiper Select
05
All Default Value
27
SEN00445-03
4) Function for AA/Language
In Service Menu, the language in use can
be changed between Japanese and
English.
a English is used as the language for default setting in the machine monitor.
a If the machine monitor for spare parts is
to be used in a Japanese-speaking region or organization, change the language from English to Japanese, using
this function.
6) Function for wiper select

The wiper specification can be set.
1 wiper: Machine with standard cab or
fixed-front window cab
(Only upper wiper)
2 wipers: Machine with fixed-front window cab (if equipped)
(Upper wiper and lower wiper)
a If this setting is not matched to the specification of the actually installed wiper,
the wiper may not operate normally or an
error is detected.
5) Function for Unit

As the unit to be used in the monitoring
function display of Service Menu, three
kinds of unit are provided.
a Unit used for default setting in the machine monitor is SI, i.e. International system of units.
28
PC600-8
SEN00445-03
22. Function for Adjustment [07]

The machine can be adjusted with the machine
monitor.
Select "07 Adjustment" on the service menu
3) Function of pump absorption torque

The pump absorption torque can be
adjusted in the following ranges.
a Basically, this setting does not need to
be changed.
Adjustment
value
2) Selection of sub menu

Select the sub menu to check the setting
No.
PC600-8
Pump absorption torque
220
+98.1 Nm {+10.0 kgm}
221
+73.5 Nm {+7.5 kgm}
222
+49.0 Nm {+5.0 kgm}
223
+24.5 Nm {+2.5 kgm}
224
0.0 Nm {0.0 kgm}
225
24.5 Nm {2.5 kgm}
226
49.0 Nm {5.0 kgm}
227
73.5 Nm {7.5 kgm}
228
98.1 Nm {10.0 kgm}
Sub menu of adjustment
00
Return (Finish adjustment)
01
Pump Absorption Torque
02
Fan Speed Mode Select
03
Fan 100% Speed Adjust
04
Fan 70% Speed Adjust
29
SEN00445-03
4) Fan speed mode selection function

To adjust the fan speed, it must be fixed
temporarily. Select one of the following
modes as necessary.
Adjustment
value
Fan speed mode selection
550
Normal mode: For normal operation
551
70% speed mode: For check of

meeting of regulations
552
100% speed mode: For fan speed

adjustment
a If the starting switch is turned OFF, the

fan speed mode returns to "550: Normal
mode".
Keep the starting switch ON while adjusting the fan speed.
a The set value is kept even after the starting switch is turned OFF.
Adjustment
value
Fan 100% Speed
560
+ 140 rpm
561
+ 120 rpm
562
+ 100 rpm
563
+ 80 rpm
564
+ 60 rpm
565
+ 40 rpm
566
+ 20 rpm
567
568
20 rpm
569
40 rpm
56A
60 rpm
56B
80 rpm
56C
100 rpm
56D
120 rpm
56E
140 rpm
6) Fan 70% speed adjustment function

After "70% speed" is set in 4) above, the fan
speed can be adjusted within the following
range.
5) Fan 100% speed adjustment function

After "100% speed" is set in 4) above, the
fan speed can be adjusted within the following range.
a Adjust the fan speed within the standard
range (1,050 50 rpm).
30
PC600-8
SEN00445-03
a The set value is kept even after the starting switch is turned OFF (only when the
fan is set in the 70% speed mode).
Adjustment
value
PC600-8
Fan 70% Speed
570
+ 140 rpm
571
+ 120 rpm
572
+ 100 rpm
573
+ 80 rpm
574
+ 60 rpm
575
+ 40 rpm
576
+ 20 rpm
577
578
20 rpm
579
40 rpm
57A
60 rpm
57B
80 rpm
57C
100 rpm
57D
120 rpm
57E
140 rpm
31
SEN00445-03
23. Function of Cylinder Cut Out [08]

The Cylinder Cut Out operation of engine can be
controlled with the machine monitor.
Cylinder Cut Out operation means to run the
engine with 1 or more fuel injectors disabled
electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (or,
combustion in it is abnormal).
Select "08 Cylinder Cut Out" on the initial
screen of the Service Menu and press the
[ ] switch.
3) Cancellation of disabled cylinders
Press switches [1] [6] on the machine
monitor corresponding to the disabled cylinder Nos. to cancel disabling of those cylinders.
a After a switch is pressed, if the cylinder
No. corresponding to it on the monitor
panel is displayed black in a black frame,
disabling of the cylinder is cancelled.
2) Setting of cylinders to be disabled

Press switches [1] [6] on the machine
monitor corresponding to the cylinder Nos.
to be disabled.
a After a switch is pressed, if the cylinder
No. corresponding to it on the monitor
panel is displayed white in a white frame,
the cylinder is disabled (If setting is
wrong, press the same switch again).
a Only one or more cylinders can be disabled for the reduced cylinder mode operation.
32
PC600-8
4) Function of holding engine speed

If the [ ] switch is pressed while the Cylinder Cut Out operation screen is used, the
engine speed is held and displayed on the
lower line.
If the [ ] switch is pressed while the engine
speed is held, holding of the engine speed is
cancelled and the engine speed displayed
on the lower line goes off.
a If the holding function is used, the held
engine speed is displayed in ( ) on the
lower line and the current engine speed
is displayed on the upper line.
a The holding function can be used both in
and out of the Cylinder Cut Out operation.
PC600-8
SEN00445-03
[Reference]: How to use holding function effectively
The engine speed displayed by the holding
function is held on the screen until the holding
function is cancelled, regardless of setting and
cancellation of the Cylinder Cut Out operation.
Accordingly, a defective cylinder can be found
out effectively according to the following procedure.
(1) Run the engine normally (without disabling
any cylinder) and hold the engine speed.
(2) Disable a cylinder to be checked.
(3) Run the engine under the same condition as
the normal operation in step (1) and compare the engine speed at this time with the
held engine speed.
(4) Check the cylinder once, regardless of
change of the engine speed.
(5) Repeat steps (2) - (4) to check the other cylinders.
a If the engine speed does not lower at all
or lower less when a cylinder is selected
for the Cylinder Cut Out operation, combustion in that cylinder must be abnormal.
33
SEN00445-03
24. Function of no injection [09]

The operator can perform no-injection with the
machine monitor.
No-injection cranking is the function of preventing fuel injection through the injector when the
engine is rotated with the starting motor for measuring compression pressure, etc.
a Be sure to set the no-injection while the engine is stopped.
1) Selecting menu
In the initial screen of the service menu,
select "09 No Injection" and press the [ ]
switch.
4) Select "No Injection" and press the [ ]
switch, and the letters of "Under Preparation" appear.
a The letters of "Under Preparation" are
red.
2) The initial screen of no-injection appears.

a The letters of "Check Communication"
are red.
5) When the engine is ready for no injection

cranking, the letters of "Under Preparation"
change to "After No Injection".
a The letters of "After No Injection" are
green.
6) Under this condition, crank the engine with
the starting motor.
a Limit the no injection cranking to 20 seconds to protect the starting motor.
3) After communication is checked, the letters

disappear and the following screen appears.
34
PC600-8
SEN00445-03
7) After finishing no injection, press the [ ]

switch on the previous screen, and the letters of "End" are displayed for 3 seconds.
a The letters of "End" are green.
8) To finish no injection cranking, select "Return".
a If you select the function of no injection

cranking and then select No Injection in
4) by mistake while the engine is running, the letters of "Engine Running" are
displayed. Even if the engine is stopped,
the letters of "Engine Running" are kept
displayed until the screen returns to the
service menu screen.
PC600-8
35
SEN00445-03
Handling controller voltage circuit

1. When disconnecting or connecting a connector
between the engine controller and engine, be
sure to turn the starting switch OFF.
2. If a T-adapter is inserted in or connected to a
connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.
36
PC600-8
SEN00445-03
Procedure for turning on

KOMTRAX terminal
When the machine is delivered, KOMTRAX terminal is installed:
a When the machine is delivered, KOMTRAX terminal is installed (machine with the standard
equipment), implement the following procedure.
1. Reporting of machine model, model number
and serial number
Report the machine model, model number and
serial number to the person responsible to operation of KOMTRAX.
2. Registration of KOMTRAX terminal
The person responsible to operation of
KOMTRAX shall register the subject terminal
using the KOMTRAX client PC.
a See KOMTRAX administrator manual for
the procedure.
a Above completes the necessary operations.
When installing KOMTRAX terminal after the
machine is delivered:
a When installing KOMTRAX terminal after the
machine is delivered (machine with the retrospective equipment), implement the following
procedure.
1. Station opening inspection
a Finish the operations of steps 4) to 7) within
30 seconds.
1) Turn OFF the starting switch and then, after
making sure 5 seconds have elapsed, proceed to the next step.
2) Make sure visually that the inspecting connectors 1 and 2 are connected.
a The test connector is clamped to the back
side of the KOMTRAX terminal cover (See
Preparation work for troubleshooting for
electrical system).
Inspecting connector 1:
G02 (female) and G03 (male)
Inspecting connector 2:
G04 (female) and G05 (male)
PC600-8
3) Disconnect the inspecting connector 1 and

maintain that state for 5 seconds.
4) Turn ON the starting switch and maintain
that state for 5 seconds.
5) Disconnect the inspecting connector 2 and
maintain that state for 5 seconds.
6) Connect the inspecting connector 1 again
and maintain that state for 5 seconds.
7) Connect the inspecting connector 2 again
8) Make sure that the KOMTRAX terminal 7segment indicator lamps are normally
turned on.
a After step 7), if display is normal, the 7segment indicator lamp displays for 30
seconds (d, 0, and are displayed
repeatedly).
37
SEN00445-03
a As [Normal] is indicated, proceed to the

next step.
a If [Abnormal] is indicated, repeat the procedure from step 1).
9) Set the starting switch to START position

and maintain it in that state for 5 seconds.
Make sure the engine is not started.
a If the engine is started, repeat the procedure from step 1).
10) Return the starting switch to ON position
a Don't return it to OFF position.
11) Set the starting switch to START position
again and make sure the engine is started.
12) Make sure that the KOMTRAX terminal 7segment indicator lamps are normally
turned on.
a As [Normal] is confirmed, proceed to the
next step (it will take 90 seconds to 15
minutes until normal display is restored).
a If [GPS position data sensing error] were
displayed, check the GPS antenna and
cable for external troubles. If any, repair
the trouble and repeat the procedure
from step 1).
a If [Receiving error] were displayed,
check the communication antenna and
cable for external troubles. If any, repair
the trouble and repeat the procedure
from step 1).
a If [GPS position data sensing error and
receiving error] were displayed, check
the GPS antenna and cable as well as
the communication antenna and cable
for external troubles. If any, repair the
trouble and repeat the procedure from
step 1).
a If [Network error] were displayed, check
the indication of [LED-C4] referencing
KOMTRAX terminal lamp indications.
(When CAN is not recognized, check
KOMTRAX terminal CAN harness for
troubles. If any, repair the trouble and repeat the procedure from step 1)).
38
13) Turn the starting switch OFF.

14) Make sure that the 7-segment indicator
lamp (a) comes on normally in 5 seconds.
a As [Normal] is displayed, the station
opening inspection is complete.
a If [Abnormal] is displayed, the inspection
is incomplete and must be repeated from
step 1).
PC600-8
SEN00445-03
2. Application for start of use

a The application for start of use is allowed
only after the terminal station opening inspection has been successfully ended.
1) Concerning the machine body for which the
station opening inspection has been completed, report the following information to
the person responsible to operation of KOMTRAX.
(1) Information of the machine body for
which the station opening inspection
has been completed (machine model,
model number and serial number)
(2) Part number and serial number of
KOMTRAX terminal
(3) The service meter reading when KOMTRAX
terminal was installed (in 0.1 h unit)
2) The person responsible to operation of

KOMTRAX shall register the machine body
using the KOMTRAX client PC.
a See KOMTRAX administrator manual
for the procedure.
a Above completes the necessary operations.
PC600-8
39
SEN00445-03
KOMTRAX terminal lamp indications
LED for CPU

1. LED-C1 (R signal and ACC signal)
2. LED-C2 (Initial output state)
3. LED-C3 (S-NET and C signal state)
4. LED-C4 (CAN state)
5. LED-C5 (Download writing state)
6. LED-C6 (Download writing state)
40
7-segment and dot for CPU

7. 7-segment (Number of mails which are not transmitted yet and condition of satellite link)
8. Dot (GPS positioning state)
PC600-8
SEN00445-03
KOMTRAX system displays various information in the system as well as contents of information processing on
the LED display unit located at the top of KOMTRAX terminal. Thus, when a failure on the system is suspected,
implement the following checkups.
Checking antennas
Checking terminal LED display
Before using KOMTRAX, the application for start of use and the machine side station opening inspection must
be completed.
Checking antennas
a Before inspecting display of LED, check the communication antenna and its vicinity as well as GPS antenna
and its vicinity for any trouble.
The communication antenna shall not be disconnected or damaged.
The communication antenna cable shall not be broken and shall be appropriately connected to KOMTRAX
terminal.
GPS antenna shall not be disconnected or damaged.
GPS antenna cable shall not broken and shall be appropriately connected to KOMTRAX terminal.
Checking terminal LED indication
1. Display contents of LED for CPU
a Turn ON, START the starting switch or the engine prior to inspection of LED display.
No.
LED
LED-C1
LED-C2
LED-C3
LED-C4
Name and function
State of starting switch

ACC signal, alternator R
signal
State of engine control

signal
State of S-NET connection and starting switch C

signal
State of CAN connection
LED-C5
Download writing state
LED-C6
Display (*1)
Contents of display
ON
Starting switch ACC signal: ON, Alternator R signal: ON
Quick
flashing
Starting switch ACC signal: OFF, Alternator R signal: ON
Slow
flashing
Starting switch ACC signal: ON, Alternator R signal: OFF
OFF
Starting switch ACC signal: OFF, Alternator R signal: OFF
ON
Engine control signal: ON
OFF
Engine control signal: OFF
ON
S-NET: Connected, starting switch C signal: OFF
Quick
flashing
Starting switch C signal: ON
Slow
flashing
(Not used)
OFF
S-NET: Disconnected, Starting switch C signal: OFF
ON
CAN: Present (Fuel sensor: Absent)
Quick
flashing
CAN: Present (Fuel sensor: Present)
Slow
flashing
CAN: Absent (Fuel sensor: Present)
OFF
CAN: Absent (Fuel sensor: Absent)
Single side Download writing mode (Special function for system adminisON
trator)
Both sides
OFF
Normal working mode
*1: Types of flashing and flashing duration

Quick flashing: Flashing of approximately 1 second cycle
Slow flashing: Flashing of approximately 4 seconds cycle
PC600-8
41
SEN00445-03
2. Display contents of 7-segment and dots for CPU

a Turn ON the starting switch prior to inspection of LED display.
No.
Display unit
Name and function
7-segment
Number of mails which

are not sent yet and satellite capturing condition)
Dot
State of positioning with

GPS
Display (*2)
Contents of display
Lighting of
09
Figure indicates number of mails which are not sent yet

(When 10 or more mails are not sent yet, 9 is indicated).
Lighting indicates that satellite is captured.
Quick
blinking of
09
Figure indicates number of mails which are not sent yet

(When 10 or more mails are not sent yet, 9 is indicated).
Quick blinking indicates that satellite is not captured.
ON
Positioning with GPS complete (Position is recognized, *3)
OFF
Positioning with GPS incomplete (Position is not recognized, *3)
*2: Types of flashing and flashing duration

Quick flashing: Flashing of approximately 1.0 second cycle.
Slow flashing: Flashing of approximately 4.0 seconds cycle
*3: Remarks on measuring condition of GPS
In a outdoor location within radio waves penetration range, it sometimes takes more than a minute from
turning on of the starting switch to completion of the positioning.
Positioning is not available in a location where radio waves are extremely weak or unreachable.
42
PC600-8
Preparation work for

troubleshooting electrical
system
SEN00445-03
2. Engine controller
1) Remove controller cover (1).
a When troubleshooting an electric circuit related

to the machine monitor, engine controller, or
pump controller, expose the related connectors
1. Machine monitor
1) Remove cover (1).
a The cover is secured with 2 clips at the
top and bottom. Those clips can be removed by pulling them up.
a If a sunlight sensor for the air conditioner
is installed, disconnect connector P15
on the backside of the cover.
2) Insert or connect T-adapters for troubleshooting to connectors ENG, CE02, and

CE03 of the engine controller.
a Since the connectors are secured with
screws, loosen those screws before disconnecting them.
a After returning the connectors, tighten
the screws to the specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
2) Remove the 3 mounting screws and disconnect machine monitor (2) from the mount.
a Take care not to drop the mounting
screws in the console.
3) Insert or connect T-adapters for troubleshooting to connectors CM01, CM02, and
CM03 of the machine monitor.
PC600-8
43
SEN00445-03
3. Pump controller
a The pump controller is installed in the cover
at the rear of the operator's seat.
2) Insert or connect T-adapters for troubleshooting to connectors CP01, CP02, and

CP03 of the pump controller (6).
a Since the connectors are secured with
screws, loosen those screws before disconnecting them.
a After returning the connectors, tighten
the screws to the specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
44
PC600-8
Adjusting mirrors
1. Mirrors installed positions
SEN00445-03
3. Adjusting mirror (b)
Adjust mirror (b) so that the operator can see
hatched area (b') at the right rear end of the
machine.
a Installed position, dimension and visibility
Dimension X1 of installed position:
195 mm
Visibility Y (right): 3,100 mm
Hatched area (b') must be seen.
a Loosen mirror mounting screw (2) and bolt
(3) and adjust the mirror so that the operator
can see (b') most from the operator's seat.
2. Adjusting mirror (a)

Adjust mirror (a) so that the operator can see
hatched area (a') at the left rear end of the
machine.
a Installed position, dimension and visibility
Dimension X2 of installed position:
75 mm
Visibility Z (left): 2,500 mm
Visibility H (height): 1,600 mm
Hatched area (a') must be seen.
a Loosen mirror mounting nut (1) and adjust
the mirror so that the operator can see (a')
most from the operator's seat.
PC600-8
45
Pm-clinic service
46
PC600-8
Measuring procedures
Positions to install measuring devices (Related to engine and PTO)
PC600-8
47
Measuring procedures
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)
48
PC600-8
PC600-8
49
3.14 - 3.53
{32 - 36}
50
3.14 - 3.53
{32 - 36}
PC600-8
Pm-CLINIC SERVICE PC600, 600LC-8

Visual check of welded structures
a If any crack is found, draw its shape below.
Arm
1. Arm cylinder bracket
T Left
T Right
2. Arm foot
T Left
T Right T End plate
3. Arm top boss
T Left
T Right
PC600-8
Boom
4. Boom top bracket
T Left
T Right
5. Boom cylinder bracket
T Left
T Right
6. Arm cylinder bracket
T Left
T Right
7. Boom lower plate
T Left
T Right
8. Boom foot
T Left
T Right
Revolving frame
9. Boom bracket
T Left
T Right
Track frame
10. Circle bracket
T Front T Rear
T Left
T Right
11. Track frame mounting section
T Front T Rear
T Left
T Right
51
Undercarriage inspection
(Program form No.: SELA195001)
52
PC600-8
SEN00445-03
PC600-8
53
SEN00445-03

2009 KOMATSU
All Rights Reserved
54
SEN03960-04
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up
40 Troubleshooting
Failure codes table............................................................................................................................................... 2
Fuse locations...................................................................................................................................................... 6
PC600-8
SEN03960-04
40 Troubleshooting
Failure codes table
Action
code
Failure
code
A000N1
Alarm
buzzer
in charge
record
MON
Mechanical
system
AA10NX Aircleaner Clogging
MON
Mechanical
system
AB00KE Charge Voltage Low
MON
Mechanical
system
B@BAZG Eng. Oil Press. Low
MON
Mechanical
system
B@BAZK Eng. Oil Level Low
MON
Mechanical
system
B@BCNS Eng. Water Overheat
MON
Mechanical
system
B@BCZK Eng. Water Lvl Low
MON
Mechanical
system
B@HANS Hydr. Oil Overheat
MON
Mechanical
system
ENG
Electrical
system
Eng. Hi Out of Std
E10
CA111
E10
CA115
ENG
Electrical
system
E11
CA122
ENG
Electrical
system
E11
CA123
ENG
Electrical
system
E14
CA131
ENG
Electrical
system
E14
CA132
ENG
Electrical
system
E15
CA135
ENG
Electrical
system
E15
CA141
ENG
Electrical
system
E15
CA144
ENG
Electrical
system
E15
CA145
ENG
Electrical
system
E15
CA153
ENG
Electrical
system
E15
CA154
ENG
Electrical
system
E15
CA187
ENG
Electrical
system
E15
CA221
ENG
Electrical
system
E15
CA222
ENG
Electrical
system
E15
CA227
ENG
Electrical
system
CA234
Eng Overspeed
ENG
Mechanical
system
E03
CA238
ENG
Electrical
system
E15
CA263
ENG
Electrical
system
E15
CA265
ENG
Electrical
system
E11
CA271
ENG
Electrical
system
Reference
document No.
Troubleshooting
by failure code,
Part 1
SEN00448-02
PC600-8
40 Troubleshooting
Action
code
Failure
code
E11
CA272
SEN03960-04

IMV/PCV1 Open Error
Alarm
buzzer
q
in charge
record
ENG
Electrical
system
E11
CA273
PCV2 Short Error
ENG
Electrical
system
E11
CA274
PCV2 Open Error
ENG
Electrical
system
E11
CA322
ENG
Electrical
system
E11
CA323
ENG
Electrical
system
E11
CA324
ENG
Electrical
system
E11
CA325
ENG
Electrical
system
E11
CA331
ENG
Electrical
system
E11
CA332
ENG
Electrical
system
E10
CA342
ENG
Electrical
system
E10
CA351
ENG
Electrical
system
E15
CA352
ENG
Electrical
system
E15
CA386
ENG
Electrical
system
E10
CA441
Battery Voltage low error
ENG
Electrical
system
E10
CA442
Battery Voltage high error
ENG
Mechanical
system
E11
CA449
ENG
Electrical
system
E11
CA451
ENG
Electrical
system
E11
CA452
ENG
Electrical
system
E15
CA553
ENG
Electrical
system
CA554
ENG
Electrical
system
E15
CA559
ENG
Electrical
system
E11
CA689
ENG
Electrical
system
E11
CA731
ENG
Electrical
system
E10
CA757
ENG
Electrical
system
E11
CA778
Eng Bkup Speed Sensor Error
ENG
Electrical
system
E15
CA1228
ENG
Electrical
system
E11
CA1625
ENG
Electrical
system
E11
CA1626
ENG
Electrical
system
E11
CA1627
ENG
Electrical
system
E15
CA1628
ENG
Electrical
system
PC600-8
Reference
document No.
Troubleshooting
by failure code,
Part 1
SEN00448-02
Troubleshooting
by failure code,
Part 2
SEN00449-02
SEN03960-04
40 Troubleshooting
Action
code
Failure
code
E11
CA1629
ENG
Electrical
system
E11
CA1631
ENG
Electrical
system
E11
CA1632
ENG
Electrical
system
E0E
CA1633
ENG
Electrical
system
E11
CA1642
ENG
Electrical
system
E11
CA1653
ENG
Electrical
system
E14
CA2185
ENG
Electrical
system
Alarm
buzzer
in charge
record
E14
CA2186
ENG
Electrical
system
E11
CA2249
ENG
Electrical
system
E11
CA2271
ENG
Electrical
system
E11
CA2272
ENG
Electrical
system
E11
CA2351
ENG
Electrical
system
E11
CA2352
ENG
Electrical
system
E15
CA2555
Grid Htr relay Volt Low Error
ENG
Electrical
system
E15
CA2556
Grid Htr relay Volt High Error
ENG
Electrical
system
D110KB
PUMP
D163KB
PUMP
D195KB
PUMP
E0E
DA22KK Pump Solenoid Power Low Error
PUMP
DA25KP Press. Sensor Power Abnormality
PUMP
DA2SKQ Model selection Abnormality
PUMP
DA80MA Auto. Lub. Abnormal
PUMP
E0E
DA2RMC Pump Comm. Abnormality
PUMP
E0E
DAFRMC Monitor Comm. Abnormality
PUMP
DGE5KY Ambi. Temp. Sensor S/C
PUMP
DGH2KB Hydr. Oil Temp. Sensor S/C
PUMP
DHPAMA F Pump P.Sensor Abnormality
PUMP
DHPBMA R Pump P.Sensor Abnormality
PUMP
DV20KB Travel Alarm S/C
PUMP
DW43KA Travel Speed Sol. Disc.
PUMP
DW43KB Travel Speed Sol. S/C
PUMP
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Mechanical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Reference
document No.
Troubleshooting
by failure code,
Part 2
SEN00449-02
Troubleshooting
by failure code,
Part 3
SEN00450-02
PC600-8
40 Troubleshooting
Action
code
Failure
code
SEN03960-04
Alarm
buzzer
in charge
record
E03
DW45KA Swing Brake Sol. Disc.
PUMP
Electrical
system
E03
DW45KB Swing Brake Sol. S/C
PUMP
Electrical
system
DW48KA CO Cancel Sol. Disc.
PUMP
Electrical
system
DW48KB CO Cancel Sol. S/C
PUMP
Electrical
system
DW7BKA Fan Reverse Sol. Disc.
PUMP
Electrical
system
DW7BKB Fan Reverse 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
DWK0KA 2-stage Relief Sol. Disc.
PUMP
Electrical
system
DWK0KB 2-stage Relief Sol. S/C
PUMP
Electrical
system
E11
DX16KA Fan Pump EPC Sol. Disc.
PUMP
Electrical
system
E11
DX16KB Fan Pump EPC Sol. S/C
PUMP
Electrical
system
E02
DXA0KA TVC Sol. Disc.
PUMP
Electrical
system
E02
DXA0KB TVC Sol. S/C
PUMP
Electrical
system
DY20KA Wiper Working Abnormality
PUMP
Electrical
system
DY20MA Wiper Parking Abnormality
PUMP
Electrical
system
DY2CKB Washer Drive S/C
PUMP
Electrical
system
DY2DKB Wiper Drive (For) S/C
PUMP
Electrical
system
DY2EKB Wiper Drive (Rev) S/C
PUMP
Electrical
system
PC600-8
Reference
document No.
Troubleshooting
by failure code,
Part 3
SEN00450-02
SEN03960-04
40 Troubleshooting
Fuse locations
Connection table of circuit breakers
a This connection table shows the devices to which each power supply of the circuit breakers supplies power
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting for a displayed code, you should check the circuit breakers to see if the
power is supplied normally.
Type of power
supply
Switch power
supply
(Battery relay
terminal M)
Constant power
supply
(Battery relay
terminal B)
Circuit breaker
No.
1
2
3
4
5
6
7
8
9
Circuit breaker
capacity
40A
20A
20A
20A
20A
20A
30A
20A
20A
Destination of power
Fuse box (Fuses No. 1 15)
Boom working lamp, right headlamp
Grease pump
Pump controller power source
Head lamp on cab
Starting switch, Pump controller (Power supply for solenoid)
Engine controller (Power supply drive)
Machine monitor, Buzzer
Fuse box (Fuses No. 16 20)
Circuit breaker box inside the grease pump box locatd at the front right of machine.
PC600-8
40 Troubleshooting
SEN03960-04
Connection table of fuse boxes

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

2010 KOMATSU
All Rights Reserved
SEN00447-04
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up
40 Troubleshooting
Points to remember when troubleshooting........................................................................................................... 2
Sequence of events in troubleshooting ................................................................................................................ 3
Checks before troubleshooting ............................................................................................................................ 4
Classification and procedures of troubleshooting ................................................................................................ 5
Information contained in troubleshooting table .................................................................................................... 6
Failure-looking phenomenon and troubleshooting No. ........................................................................................ 8
Connection table for connector pin numbers ..................................................................................................... 12
T- branch box and T- branch adapter table ........................................................................................................ 48
PC600-8
SEN00447-04
40 Troubleshooting
Points to remember when troubleshooting

k
k
k
k
k
k
Stop the machine in a level ground, and check that the lock pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.
When carrying out troubleshooting, an important point is of course to understand the structure and function.
However, a shortcut to effective troubleshooting is to ask the operator various questions to form some idea of
possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry
to disassemble the components.
If components are disassembled immediately
after any failure occurs:
Parts that have no connection with the failure
or other unnecessary parts will be disassembled.
It will become impossible to find the cause of
the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in
accordance with the fixed procedure.
2. Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure?
6) When were these repairs carried out?
7) Has the same kind of failure occurred
before?
3. Check before troubleshooting
1) Check the oil level
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
5) Other maintenance items can be checked

externally, so check any item that is considered to be necessary.
4. Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation,
etc.
a When operating the machine to reenact
the troubleshooting symptoms, do not
carry out any investigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the
causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly.
a The basic procedure for troubleshooting
is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or
information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root
cause of the failure is not repaired, the same
failure will occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root
cause.
PC600-8
40 Troubleshooting
SEN00447-04
Sequence of events in troubleshooting
PC600-8
SEN00447-04
40 Troubleshooting
Checks before troubleshooting
Electrics, electrical equipment
Hydraulic,
Electrical
mechanical
equipment
equipment
Lubricating oil,
coolant
Item
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Check fuel level, type of fuel

Check for impurities in fuel
Check hydraulic oil level
Check hydraulic oil strainer
Check swing machinery oil level
Check engine oil level (oil pan oil level)
Check coolant level
Check dust indicator for clogging
Check hydraulic filter
Check final drive oil level
Judgement
value
Action
Add fuel
Clean, drain
Add oil
Clean, drain
Add oil
Add oil
Add coolant
Clean or replace
Replace
Add oil
1. Check for looseness, corrosion of battery terminal, wiring

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

2. Check for oil leakage
3. Carry out air bleeding
Repair
Repair
Bleed air
1.
2.
3.
4.
5.
Check battery voltage (engine stopped)

Check battery electrolyte level
Check for discolored, burnt, exposed wiring
Check for missing wiring clamps, hanging wiring
Check for water leaking on wiring (be particularly careful attention to
water leaking on connectors or terminals)
6. Check for blown, corroded fuses
7. Check alternator voltage (engine running at 1/2 throttle or above)
8. Check operating sound of battery relay

(when switch is turned ON/OFF)
20 30V
Replace
Add or replace
Replace
Repair
Disconnect
connector and dry
Replace
Replace
After
running for
several
minutes :
27.5 29.5V
Replace
PC600-8
SEN00447-04
40 Troubleshooting
Classification and procedures of troubleshooting

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

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to
the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, press the [ ] switch of the panel switch section in
the current condition to display the failure code.
Carry out troubleshooting in [Display of code] according to the displayed failure code of electrical system.
2. Procedure for troubleshooting to be taken when electrical system failure code or mechanical system
failure code is recorded in abnormality record:
If an action code is not displayed on the machine monitor, check for an electrical system failure code or
mechanical system failure code with the abnormality record function of the machine monitor.
If a code is recorded, carry out troubleshooting in [Display of code] according to that code.
a If failure codes of electrical system are recorded, delete all of them and reproduce them, and then see if
the trouble is still detected.
a A mechanical system failure code cannot be deleted.
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is not
recorded:
If an action code is not displayed and a abnormality record is not recorded in the machine monitor, a trouble
that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and
mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the
table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting
related to that phenomenon in the "E mode" or "H mode".
PC600-8
SEN00447-04
40 Troubleshooting
Information contained in troubleshooting table

a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their contents fully before proceeding to actual troubleshooting work.
Action Code
Failure Code
Display in
monitor panel
Display in
monitor panel
Failure content
Failure
phenomenon
Title of failure phenomenon shown in abnormality record
Failure status as detected by machine monitor or controller
Response from
Action taken by the machine monitor or controller to protect an affected system or equipment, when they
machine monidetect some failure.
tor or controller
Phenomenon
occurring on
machine
Phenomenon that occurs on the machine, resulting from the above action taken by the machine monitor
or controller
Relative
information
Information on the failure occurred as well as the troubleshooting

Cause
Presumed cause and

standard value in normalcy
Cause for presumed

failure
3 (The attached No. for
filing and reference
purpose only. It does not
stand for any priority)
Standard value in normalcy and references for troubleshooting

<Content Included>
Standard value in normalcy by which to pass "Good" or "No good" judgement over
the presumed cause
Reference for passing the above "Good" or "No Good" judgement
<Phenomenon of Wiring Harness Failure>
Disconnection
There is a faulty contact at the connector or disconnection of wiring harness
occurred.
Grounding fault
A wiring harness that is not connected with a grounding circuit has a contact with
the grounding circuit.
Hot short
Wiring harness which is not connected to power source (24 V) circuit is in contact
with power source (24 V) circuit.
<Precaution for Troubleshooting>
1) Connector No. display method and handling of T-adapter
Insert or connect T-adapters in the following manner before starting troubleshooting unless otherwise instructed.
If there is no indication of "male" or "female" in a specific connector No., disconnect the connector and insert the T-adapter into both male and female sides.
If there is an indication of "male" or "female" in a specific connector No., disconnect the connector and connect the T-adepter with only one side of either "male"
or "female".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative () lead OFF a circuit tester in the
following manner unless otherwise instructed.
Connect the positive (+) lead with the pin No. indicated at the front or the wiring
harness.
Connect the negative () lead with the pin No. indicated at the rear or the wiring
harness.
PC600-8
SEN00447-04
40 Troubleshooting
Related circuit diagram
This drawing is a part of the electric circuit diagram related to

troubleshooting.
Connector No.: Indicates (Model Number of pins) and
(Color).
"Connector No. and pin No." from each branching/merging
point: Shows the ends of branch or source of merging within
the parts of the same wiring harness.
Arrow (io): Roughly shows the location on the machine.
PC600-8
SEN00447-04
40 Troubleshooting
Failure-looking phenomenon and troubleshooting No.

Troubleshooting
No.
Failure-looking phenomenon
Code
display
E mode
H mode
S mode
Action to be taken concerning User Code, Error Code and Failure Code
1
Display User Code in monitor panel
Display Failure Code in mechanical system after checking Abnormality

Record
According to
displayed
code
Engine related failure

3
Starting performance is poor (starting always takes time)
4
5
Engine does not turn

Engine does not start
S-1
E-1
S-2 a)
Engine turns but no exhaust smoke

comes out
S-2 b)
Exhaust smoke comes out but engine

does not start (Fuel is being injected)
S-2 c)
Engine does not pick up smoothly (follow-up is poor)
S-3
Engine stops during operations
S-4
Engine does not rotate smoothly (hunting)
S-5
10
Engine lacks output (or lacks power)
S-6
11
Exhaust smoke is black (incomplete combustion)
S-7
12
Oil consumption is excessive (or exhaust smoke is blue)
S-8
13
Oil becomes contaminated quickly
S-9
14
Fuel consumption is excessive
S-10
15
Oil is in cooling water (or water spurts back, or water level goes down)
S-11
16
Oil pressure caution lamp lights up (drop in oil pressure)
S-12
17
Oil level rises (water, fuel in oil)
S-13
18
Water temperature becomes too high (overheating)
S-14
19
Abnormal noise is made
S-15
20
Vibration is excessive
S-16
21
Preheater does not operate
E-2
22
Auto engine warm-up device does not work
E-3
23
Auto-decelerator does not operate
E-4
H-5
Failure related to work equipment, swing and travel

24
Speed or power of all work equipment, travel, and swing is low
H-1
25
Engine speed lowers remarkably or engine stalls
H-2
26
All work equipment, travel, and swing systems do not work
27
Abnormal sound is heard from around pump
E-5
H-3
H-4
Work equipment-related failure

28
Boom speed or power is low
H-6
29
Arm speed or power is low
H-7
30
Bucket speed or power is low
H-8
31
Boom does not move
H-9
PC600-8
SEN00447-04
40 Troubleshooting
Troubleshooting
No.
Code
display
E mode
H mode
32
Arm does not move
H-10
33
Bucket does not move
H-11
34
Bottom dump does not move
35
Hydraulic drift of work equipment is large
H-13
36
Time lag of work equipment is large
H-14
37
Power max. function does not operate
E-6
H-15
38
Machine push-up function does not operate or stop
E-7
H-16
39
When arm and boom bucket are operated simultaneously,

boom bucket speeds are low
H-17
40
When bucket and boom arm swing travel are operated simultaneously, boom arm swing travel speeds are low
H-18
41
When arm and swing are operated simultaneously, swing speed is low
H-19
E-31
S mode
H-12
Travel related failure

42
Machine deviates in one direction
H-20
43
Machine deviates largely at start
H-21
44
Machine deviates largely during compound operation
H-22
45
Travel speed or power is low
H-23
46
Machine does not travel (only one track)
H-24
47
Travel speed does not change
H-25
48
Travel alarm does not sound or does not stop sounding
E-29
Swing related falure

49
Upper structure does not swing
H-26
50
Swing speed or acceleration is low
H-27
51
Upper structure overruns excessively when it stops swinging
H-28
52
Large shock is made when upper structure stops swinging
H-29
53
Large abnormal sound is made when upper structure stops swinging
H-30
54
Hydraulic drift of swing is large
H-31
Machine monitor related failure (Operators Menu: Ordinary Display)

55
Any item is not displayed on machine monitor
E-8
56
Part of display on machine monitor is missing
E-9
57
Machine monitor displays contents irrelevant to the model
E-10
58
Fuel level monitor red lamp lights up while engine is running
E-11
59
Engine water thermometer does not display normally
E-12
60
Hydraulic oil temperature gauge does not display correctly
E-13
61
Fuel gauge does not display correctly
E-14
62
Swing lock monitor does not display correctly
E-15
63
When monitor switch is operated, nothing is displayed
E-16
64
Windshield wiper and window washer do not work
E-17
PC600-8
SEN00447-04
40 Troubleshooting
Troubleshooting
No.
Code
display
E mode
H mode
S mode
Machine monitor related failure (Service Menu: Special Function Display)

65
"Boom RAISE" is not correctly displayed in monitoring function
E-18
66
"Boom LOWER" is not correctly displayed in monitoring function
E-19
67
"Arm IN" is not correctly displayed in monitoring function
E-20
68
"Arm OUT" is not correctly displayed in monitoring function
E-21
69
"Bucket CURL" is not correctly displayed in monitoring function
E-22
70
"Bucket DUMP" is not correctly displayed in monitoring function
E-23
71
"Swing" is not correctly displayed in monitoring function
E-24
72
"Travel" is not correctly displayed in monitoring function
E-25
Other failure
73
Air conditioner does not work
E-26
74
Step light does not light up or go off
E-27
75
Electric grease gun does not operate
E-28
76
Horn does not sound
E-30
10
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40 Troubleshooting
PC600-8
SEN00447-04
11
SEN00447-04
Connection table for connector pin numbers

a
12
40 Troubleshooting
(Rev. 2009.04)
The terms of male and female refer to the pins, while the terms of male housing and female housing refer to
the mating portion of the housing.
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40 Troubleshooting
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40 Troubleshooting
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40 Troubleshooting
T- branch box and T- branch adapter table
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
Out of kit
799-601-4201
799-601-4101
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
(Rev. 2009.03)
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
799-601-3380 Plate for MS (14-pin)

799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
24
MS-24P
17
MS-17P
17
MS-17P
MS-5P
10
MS-10P
MS-5P
17
MS-17P
19
MS-19P
14
MS-14P
799-601-2710 Adapter for MIC
MIC-5P
q q
13
MIC-13P
q q
17
MIC-17P
q q q
q q
21
MIC-21P
q q q
q q
MIC-9P
q q q
799-601-2750 Adapter for ECONO
ECONO2P
q q
ECONO3P
q q
ECONO4P
q q
ECONO8P
q q
12 ECONO12P q q
799-601-3470 Case
799-601-2810 Adapter for DLI
DLI-8P
q q
12
DLI-12P
q q
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
799-601-4350 T-box (for DRC 60, ECONO)
799-601-2850 Case
60
799-601-4360 Case
799-601-7010 Adapter for X (T-adapter)
799-601-7020 Adapter for X
X2P
q q q
X3P
q q q
X4P
q q q
799-601-7050 Adapter for SWP
SW6P
q q q
SW8P
q q q
12
SW12P
14
SW14P
16
SW16P
799-601-7080 Adapter for M (T-adapter)
799-601-7090 Adapter for M
M2P
q
q
q
q
q q q
M3P
q q q
M4P
q q q
48
PC600-8
SEN00447-04
40 Troubleshooting
q q q
S8P
q q q
q
q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7140 Adapter for S
799-601-7400
M8P
799-601-7100
M6P
799-601-7000
799-601-2800
Part name
799-601-2700
Identification
symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
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
16
S16PW
12
S12PW
799-601-7180 Adapter for AMP040
A8P
12
A12P
q
q
q
q
16
A16P
q q q
20
A20P
q q q
799-601-7230 Short connector for X
q q q
q q
799-601-7240 Case
799-601-7270 Case
799-601-7510 Adapter for 070
10
07-10
799-601-7520 Adapter for 070
12
07-12
799-601-7530 Adapter for 070
14
07-14
799-601-7540 Adapter for 070
18
07-18
799-601-7550 Adapter for 070
20
07-20
799-601-7360 Adapter for relay
REL-5P
799-601-7370 Adapter for relay
REL-6P
799-601-7380 Adapter for JFC
799-601-9010 Adapter for DTM
DTM2
799-601-9020 Adapter for DT
DT2
DT3
DT4
DT6
799-601-9060 Adapter for DT (Gray)
DT8GR
799-601-9070 Adapter for DT (Black)
DT8B
799-601-9080 Adapter for DT (Green)
DT8G
799-601-9090 Adapter for DT (Brown)
DT8BR
799-601-9110 Adapter for DT (Gray)
12
DT12GR
799-601-9120 Adapter for DT (Black)
12
DT12B
799-601-9130 Adapter for DT (Green)
12
DT12G
799-601-9140 Adapter for DT (Brown)
12
DT12BR
799-601-9210 Adapter for HD30-18
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
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)

799-601-9320 T-box (for ECONO)
799-601-9330 Case
PC600-8
24
q q
q q
q q
q q
49
SEN00447-04
40 Troubleshooting
q q
799-601-9440* Socket for engine (CRI-T2)
1,2,3
795-799-5520* Socket for engine (HPI-T2)
Socket for engine (HPI-T2)

Temperature sensor
q q
q q
795-799-5460 Cable for engine (HPI-T2)
799-601-4110 Adapter for engine (140-T3) PIM
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
FCIN
q q
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
FCIB
q q
Adapter for engine (CRI-T3)

799-601-4160
Oil pressure switch
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
4180
q q
Socket for engine (CRI-T3)

799-601-4190*
Commonrail pressure
1,2,3L
q q
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
1,2,3A
q q
799-601-4250* Socket for engine (CRI-T3) PIM
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
1,2,3,G
q q

799-601-4340*
Pump actuator
2,PA
q q
1,2,3,4T
799-601-4260 Adapter for controller (ENG)
DTP4
799-601-9340 Case
799-601-9430*
795-799-5540*
799-601-4140
799-601-4230*
799-601-4380*

Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2)

Socket for engine (CRI-T3) TIM

Atomosphere pressure

Air intake pressure/temperature
Socket for engine (CRI-T3)(95)

Air intake pressure/temperature
Out of kit
q q
799-601-4201
A3
799-601-4101
799-601-9300
799-601-9200

799-601-9420 Adapter for engine (CRI-T3) PFUEL
Oil pressure sensor
799-601-9100
799-601-9000
799-601-8000
DRC-24
799-601-7500
24
799-601-7400
799-601-9360 Adapter for DRC
799-601-7100
DRC-40
799-601-7000
40
799-601-2800
799-601-9350 Adapter for DRC
Part name
799-601-2700
Identification
symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
q q
50
DRC50
60
DRC60
799-601-4390* Socket for controller (95 ENG)
60
799-601-4280* Box for controller (PUMP)
121
799-601-9720 Adapter for controller (HST)
16
HST16A
16
HST16B
26
HST26A
2,
3,
4,
799-601-9890
Multi-adapter for
DT2 4 and DTM2
* Shows not T-adapter but socket.
50
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51
SEN00447-04
40 Troubleshooting

2009 KOMATSU
All Rights Reserved
52
SEN00448-03
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up
40 Troubleshooting
Troubleshooting by failure code
(Display of code), Part 1
Failure code [A000N1] Eng. Hi Out of Std ...................................................................................................... 3
Failure code [AA10NX] Aircleaner clogging ................................................................................................... 4
Failure code [AB00KE] Charge Voltage Low .................................................................................................. 6
Failure code [B@BAZG] Eng. Oil Press. Low ................................................................................................ 8
Failure code [B@BAZK] Eng. Oil Level Low ................................................................................................ 10
Failure code [B@BCNS] Eng. Water Overheat .............................................................................................11
Failure code [B@BCZK] Eng. Water Lvl Low ............................................................................................... 12
Failure code [B@HANS] Hydr. Oil Overheat ................................................................................................ 14
Failure code [CA111] ECM Critical Internal Failure ...................................................................................... 15
Failure code [CA115] Eng Ne and Bkup Speed Sens Error.......................................................................... 16
Failure code [CA122] Chg Air Press Sensor High Error ............................................................................... 18
Failure code [CA123] Chg Air Press Sensor Low Error................................................................................ 20
Failure code [CA131] Throttle Sensor High Error ......................................................................................... 22
Failure code [CA132] Throttle Sensor Low Error.......................................................................................... 24
Failure code [CA135] Eng Oil Press Sensor High Error ............................................................................... 26
Failure code [CA141] Eng Oil Press Sensor Low Error ................................................................................ 28
Failure code [CA144] Coolant Temp Sens High Error .................................................................................. 30
Failure code [CA145] Coolant Temp Sens Low Error ................................................................................... 32
Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................... 34
Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................ 36
PC600-8
SEN00448-03
40 Troubleshooting
Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................................... 36

Failure code [CA221] Ambient Press Sens High Error ................................................................................. 38
Failure code [CA222] Ambient Press Sens Low Error.................................................................................. 40
Failure code [CA227] Sens Supply 2 Volt High Error ................................................................................... 42
Failure code [CA234] Eng Overspeed .......................................................................................................... 44
Failure code [CA238] Ne Speed Sens Supply Volt Error .............................................................................. 45
Failure code [CA263] Fuel Temp Sensor High Error .................................................................................... 46
Failure code [CA265] Fuel Temp Sensor Low Error ..................................................................................... 48
Failure code [CA271] IMV/PCV1 Short Error................................................................................................ 49
Failure code [CA272] IMV/PCV1 Open Error ............................................................................................... 50
Failure code [CA273] PCV2 Short Error ....................................................................................................... 51
Failure code [CA274] PCV2 Open Error....................................................................................................... 52
PC600-8
SEN00448-03
40 Troubleshooting
Failure code [A000N1] Eng. Hi Out of Std

Action code
Failure code
A000N1
Failure content
Failure
phenomenon
Eng. Hi Out of Std

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

Cause
Engine overrun
1
(While system is normal)

Check for external and internal causes for abnormal rise of the engine high idle
speed, then carry out troubleshooting for the mechanical system of the engine.
Engine Ne sensor system

If failure code [CA238] is displayed, carry out troubleshooting for it.
defective
Engine G sensor system

defective
If failure code [CA778] is displayed, carry out troubleshooting for it.

a Turn the engine starting switch ON for the preparations, and keep the engine
running during the troubleshooting.
PC600-8
Engine controller
defective
Monitoring
Engine
Engine speed
010006
Engine speed
High idle
1,900 2,000 rpm
SEN00448-03
40 Troubleshooting
Failure code [AA10NX] Aircleaner clogging

Action code
Failure code
AA10NX
Failure content
Failure
phenomenon
Aircleaner clogging
(Machine monitor system)
The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine
is running.
Response from
None in particular.
controller
Phenomenon
occurring on
machine
Relative
information
If the air cleaner clogging monitor on the machine monitor lights up in red while the engine is running,
this failure code is recorded.
Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function.
(Code No. 04501: Monitor input 1)
Cause
Presumed cause and

Air cleaner clogged


2 switch defective
(Internal disconnection)

Check the air cleaner. If it is clogged, clean or replace it.
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position or keep the engine running during the troubleshooting.
P23 (male)
Between (1) and (2)
Disconnection of wiring
harness
3 (Disconnection or defective contact with connector)
Air cleaner
Resistance value
Normal
Max. 1 z
Clogged
Min. 1 Mz
position during the troubleshooting.
Wiring harness between CM02 (female) (5) and P23
(female) (1)
Resistance
value
Max. 1 z
Wiring harness between P23 (female) (2) and grounding
Resistance
value
Max. 1 z
position or keep the engine running during the troubleshooting.
4
Machine monitor defective
CM02
Between (5) and grounding
Air cleaner
Voltage
Normal
Max. 1 V
Clogged
20 30 V
PC600-8
40 Troubleshooting
SEN00448-03
Electrical circuit diagram related to air cleaner clogging switch
PC600-8
SEN00448-03
40 Troubleshooting
Failure code [AB00KE] Charge Voltage Low

Action code
Failure code
AB00KE
Failure content
Failure
phenomenon
Charge Voltage Low

Signal voltage from alternator is Max. 20 V while the engine is running.
Response from
None in particular.
controller
Phenomenon
occurring on
machine
If the machine is used as it is, the battery may not be charged.
Relative
information
If the charge level monitor on the machine monitor lights up in red while the engine is running, this failure code is recorded.
Input from the alternator (Voltage, ON or OFF) can be checked in the monitoring function.
(Code No. 04300: Charge voltage, 04501: Monitor input 2)
Cause

a Turn the engine starting switch OFF for the preparations, and keep the engine
Alternator defective
(Internal defect)
Alternator
Engine
Voltage
Between terminal R
and grounding
Above low idle
27.5 29.5 V
Presumed cause and

If the voltage is abnormal, check the belt tension too.

harness
Grounding fault of wiring

harness
3
(Contact with grounding
circuit)
Wiring harness between CM02 (female) (11) and alternator terminal R
Resistance
value
Max. 1 z
Between wiring harness between CM02 (female) (11)
and alternator terminal R, or between CM02 (female)
(11), D01, J01, and starting switch terminal BR, or
between CM02 (female) (11), battery relay terminal BR
and grounding
Resistance
value
Min. 1 Mz
4 Machine monitor defective
CM02
Engine
Voltage
Between (11) and

grounding
Above low idle
27.5 29.5 V
PC600-8
40 Troubleshooting
SEN00448-03
Electrical circuit diagram related to engine preheating, starting, charging
PC600-8
SEN00448-03
40 Troubleshooting
Failure code [B@BAZG] Eng. Oil Press. Low

Action code
Failure code
B@BAZG
Failure content
Failure
phenomenon
Eng. Oil Press. Low

Signal voltage from engine oil pressure sensor is Max. 0.3 V or Min. 4.42 V.
Response from Assumes pressure to be 0 MPa {0 kg/cm2} and continues control.

If cause of failure disappears, system resets itself.
controller
Phenomenon
occurring on
machine
Relative
information
Input state (Pressure) from engine oil pressure sensor can be checked with monitoring function.
(Code 37200: Engine oil pressure)
Cause
Defective sensor power

1
supply system

If failure code [CA227] is also displayed, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective pressure sensor

(Internal defect)
POIL
Source voltage
Between (1) (2)
4.5 5.5 V
Between (3) (2)
0.5 4.5 V
Presumed cause and

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)
Wiring harness between ENG (female) (13) POIL

(female) (3)
Resistance
Max. 1 z

(female) (1)
Resistance
Max. 1 z

(female) (2)
Resistance
Max. 1 z
Ground fault in wiring
starting switch ON.
4 harness
Wiring
harness between ENG (female) (13) POIL
(Contact with GND circuit)
Resistance
Min. 1 Mz
(female) (3)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Hot short (Short circuit
5 with 24V circuit) in wiring
harness

(female) (3)
Voltage
Max. 1 V

(female) (1)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
6 Defective engine controller
ENG CE01
Voltage
Between (37) (47)
4.5 5.5 V
Between (13) (47)
0.5 4.5 V
PC600-8
40 Troubleshooting
SEN00448-03
Electrical circuit diagram related to Eng. Oil Press. Low
PC600-8
SEN00448-03
40 Troubleshooting
Failure code [B@BAZK] Eng. Oil Level Low

Action code
Failure code
B@BAZK
Failure content
Failure
phenomenon
Eng. Oil Level Low

(Mechanical system)
The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the
engine is stopped.
Response from
None in particular.
controller
Phenomenon
occurring on
machine
Relative
information
If the engine oil level monitor on the machine monitor lights up in red while the engine is running, this
failure code is recorded.
Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function.
Cause
Presumed cause and

Engine oil level low

Engine oil level switch

2 defective

Check the oil level in the engine oil pan. If it is low, add oil. (If it is reduced frequently, find out the cause.)
P44 (male)
harness
Engine oil level
Resistance value
Normal level
Max. 1 z
Below normal level
Min. 1 Mz
(female) (1)
Resistance
value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
CM02
Engine oil level
Voltage
Normal level
Max. 1 V
Below normal level
20 30 V
Electrical circuit diagram related to engine oil level switch
10
PC600-8
SEN00448-03
40 Troubleshooting
Failure code [B@BCNS] Eng. Water Overheat

Action code
Failure code
B@BCNS
Failure content
Failure
phenomenon
Eng. Water Overheat

(Mechanical system)
The signal circuit of the engine water high temperature sensor detected temperature above 105C.
Response from
None in particular.
controller
Phenomenon
occurring on
machine
Relative
information
If the engine coolant temperature monitor on the machine monitor lights up in red while the engine is
running, this failure code is recorded.
Input from the engine coolant high temperature sensor (coolant temperature and voltage) can be
checked in the monitoring function. (Code No. 04107: Engine coolant temperature, 04105: Engine
coolant temperature sensor voltage)
Presumed cause and

Cause
1
Engine overheated
Engine coolant
2 temperature sensor
system defective
Engine controller
defective

Check the engine for overheating. If it has been overheated, find out the cause and
check the engine for damage, then repair.
Carry out troubleshooting for "E-12 Display of engine coolant temperature gauge on
machine monitor is abnormal" in E-mode.
ENG (female)
Engine water temperature
Resistance value
Between (15) and (38)
105C
3.28 kz
Electrical circuit diagram related to engine coolant temperature sensor
PC600-8
11
SEN00448-03
40 Troubleshooting
Failure code [B@BCZK] Eng. Water Lvl Low

Action code
Failure code
B@BCZK
Failure content
Failure
phenomenon
Eng. Water Lvl Low

The signal circuit of the radiator coolant level switch is opened (disconnected from grounding) while the
engine is running.
Response from
None in particular.
controller
Phenomenon
occurring on
machine
If the machine is used as it is, the engine will overheat.
Relative
information
If the radiator coolant level monitor on the machine monitor lights up in red while the engine is stopped
(the starting switch is at the ON position), this failure code is recorded.
Input from the radiator coolant level switch (ON or OFF) can be checked in the monitoring function.
Cause
Presumed cause and

Sub-tank coolant level low Check the radiator sub-tank coolant level. If it is low, add coolant. (If it is reduced fre(While system is normal) quently, find out the cause.)
Radiator coolant level

2 switch defective
P24 (male)
Between (1) and (2)
harness
Sub-tank coolant level
Resistance value
Within normal level
Max. 1 z
Below LOW level
Min. 1 Mz
(female) (1)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
CM02
12
Sub-tank coolant level
Voltage
Within normal level
Max. 1 V
Below LOW level
20 30 V
PC600-8
40 Troubleshooting
SEN00448-03
Electrical circuit diagram related to radiator coolant level switch
PC600-8
13
SEN00448-03
40 Troubleshooting
Failure code [B@HANS] Hydr. Oil Overheat

Action code
Failure code
B@HANS
Failure content
Failure
phenomenon
Hydr. Oil Overheat

The signal of the hydraulic oil temperature sensor rises above 102C while the engine is running.
Response from
None in particular.
controller
Phenomenon
occurring on
machine
If the machine is used as it is, the hydraulic equipment may be damaged.
Relative
information
If the hydraulic oil temperature monitor on the machine monitor lights up in red while the engine is running, this failure code is recorded.
Input from the hydraulic oil temperature sensor can be checked in the monitoring function.
(Code No. 04401: Hydraulic oil temperature, 04402: Hydraulic oil temperature sensor voltage)
Cause
Presumed cause and

Hydraulic oil overheated


2 sensor defective
(Internal short-circuiting)

Check the hydraulic oil for overheating. If it has been overheated, find out the cause
and check the hydraulic equipment for damage, then repair.
P22 (male)
Between (1) and (2)

harness
3
circuit)

10 100C
Resistance value
90 3.5 kz
Min. 1 Mz
and P22 (female) (1) and grounding
Resistance
value
Min. 1 Mz
CM02

Between (12) and
grounding
Resistance value
90 3.5 kz
10 100C
Min. 1 Mz
Electrical circuit diagram related to hydraulic oil temperature sensor
14
PC600-8
SEN00448-03
40 Troubleshooting
Failure code [CA111] ECM Critical Internal Failure

Action code
Failure code
E10
CA111
Trouble

(Engine controller system)
Contents of trouble
Abnormality occurred in controller.
Action of controller
None in particular.
Problem that appears

Engine runs normally but it may stop during operation or may not be able to start.
on machine
Related information
Possible causes and

standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective circuit breaker No.7
Check circuit breaker No.7 directly for defect.

(If circuit breaker is turned OFF, circuit probably has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir- Wiring harness between CE03
2
Resistance Max. 1 z
ing or defective contact in
(female) (3) battery (B)
connector)
Wiring harness between CE03
Resistance Max. 1 z
(female) (1) chassis ground
Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between CE03
circuit)
(female) (3) battery (B) and chassis Resistance Max. 1 z
ground
a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
CE03
Voltage
Between (3) (1)
20 30 V
Circuit diagram related to controller power supply
PC600-8
15
SEN00448-03
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

Action code
Failure code
E10
CA115
Trouble

Contents of trouble
Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
None in particular.
Problem that appears Engine cannot be started (if engine has been stopped).
on machine
Engine stops (if engine has been running).
Related information
Cause
Possible causes and

Defective Ne speed sensor

Carry out troubleshooting for Failure code [CA689].
system
Defective Bkup speed senCarry out troubleshooting for Failure code [CA778].
sor system
Defective mount of Ne
speed sensor
Check mount of Ne speed sensor directly for defect (defective

installation of sensor, internal trouble of flywheel, etc.)
Defective mount of Bkup

speed sensor
Check mount of Bkup speed sensor directly for defect (defective installation of sensor, internal trouble of supply pump, etc.)
Defective connection
(Wrong connection)
Check Ne speed sensor and Bkup speed sensor directly for

defective connection (wrong connection).
16
If causes 1 5 are not detected, engine controller may be

defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
PC600-8
40 Troubleshooting
PC600-8
SEN00448-03
17
SEN00448-03
40 Troubleshooting
Failure code [CA122] Chg Air Press Sensor High Error

Action code
E11
Contents of trouble
Failure code
Trouble
CA122
Signal voltage in charge pressure sensor circuit is abnormally high.
Fixes charge pressure (400 kPa {4.1 kg/cm2}) and continues operation.

Acceleration performance of engine drops.
on machine
Related information
Signal voltage of boost pressure sensor can be checked with monitoring function.
(Code: 36501 Boost pressure sensor voltage)
Cause
1
supply system
Defective charge pres2 sure sensor (Internal

trouble)
Possible causes and

Short circuit in wiring har3 ness (with another wiring

harness)

harness
18
Defective engine controller

If failure code [CA187] or [CA227] is indicated, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
PIM
Voltage
Between (1) (2)
Power supply
4.75 5.25 V
Pressure sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness
and controller, too, for another cause of trouble, and then judge.
Wiring harness between ENG (female)
(37) PIM (female) (1) and between
Resistance Min. 1 Mz
ENG (female) (47) PIM (female) (2)
(37) PIM (female) (1) and chassis
Voltage
Max. 1 V
ground
Voltage
Max. 1 V
ground
Voltage
Max. 1 V
ground
ENG
Voltage
Between (37) (47)
Power supply
4.75 5.25 V
PC600-8
40 Troubleshooting
SEN00448-03
Circuit diagram related to charge pressure sensor
PC600-8
19
SEN00448-03
40 Troubleshooting
Failure code [CA123] Chg Air Press Sensor Low Error

Action code
Failure code
E11
CA123
Trouble

Contents of trouble
Signal voltage in charge pressure sensor circuit is abnormally low.
Fixes charge pressure (400 kPa {4.1 kg/cm2}) and continues operation.

Acceleration performance of engine drops.
on machine
Related information
Possible causes and
20
Signal voltage of boost pressure sensor can be checked with monitoring function.
(Code: 36501 Boost pressure sensor voltage)
Cause

Carry out troubleshooting for failure Code [CA122].
PC600-8
40 Troubleshooting
PC600-8
SEN00448-03
21
SEN00448-03
40 Troubleshooting
Failure code [CA131] Throttle Sensor High Error

Action code
Failure code
E14
CA131
Trouble

Contents of trouble
Throttle sensor circuit has high error.
Continues operation by setting throttle angle with signal other than throttle sensor signal.
If this error is detected while engine is running, controller keeps signal of fuel control dial just
before error is detected.

Engine speed may not be controlled.
on machine
Related information
Signal voltage of fuel control dial can be checked with monitoring function.
(Code: 03000 Fuel control dial voltage)
Cause
1

supply system

If failure code [CA2185] or [CA2186] is also displayed, carry
out troubleshooting for it first.
Defective fuel control dial

(Internal defect)
P20 (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
Possible causes and

Short circuit in wiring har3 ness (with another wiring

harness)

(female) (22) P20 (female) (1) and
between CE02 (female) (9) P20
(female) (2)

(female) (3)

(female) (2)

Hot short (short circuit with
4 24V circuit) in wiring harness

(female) (22) P20 (female) (1)
Voltage
Max. 1 V

Voltage
Max. 1 V

Voltage
Max. 1 V

22
CE02
Voltage
Between (22) (23)
Power supply
4.75 5.25 V
Between (9) (23)
Signal
0.5 4.5 V
PC600-8
40 Troubleshooting
SEN00448-03
Circuit diagram related to throttle sensor of fuel control dial type
PC600-8
23
SEN00448-03
40 Troubleshooting
Failure code [CA132] Throttle Sensor Low Error

Action code
Failure code
E14
CA132
Trouble

Contents of trouble
Signal voltage in throttle sensor circuit is abnormally low.
Sets throttle angle with signal other than throttle signal and continues operation.
on machine
Related information
Possible causes and

24
If this error is detected while engine is running, controller keeps signal of fuel control dial just
before error is detected.
(Code: 03000 Fuel control dial voltage)
Cause

Carry out troubleshooting for failure Code [CA131].
PC600-8
40 Troubleshooting
PC600-8
SEN00448-03
25
SEN00448-03
40 Troubleshooting
Failure code [CA135] Eng Oil Press Sensor High Error

Action code
Failure code
Trouble
E15
CA135
Contents of trouble Signal voltage in oil pressure sensor circuit is abnormally high.
Action of controller Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
on machine
Signal voltage of oil pressure sensor can be checked with monitoring function.
Related information
(Code: 37201 Oil pressure sensor voltage)
Possible causes and

standard value in
normal state
26
Cause
supply system


POIL
Voltage
Defective oil pressure
Between (1) (2)
Power supply
4.75 5.25 V
sensor (Internal trouble)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
(37) POIL (female) (1) and between Resistance Min. 1 Mz
ENG (female) (47) POIL (female) (2)
Short circuit in wiring
harness (with another
wiring harness)
Voltage
Max. 1 V
(37) POIL (female) (1)
with 24V circuit) in wirWiring harness between ENG (female)
ing harness
Voltage
Max. 1 V
Voltage
Max. 1 V
ENG
Voltage
Between (37) (47)
Power supply
4.75 5.25 V
PC600-8
40 Troubleshooting
SEN00448-03
Circuit diagram related to oil pressure sensor
PC600-8
27
SEN00448-03
40 Troubleshooting
Failure code [CA141] Eng Oil Press Sensor Low Error

Action code
Failure code
E15
CA141
Trouble

Contents of trouble
Signal voltage in oil pressure sensor circuit is abnormally low.
Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
on machine
Related information
Possible causes and
28
Signal voltage of oil pressure sensor can be checked with monitoring function.
(Code: 37201 Oil pressure sensor voltage)
Cause

Carry out troubleshooting for failure code [CA135].
PC600-8
40 Troubleshooting
PC600-8
SEN00448-03
29
SEN00448-03
40 Troubleshooting
Failure code [CA144] Coolant Temp Sens High Error

Action code
Failure code
E15
CA144
Trouble

Contents of trouble
Signal voltage in coolant temperature sensor circuit is abnormally high.
Fixes coolant temperature (90C) and continues operation.
on machine
Related information
Signal voltage of coolant temperature sensor can be checked with monitoring function.
(Code: 04105 Coolant temperature sensor voltage)
Cause
Defective coolant tempera1 ture sensor (Internal trouCoolant
TWTR (male)
Resistance
ble)
temperature
Between (A) (B)
Possible causes and

10 100C
0.6 20 kz
Disconnection in wiring harness (Disconnection in wir- Wiring harness between ENG
2
Resistance Max. 1 z
(female) (15) TWTR (female) (A)
connector)
Wiring harness between ENG
Resistance Max. 1 z
(female) (38) TWTR (female) (B)
Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between ENG
circuit)
(female) (15) TWTR (female) (A)
and chassis ground
30
ENG (female)
Coolant
temperature
Resistance
Between (15) (38)
10 100C
0.6 20 kz
PC600-8
40 Troubleshooting
SEN00448-03
Circuit diagram related to coolant temperature sensor
PC600-8
31
SEN00448-03
40 Troubleshooting
Failure code [CA145] Coolant Temp Sens Low Error

Action code
Failure code
E15
CA145
Trouble

Contents of trouble
Signal voltage in coolant temperature sensor circuit is abnormally low.
Fixes coolant temperature (90C) and continues operation.
on machine
Related information
Possible causes and
32
Signal voltage of coolant temperature sensor can be checked with monitoring function.
(Code: 04105 Coolant temperature sensor voltage)
Cause

PC600-8
40 Troubleshooting
PC600-8
SEN00448-03
33
SEN00448-03
40 Troubleshooting
Failure code [CA153] Chg Air Temp Sensor High Error

Action code
Failure code
E15
CA153
Trouble

Contents of trouble
Signal voltage in charge temperature sensor circuit is abnormally high.
Fixes charge temperature (intake air temperature) (70C) and continues operation.
on machine
Related information
Signal voltage of boost temperature sensor can be checked with monitoring function.
(Code: 18501 Boost temperature sensor voltage)
Cause

TIM (male)
Defective charge tempera1 ture sensor

(Internal trouble)
Between (A) (B)
Between (A)
chassis ground
Possible causes and

Intake air
temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
All range
Min. 1 Mz
2
Resistance Max. 1 z
(female) (23) TIM (female) (A)
connector)
Resistance Max. 1 z
(female) (47) TIM (female) (B)
circuit)
(female) (23) TIM (female) (A) and
chassis ground
ENG (female)
4

Between (23) (47)
34
Intake air
temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
PC600-8
40 Troubleshooting
SEN00448-03
Circuit diagram related to charge temperature sensor
PC600-8
35
SEN00448-03
40 Troubleshooting
Failure code [CA154] Chg Air Temp Sensor Low Error

Action code
Failure code
E15
CA154
Trouble

Contents of trouble
Signal voltage in charge temperature sensor circuit is abnormally low.
Fixes charge temperature (intake air temperature) (70C) and continues operation.
on machine
Related information
Possible causes and
Signal voltage of boost temperature sensor can be checked with monitoring function.
(Code: 18501 Boost temperature sensor voltage)
Cause

Failure code [CA187] Sens Supply 2 Volt Low Error

Action code
E15
Failure code
CA187
Trouble

Contents of trouble
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
Operates Bkup speed sensor with signals of Ne speed sensor.

Sets oil pressure sensor to default value (250 kPa {2.5 kg/cm2}) and continues operation.
Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues
operation.
Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
Sets EGR inlet pressure sensor to default value (102 kPa {1.0 kg/cm2}) and continues operation.
Limits output of EGR valve lift sensor and closes EGR valve and bypass valve.
Limits output of bypass valve lift sensor and closes EGR valve and bypass valve.

Output drops.
on machine
Related information
Possible causes and
36
Cause

PC600-8
40 Troubleshooting
PC600-8
SEN00448-03
37
SEN00448-03
40 Troubleshooting
Failure code [CA221] Ambient Press Sens High Error

Action code
Failure code
E15
CA221
Trouble

Contents of trouble
Signal voltage in atmospheric pressure sensor circuit is abnormally high.
Sets atmospheric pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.

Output drops.
on machine
Related information
Signal voltage of atmospheric pressure sensor can be checked with monitoring function.
(Code: 37401 Atmospheric pressure sensor voltage)
Cause

1
supply system
and carry out troubleshooting.
PAMB
Defective atmospheric
2 pressure sensor (Internal
trouble)
Voltage
Between (1) (2)
Power supply
4.75 5.25 V
Between (3) (2)
Signal
0.5 4.5 V

Possible causes and


(33) PAMB (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (38) PAMB (female) (2)
3 ness (with another wiring Wiring harness between ENG (female)
harness)
(33) PAMB (female) (1) and between Resistance Min. 1 Mz
ENG (female) (3) PAMB (female) (3)
(38) PAMB (female) (2) and between
ENG (female) (3) PAMB (female) (3)

(33) PAMB (female) (1) and chassis
ground

4 with 24V circuit) in wiring Wiring harness between ENG (female)
harness
ground
ground
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V

5
38
ENG
Voltage
Between (33) (38)
4.75 5.25 V
Between (3) (38)
0.5 4.5 V
PC600-8
40 Troubleshooting
SEN00448-03
Circuit diagram related to atmospheric pressure sensor
PC600-8
39
SEN00448-03
40 Troubleshooting
Failure code [CA222] Ambient Press Sens Low Error

Action code
Failure code
E15
CA222
Trouble

Contents of trouble
Signal voltage in atmospheric pressure sensor circuit is abnormally low.
Sets atmospheric pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.

Output drops.
on machine
Related information
Possible causes and
40
Signal voltage of atmospheric pressure sensor can be checked with monitoring function.
(Code: 37401 Atmospheric pressure sensor voltage)
Cause

PC600-8
40 Troubleshooting
PC600-8
SEN00448-03
41
SEN00448-03
40 Troubleshooting
Failure code [CA227] Sens Supply 2 Volt High Error

Action code
E15
Contents of trouble
Failure code
Trouble
CA227
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
Operates Bkup speed sensor with signals of Ne speed sensor.
Sets oil pressure sensor to default value (250 kPa {2.5 kg/cm2}) and continues operation.
operation.
Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
Sets EGR inlet pressure sensor to default value (102 kPa {1.0 kg/cm2}) and continues operation.
Limits output of EGR valve lift sensor and closes EGR valve and bypass valve.

Output drops.
on machine
Related information
Cause
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Possible causes and

Defective sensor
(Internal trouble)
Bkup speed
sensor
Oil pressure
sensor
Atmospheric
Disconnect devices at
right in order. If error pressure sensor
code disappears when
Charge presa device is disconsure sensor
nected, that device
EGR inlet preshas a defect in it.
sure sensor
EGR valve lift
sensor
Common rail
pressure sensor
G connector
POIL connector
PAMB
PIM connector
PEVA connector
SEGR connector
PFUEL connector
Short circuit in wiring harness
Wiring
harness between ENG (female)
3
(with another wiring har- (37) each sensor (female) and between
ness)
ENG (female) (47) each sensor
(female)
Wiring harness between ENG (female) (37)
Voltage
Max. 1 V
each sensor (female) and chassis ground
harness
Voltage
Max. 1 V
each sensor (female) and chassis ground
Defective engine control5
ler
ENG
Voltage
Between (37) (47)
4.75 5.25 V
42
PC600-8
40 Troubleshooting
SEN00448-03
Circuit diagram related to sensor power supply 2 (5 V)
PC600-8
43
SEN00448-03
40 Troubleshooting
Failure code [CA234] Eng Overspeed

Action code
Failure code
CA234
Trouble
Eng Overspeed
Contents of trouble
Engine speed is above operating range.
Limits fuel injection rate until engine speed lowers to operating range.

Engine speed fluctuates.
on machine
Related information
Cause
Possible causes and
44
1 Defective related system
If another failure code is indicated, carry out troubleshooting for it.
2 Improper way of use
Way of use may be improper. Teach proper way of use to operator.

be carried out.)
PC600-8
SEN00448-03
40 Troubleshooting
Failure code [CA238] Ne Speed Sens Supply Volt Error

Action code
Failure code
E15
CA238
Trouble

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

Defective Ne speed sen- Disconnect devices at right

in order. If error code disapsor (Internal trouble)
Ne speed
pears when a device is dissensor
connected, that device has
a defect in it.
NE connector
Possible causes and

harness (Disconnection Wiring harness between ENG (female)
2
in wiring or defective con- (16) NE (female) (1)
tact in connector)
(48) NE (female) (2)
Resistance Max. 1 z
Resistance Max. 1 z
3 harness (Short circuit
with GND circuit)

(16) NE (female) (1) and chassis ground
(48) NE (female) (2) and chassis ground
Short circuit in wiring har4 ness (with another wiring Wiring harness between ENG (female)
harness)
(16) NE (female) (1) and between ENG Resistance Min. 1 Mz
(female) (48) NE (female) (2)
ler

ENG
Voltage
Between (16) (48)
4.75 5.25 V
Circuit diagram related to Ne speed sensor power supply
PC600-8
45
SEN00448-03
40 Troubleshooting
Failure code [CA263] Fuel Temp Sensor High Error

Action code
Failure code
E15
CA263
Trouble

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

Possible causes and

Defective fuel temperature

sensor (Internal trouble)
TFUEL (male)
Fuel
temperature
Resistance
Between (A) (B)
10 100C
0.6 20 kz
2
Resistance Max. 1 z
(female) (30) TFUEL (female) (A)
connector)
Resistance Max. 1 z
(female) (47) TFUEL (female) (B)
circuit)
(female) (30) TFUEL (female) (A)
and chassis ground
46
ENG (female)
Fuel
temperature
Resistance
Between (30) (47)
10 100C
0.6 20 kz
PC600-8
40 Troubleshooting
SEN00448-03
Circuit diagram related to fuel temperature sensor
PC600-8
47
SEN00448-03
40 Troubleshooting
Failure code [CA265] Fuel Temp Sensor Low Error

Action code
Failure code
E15
CA265
Trouble

Contents of trouble
Signal voltage in fuel temperature sensor circuit is abnormally low.
Fixes fuel temperature (90C) and continues operation.
on machine
Related information
Possible causes and
48
Signal voltage of fuel temperature sensor can be checked with monitoring function.
(Code: 14201 fuel temperature sensor voltage)
Cause

PC600-8
SEN00448-03
40 Troubleshooting
Failure code [CA271] IMV/PCV1 Short Error

Action code
Failure code
E11
CA271
Trouble

Contents of trouble
There is short circuit in PCV1 circuit of supply pump.
None in particular.
on machine
Related information
Cause

Defective supply pump

PCV1 (Internal trouble)
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz
Possible causes and


Ground fault in wiring har(female) (4) PCV1 (female) (1) and Resistance Min. 1 Mz
2 ness (Short circuit with GND
chassis ground
circuit)
(female) (5) PCV1 (female) (2) and Resistance Min. 1 Mz
chassis ground
Hot short (Short circuit with
3 24V circuit) in wiring har(female) (4) PCV1 (female) (1)
ness
(female) (5) PCV1 (female) (2)
Voltage
Max. 1 V
Voltage
Max. 1 V
ENG (female)
Resistance
Between (4) (5)
2.3 5.3 z
Between (4), (5)

chassis ground
Min. 1 Mz
Circuit diagram related to supply pump PCV1
PC600-8
49
SEN00448-03
40 Troubleshooting
Failure code [CA272] IMV/PCV1 Open Error

Action code
Failure code
E11
CA272
Trouble
IMV/PCV1 Open Error

Contents of trouble
There is disconnection in PCV1 circuit of supply pump.
None in particular.
on machine
Related information
Cause


1 PCV1 (Internal disconnection)
Possible causes and

PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
chassis ground
circuit)
chassis ground
ENG (female)
Resistance
Between (4) (5)
2.3 5.3 z
Between (4), (5)

chassis ground
Min. 1 Mz
50
PC600-8
SEN00448-03
40 Troubleshooting
Failure code [CA273] PCV2 Short Error

Action code
Failure code
E11
CA273
Trouble
PCV2 Short Error

Contents of trouble
There is short circuit in PCV2 circuit of supply pump.
None in particular.
on machine
Related information
Cause


PCV2 (Internal trouble)
PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz
Possible causes and


chassis ground
circuit)
chassis ground
Hot short (Short circuit with
(female) (9) PCV2 (female) (1) and
3 24V circuit) in wiring harchassis ground
ness
(female) (10) PCV2 (female) (2) and
chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
ENG (female)
Resistance
Between (9) (10)
2.3 5.3 z
Between (9), (10)

chassis ground
Min. 1 Mz
PC600-8
51
SEN00448-03
40 Troubleshooting
Failure code [CA274] PCV2 Open Error

Action code
Failure code
E11
CA274
Trouble
PCV2 Open Error

Contents of trouble
There is disconnection in PCV2 circuit of supply pump.
None in particular.
on machine
Related information
Cause
1 PCV2 (Internal disconnection)

PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
Possible causes and
chassis ground
circuit)
chassis ground
52
ENG (female)
Resistance
Between (9) (10)
2.3 5.3 z
Between (9), (10)

chassis ground
Min. 1 Mz
PC600-8
40 Troubleshooting
SEN00448-03
PC600-8
53
SEN00448-03
40 Troubleshooting

2010 KOMATSU
All Rights Reserved
54
SEN00449-02
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up
40 Troubleshooting
Failure code [CA322] Inj #1 (L#1) Open/Short Error............................................................................................ 4
Failure code [CA325] Inj #6 (L#6) Open/Short Error.......................................................................................... 10
Failure code [CA342] Calibration Code Incompatibility...................................................................................... 16
Failure code [CA351] Injectors Drive Circuit Error ............................................................................................. 17
Failure code [CA352] Sens Supply 1 Volt Low Error ......................................................................................... 19
Failure code [CA386] Sens Supply 1 Volt High Error......................................................................................... 20
Failure code [CA441] Battery Voltage Low Error ............................................................................................... 22
Failure code [CA442] Battery Voltage High Error............................................................................................... 22
Failure code [CA449] Rail Press Very High Error .............................................................................................. 23
Failure code [CA451] Rail Press Sensor High Error .......................................................................................... 24
Failure code [CA452] Rail Press Sensor Low Error ........................................................................................... 26
Failure code [CA553] Rail Press High Error ...................................................................................................... 26
Failure code [CA554] Rail Press Sensor In Range Error ................................................................................... 27
Failure code [CA559] Rail Press Low Error ....................................................................................................... 28
Failure code [CA689] Eng Ne Speed Sensor Error............................................................................................ 32
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................................................ 34
PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA757] All Persistent Data Lost Error .......................................................................................... 35

Failure code [CA778] Engine Bkup Speed Sensor Error ................................................................................... 36
Failure code [CA1228] EGR Valve Servo Error 1 .............................................................................................. 38
Failure code [CA1625] EGR Valve Servo Error 2 .............................................................................................. 39
Failure code [CA1626] BP Valve Sol Current High Error ................................................................................... 40
Failure code [CA1627] BP Valve Sol Current Low Error .................................................................................... 42
Failure code [CA1628] Bypass Valve Servo Error 1........................................................................................... 43
Failure code [CA1629] Bypass Valve Servo Error 2........................................................................................... 44
Failure code [CA1631] BP Valve Pos Sens High Error ...................................................................................... 45
Failure code [CA1632] BP Valve Pos Sens Low Error ....................................................................................... 47
Failure code [CA1633] KOMNET Datalink Timeout Error .................................................................................. 48
Failure code [CA1642] EGR Inlet Press Sens Low Error ................................................................................... 51
Failure code [CA1653] EGR Inlet Press Sens High Error .................................................................................. 52
Failure code [CA2185] Throt Sens Sup Volt High Error ..................................................................................... 54
Failure code [CA2186] Throt Sens Sup Volt Low Error...................................................................................... 56
Failure code [CA2249] Rail Press Very Low Error ............................................................................................. 57
Failure code [CA2271] EGR Valve Pos Sens High Error ................................................................................... 58
Failure code [CA2272] EGR Valve Pos Sens Low Error .................................................................................... 60
Failure code [CA2351] EGR Valve Sol Current High Error ................................................................................ 62
Failure code [CA2352] EGR Valve Sol Current Low Error ................................................................................. 64
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................................................ 65
Failure code [CA2556] Grid Htr Relay Volt High Error ....................................................................................... 66
PC600-8
40 Troubleshooting
PC600-8
SEN00449-02
SEN00449-02
40 Troubleshooting
Failure code [CA322] Inj #1 (L#1) Open/Short Error

Action code
Failure code
E11
CA322
Trouble
Inj #1 (L#1) Open/Short Error

Contents of trouble
There is disconnection or short circuit in injector #1 circuit.
None in particular.

Output drops.
on machine
Related information
Cause

Defective injector #1 (Internal trouble)
CN1 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1M z
2
Resistance Max. 1 z
(female) (45) CN1 (female) (1)
connector)
Resistance Max. 1 z
Possible causes and
Ground fault in wiring har(female) (45) CN1 (female) (1) and
chassis ground
circuit)
(female) (53) CN1 (female) (2) and
chassis ground
4
Defective another cylinder

injector or wiring harness
If multiple failure codes are displayed for injector malfunction,

carry out troubleshooting for them, too.
ENG (female)
Resistance
Between (45) (53)
0.4 1.1 z
Between (45), (53)

chassis ground
Min. 1 Mz
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to injector #1
PC600-8
SEN00449-02
40 Troubleshooting

Action code
Failure code
E11
CA323
Trouble

Contents of trouble
None in particular.

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

CN5 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
Possible causes and
chassis ground
circuit)
chassis ground
4


ENG (female)
Resistance
Between (46) (60)
0.4 1.1 z
Between (46), (60)

chassis ground
Min. 1 Mz
PC600-8
40 Troubleshooting
SEN00449-02
PC600-8
SEN00449-02
40 Troubleshooting

Action code
Failure code
E11
CA324
Trouble

Contents of trouble
None in particular.

Output drops.
on machine
Related information
Cause

CN3 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2) chassis

ground
Min. 1M z
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
Possible causes and
chassis ground
circuit)
chassis ground
4


ENG (female)
Resistance
Between (55) (52)
0.4 1.1 z
Between (55), (52)

chassis ground
Min. 1M z
PC600-8
40 Troubleshooting
SEN00449-02
PC600-8
SEN00449-02
40 Troubleshooting

Action code
Failure code
E11
CA325
Trouble

Contents of trouble
None in particular.

Output drops.
on machine
Related information
Cause

CN6 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
Possible causes and
chassis ground
circuit)
chassis ground
4


10
ENG (female)
Resistance
Between (57) (59)
0.4 1.1 z
Between (57), (59)

chassis ground
Min. 1 Mz
PC600-8
40 Troubleshooting
SEN00449-02
PC600-8
11
SEN00449-02
40 Troubleshooting

Action code
Failure code
E11
CA331
Trouble

Contents of trouble
None in particular.

Output drops.
on machine
Related information
Cause

CN2 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
Possible causes and
chassis ground
circuit)
chassis ground
4


12
ENG (female)
Resistance
Between (54) (51)
0.4 1.1 z
Between (54), (51)

chassis ground
Min. 1 Mz
PC600-8
40 Troubleshooting
SEN00449-02
PC600-8
13
SEN00449-02
40 Troubleshooting

Action code
Failure code
E11
CA332
Trouble

Contents of trouble
None in particular.

Output drops.
on machine
Related information
Cause

CN4 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
2
Resistance Max. 1 z
connector)
Resistance Max. 1 z
Possible causes and
chassis ground
circuit)
chassis ground
4


14
ENG (female)
Resistance
Between (56) (58)
0.4 1.1 z
Between (56), (58)

chassis ground
Min. 1 Mz
PC600-8
40 Troubleshooting
SEN00449-02
PC600-8
15
SEN00449-02
40 Troubleshooting
Failure code [CA342] Calibration Code Incompatibility

Action code
Failure code
E10
CA342
Trouble

Contents of trouble
Matching error occurred in engine controller data.
None in particular.
Problem that appears Engine continues operation normally, but it may stop during operation or may not be able to
on machine
start.
Related information
Possible causes and
16
Cause

PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA351] Injectors Drive Circuit Error

Action code
Failure code
E10
CA351
Trouble

Contents of trouble
Abnormality occurred in injector drive circuit.
Limits output and continues operation (Limits common rail pressure).

Output drops.
on machine
Related information
Cause
Possible causes and

Defective circuit breaker

No.7

If another failure code (code of abnormality in injector system)
is indicated, carry out troubleshooting for it.
Check circuit breaker No.7 directly for defect.
(If circuit breaker is turned OFF, circuit probably has ground
fault.)
Disconnection in wiring harness (Disconnection in wir- Wiring harness between CE03
3
Resistance Max. 1 z
(female) (3) battery (+)
connector)
Resistance Max. 1 z
Ground fault in wiring har(female) (3) battery (+) and chassis Resistance Min. 1 Mz
ground
circuit)
(female) (1) chassis ground and
chassis ground
PC600-8
CE03
Voltage
Between (3) (1)
20 30 V
17
SEN00449-02
40 Troubleshooting
Circuit diagram related to controller power supply
18
PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA352] Sens Supply 1 Volt Low Error

Action code
Failure code
E15
CA352
Trouble

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

Output drops.
on machine
Related information
Possible causes and
PC600-8
Cause

19
SEN00449-02
40 Troubleshooting
Failure code [CA386] Sens Supply 1 Volt High Error

Action code
Failure code
E15
CA386
Trouble

Contents of trouble
Signal voltage in sensor power supply (5 V) circuit is abnormally high.
operation.

Output drops.
on machine
Related information
Cause
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Defective sensor (Inter2
nal trouble)
harness (Disconnection
3
in wiring or defective
contact in connector)
Possible causes and
Disconnect devices at
Atmospheric
right in order. If error
pressure sensor
code disappears when a
device is disconnected, Bypass valve lift
that device has a defect
sensor
in it.
PAMB connector
SBP connector
a Prepare with starting switch OFF, then carry out troubleshooting

without turning starting switch ON.
(33) each sensor (female) (5 V circuit)
Resistance Max. 1 z

Resistance Max. 1 z
(38) each sensor (female) (ENG circuit)

with GND circuit)


(38) each sensor (female) (ENG circuit)

5 harness (with another
wiring harness)

and between ENG (female) (38) each
sensor (female) (ENG circuit)

ler
ENG
Voltage
Between (33) (38)
20
4.75 5.25 V
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to sensor power supply 1 (5 V)
PC600-8
21
SEN00449-02
40 Troubleshooting
Failure code [CA441] Battery Voltage Low Error

Action code
Failure code
E10
CA441
Trouble
Battery Voltage Low Error

Contents of trouble
Power supply voltage is abnormally low.
None in particular.
on machine
start.
Related information
Signal voltage of power supply voltage can be checked with monitoring function.
(Code: 03200 Power supply voltage)
Possible causes and

Cause

Failure code [CA442] Battery Voltage High Error

Action code
Failure code
E10
CA442
Trouble
Battery Voltage High Error

Contents of trouble
Power supply voltage is abnormally high.
None in particular.
on machine
start.
Related information
Possible causes and
22
Cause

PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA449] Rail Press Very High Error

Action code
Failure code
E11
CA449
Trouble

Contents of trouble
Common rail pressure sensor circuit detected abnormally high pressure (level 2).

Output drops.
on machine
Related information
Possible causes and
PC600-8
Signal voltage of common rail pressure can be checked with monitoring function.
(Code: 36400 Common rail pressure)
Cause

23
SEN00449-02
40 Troubleshooting
Failure code [CA451] Rail Press Sensor High Error

Action code
Failure code
E11
CA451
Trouble

Contents of trouble
Signal voltage in common rail pressure sensor circuit is abnormally high.

Output drops.
on machine
Related information
Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure voltage)
Cause
1

supply

PFUEL
Defective common rail

2 pressure sensor (Internal
trouble)
Voltage
Between (1) (3)
Power supply
4.75 5.25 V
Between (2) (3)
Signal
0.25 4.6 V

Possible causes and

3
in wiring or defective contact in connector)

(37) PFUEL (female) (1)
Resistance Max. 1 z

Resistance Max. 1 z

Resistance Max. 1 z
(37) PFUEL (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (25) PFUEL (female) (2)
harness)
ENG (female) (47) PFUEL (female) (3)
ENG (female) (47) PFUEL (female) (3)
5
24
ENG
Voltage
Between (37) (47)
4.75 5.25 V
Between (25) (47)
0.25 4.6 V
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to common rail pressure sensor
PC600-8
25
SEN00449-02
40 Troubleshooting
Failure code [CA452] Rail Press Sensor Low Error

Action code
Failure code
E11
CA452
Trouble

Contents of trouble
Signal voltage in common rail pressure sensor circuit is abnormally low.

Output drops.
on machine
Related information
Possible causes and
Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure voltage)
Cause

Failure code [CA553] Rail Press High Error

Action code
Failure code
E15
CA553
Trouble

Contents of trouble
Common rail pressure sensor circuit detected abnormally high pressure (level 1).
None in particular.

Output drops.
on machine
Related information
Signal voltage of common rail pressure can be checked with monitoring function.
(Code: 36400 Common rail pressure)
Cause
Possible causes and

If another failure code is indicated, carry out troubleshooting for

it.
2 Use of improper fuel
Check fuel used directly (for high viscosity).
Defective electrical system

3 of common rail pressure
sensor
Common rail pressure sensor may have electric trouble. Carry

out troubleshooting for code [CA451].
Defective mechanical sys4 tem of common rail pressure sensor
Check mechanical system of common rail pressure sensor

directly.
5 Defective overflow valve
Check overflow valve directly for broken spring, worn seat, and
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.

7 Defective pressure limiter
26
Check pressure limiter directly for mechanical defect.
PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA554] Rail Press Sensor In Range Error

Action code
Failure code
CA554
Trouble

Contents of trouble
In-range error occurred in common rail pressure sensor circuit.

Output drops.
on machine
Related information
Possible causes and
PC600-8
Cause

27
SEN00449-02
40 Troubleshooting
Failure code [CA559] Rail Press Low Error

Action code
Failure code
E15
CA559
Trouble

Contents of trouble
Supply pump does not feed fuel (level 1).
Limits common rail pressure.

Output drops.
on machine
Related information
Cause

it.
2 Use of improper fuel
Check fuel used directly (for high viscosity).
Defective low-pressure circuit device
4 Clogging of filter/strainer
Possible causes and

a For contents of troubleshooting, see Note 1. For check of

pressure in fuel low-pressure circuit, see Testing and Adjusting, Testing fuel pressure.
Pressure in fuel low-pressure
circuit
Min. 0.15 MPa

{Min. 1.5 kg/cm2}
a For contents of troubleshooting, see Note 2.

Supply pump PCV may have electric trouble. Carry out troubleshooting for following codes;
[CA271], [CA272], [CA273], [CA274].

of supply pump PCV
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring
sure sensor
harness for damage.
7 Defective pressure limiter
a For testing of leakage from pressure limiter, see Testing and

adjusting, Testing leakage and return rate of fuel.
Leakage from pressure limiter Max. 10 cc/min (at 1,600 rpm)
a For testing of return (spill) limit from injector, see Testing and
adjusting, Testing leakage and return rate of fuel.
Speed at rated operation
8 Defective injector
9 Defective supply pump
Return (Spill) limit from

injector
1,600 rpm
960 cc/min
1,700 rpm
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
1,200 cc/min
If causes 1 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached Check sheet for no-pressure feed.
28
PC600-8
40 Troubleshooting
SEN00449-02
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
Overflow valve (1): Spring is seen through both holes.
Bypass valve (2): Spring is seen through hole on nut side.
Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
PC600-8
29
SEN00449-02
40 Troubleshooting
Check sheet for no-pressure feed

Model
Machine serial No.
Engine
Engine serial No.
Work No.
Date of check
Service meter
Worker's name
#
#
/
h
A. Visual check
1 Fuel leakage to outside
2 Clogging of fuel tank breather
Good NG
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function)
3 Check of failure code
/
/
/
/
Check of monitoring information
Standard value
Code
Displayed item
Checking condition
Unit
Measured value
(Reference value)
Low idle
rpm
800 25
*1
Engine speed
High idle
rpm
1,950 50
Equivalent to rating
rpm
1,800
Low idle
%
0
*2
Throttle opening
High idle
%
100
Fuel injection com*3
mm3
mand
Common rail presMPa
4
*4
sure command
{kg/cm2}
Common rail fuel
MPa
*5
pressure
{kg/cm2}
Low idle
CA
Fuel injection tim*6

High idle
CA
ing command
CA
kPa
*7
Boost pressure
{kg/cm2}
Engine coolant tem*8
Low idle
C
perature
*9
Fuel temperature
Low idle
C
Check of reduced cylinder mode operation (Engine speed)

Standard value
Measured value
Function Reduced cylinder
Checking condition
Unit
(Reference value)
No. 1 cylinder
Low idle
rpm
No. 2 cylinder
Low idle
rpm
5
No. 3 cylinder
Low idle
rpm
*10
No. 4 cylinder
Low idle
rpm
No. 5 cylinder
Low idle
rpm
No. 6 cylinder
Low idle
rpm
Good NG
C. Check of fuel circuit pressure

6
Checking condition
Fuel low-pressure circuit presHigh idle

sure
Standard value
(Reference value)
MPa
Min. 0.15 MPa
{kg/cm2} {Min. 1.5 kg/cm2}
Unit
Measured value
D. Check of strainers and filters

7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E. Check of leakage and
Checking condition
return rate
Leakage through pressure lim11
At rated output (pump relief)
iter
Equivalent to rating 1,600 rpm
12 Return rate from injector
30
Good NG
Good NG
Good NG
Good NG
Unit
Standard value
(Reference value)
cc/min
Max. 10
cc/min
cc/min
cc/min
cc/min
cc/min
960
1,020
1,080
1,140
1,200
Measured value
Good NG
Speed:
Return rate:
PC600-8
40 Troubleshooting
SEN00449-02
*1 *10:
When inspecting with the monitoring function, see the monitoring codes list.
Equivalent to rating:
Relieve the oil under the following condition.
1) Run engine at full throttle.
2) Select P mode.
3) Raise boom.
PC600-8
31
SEN00449-02
40 Troubleshooting
Failure code [CA689] Eng Ne Speed Sensor Error

Action code
Failure code
E11
CA689
Trouble

Contents of trouble
Abnormality occurred in engine Ne speed sensor circuit.
Operates with signals of Bkup speed sensor.
Problem that appears Running engine stops (when Bkup speed sensor is also abnormal).
on machine
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related information
Cause
1

supply system

If failure code [CA238] is indicated, carry out troubleshooting for
it first.
2

Resistance Max. 1 z

Resistance Max. 1 z

Resistance Max. 1 z

with GND circuit)
Possible causes and

(16) NE (female) (1) and chassis
ground

ground

ground
(16) NE (female) (1) and between
Short circuit in wiring har- ENG (female) (48) NE (female) (2)
harness)
ENG (female) (27) NE (female) (3)
ENG (female) (27) NE (female) (3)
32
If causes 1 4 are not detected, engine Ne speed sensor may

be defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
Defective engine Ne
speed sensor
If causes 1 4 are not detected, engine controller may be defecDefective engine controltive. (Since trouble is in system, troubleshooting cannot be carler
ried out.)
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to engine Ne speed sensor
PC600-8
33
SEN00449-02
40 Troubleshooting
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Action code
Failure code
E11
CA731
Trouble

Contents of trouble
Engine Bkup sensor circuit detected abnormality in phase.
Controls with signals of engine Ne speed sensor.
Problem that appears Running engine stops (when Ne speed sensor is also abnormal).
on machine
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related information
Cause
Possible causes and
34
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out troublesensor system
shooting for failure code [CA698].
Defective engine Bkup

speed sensor system
Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure code [CA778].
PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA757] All Persistent Data Lost Error

Action code
Failure code
E10
CA757
Trouble

Contents of trouble
All data in engine controller are lost.
None in particular.
on machine
start.
Related information
Possible causes and
PC600-8
Cause

35
SEN00449-02
40 Troubleshooting
Failure code [CA778] Engine Bkup Speed Sensor Error

Action code
Failure code
E11
CA778
Trouble
Engine Bkup Speed Sensor Error

Contents of trouble
Abnormality occurred in engine Bkup speed sensor circuit.
Operates with signals of Ne speed sensor.

Limits output and continues operation.
Output drops.
Running engine stops (when Ne speed sensor is also abnormal).
on machine
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related information
Cause

1
supply system
2

(37) G (female) (1)
Resistance Max. 1 z

(47) G (female) (2)
Resistance Max. 1 z

(26) G (female) (3)
Resistance Max. 1 z

with GND circuit)
Possible causes and

(37) G (female) (1) and chassis
ground

ground

ground
(37) G (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring har- (female) (47) G (female) (2)
harness)
(female) (26) G (female) (3)
(female) (26) G (female) (3)
36
If causes 1 4 are not detected, engine Bkup speed sensor may

be defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
Defective engine Bkup

speed sensor
If causes 1 5 are not detected, engine controller may be defecDefective engine controltive. (Since trouble is in system, troubleshooting cannot be carler
ried out.)
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to engine Bkup speed sensor
PC600-8
37
SEN00449-02
40 Troubleshooting
Failure code [CA1228] EGR Valve Servo Error 1

Action code
Failure code
E15
CA1228
Trouble

Contents of trouble
Abnormality (level 1) occurred in EGR valve servo.
Performs open control.
on machine
Related information
Cause

it.
a For measurement of EGR valve drive pressure, see Testing
and adjusting, Testing EGR valve and bypass valve drive oil
pressure
Improper EGR valve drive

pressure
Engine speed
EGR valve drive pressure
Low idle
Min.1.18 MPa {Min.12 kg/cm2}
High idle
Min.1.43 MPa
{Min.14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 4 and 5.

a For check of engine oil pressure, see Testing and adjusting,
Testing engine oil pressure.
Possible causes and
Defective engine oil pressure system (main circuit)
Engine speed
Engine oil pressure
Low idle
Min.0.08 MPa
{Min.0.8 kg/cm2}
High idle
Min.0.21 MPa
{Min.2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting of

engine (S-12 Oil pressure lowers).
38
Defective oil pump for EGR

Check oil pump and relief valve for EGR valve circuit directly.
valve
Defective oil feed piping for

Check oil feed piping for EGR valve circuit directly.
EGR valve
Defective oil return piping

for EGR valve
Check oil return piping for EGR valve circuit directly.
7 Defective EGR valve
Check mechanical section of EGR valve directly.

be carried out.)
PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA1625] EGR Valve Servo Error 2

Action code
Failure code
E11
CA1625
Trouble

Contents of trouble
Abnormality (level 2) occurred in EGR valve servo.

Closes EGR valve and bypass valve.

Output drops.
on machine
Related information
Possible causes and
PC600-8
Cause

39
SEN00449-02
40 Troubleshooting
Failure code [CA1626] BP Valve Sol Current High Error

Action code
Failure code
E11
CA1626
Trouble

Contents of trouble
There is short circuit in drive circuit of bypass valve solenoid.


Output drops.
on machine
Related information
Cause
Defective bypass valve
1
solenoid (Internal trouble)

BP (male)
Resistance
Between (1) (2)
10 21 z
2
Resistance Max. 1 z
in wiring or defective con- (31) BP (female) (1)
tact in connector)
Resistance Max. 1 z
(11) BP (female) (2)
Possible causes and

with GND circuit)

(31) BP (female) (1) and chassis
ground

ground

ground
harness
ground
Voltage
Max. 1 V
Voltage
Max. 1 V
ler
ENG (female)
Resistance
Between (31) (11)
40
10 21 z
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to bypass valve solenoid & lift sensor
PC600-8
41
SEN00449-02
40 Troubleshooting
Failure code [CA1627] BP Valve Sol Current Low Error

Action code
Failure code
E11
CA1627
Trouble

Contents of trouble
There is disconnection in drive circuit of bypass valve solenoid.


Output drops.
on machine
Related information
Possible causes and
42
Cause

PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA1628] Bypass Valve Servo Error 1

Action code
Failure code
E15
CA1628
Trouble

Contents of trouble
Abnormality (level 1) occurred in bypass valve servo.
Performs open control.
on machine
Related information
Cause

If another failure code is indicated, carry out troubleshooting
for it.
a For measurement of bypass valve drive pressure, see Testing and adjusting, Testing EGR valve and bypass valve
drive oil pressure
Improper bypass valve drive

pressure
Engine speed
Bypass valve drive pressure
Low idle
Min.1.18 MPa {Min.12 kg/cm2}
High idle
Min.1.43 MPa
{Min.14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 4 and

5.
Possible causes and
a For check of engine oil pressure, see TESTING AND

ADJUSTING, Testing engine oil pressure.
3
Defective engine oil pressure system (main circuit)
Engine
Engine oil pressure
Low idle
Min.0.08 MPa {Min.0.8 kg/cm2}
High idle
Min.0.21 MPa {Min.2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting

for mechanical system (S-12 Oil pressure lowers).
PC600-8
Defective oil pump for

bypass valve
Check oil pump and relief valve for bypass valve circuit
directly.
Defective oil feed piping for

Check oil feed piping for bypass valve circuit directly.
bypass valve
Defective oil return piping

for bypass valve
Check oil return piping for bypass valve circuit directly.
7 Defective bypass valve
Check mechanical section of bypass valve directly.

be carried out.)
43
SEN00449-02
40 Troubleshooting
Failure code [CA1629] Bypass Valve Servo Error 2

Action code
Failure code
E11
CA1629
Trouble

Contents of trouble
Abnormality (level 2) occurred in bypass valve servo.


Output drops.
on machine
Related information
Possible causes and
44
Cause

PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA1631] BP Valve Pos Sens High Error

Action code
Failure code
E11
CA1631
Trouble

Contents of trouble
Signal voltage in bypass valve lift sensor circuit is abnormally high.


Output drops.
on machine
Related information
Signal voltage of bypass valve position sensor can be checked with monitoring function.
(Code: 18200 Bypass valve position sensor voltage)
Cause
Defective sensor power If failure code [CA187] or [CA227] is indicated, carry out trouble1
supply
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
2 lift sensor (Internal trouble)
SBP
Between (1) (2)
Voltage
Power supply
4.75 5.25 V

Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
3
in wiring or defective
contact in connector)
Possible causes and


(33) SBP (female) (1)
Resistance Max. 1 z

Resistance Max. 1 z

(29) SBP (female) (3), (4)
Resistance Max. 1 z

with GND circuit)



(29) SBP (female) (3), (4)


wiring harness)

(33) SBP (female) (1) and between ENG Resistance Min. 1 Mz
(female) (38) SBP (female) (2)
(female) (29) SBP (female) (3), (4)
(female) (29) SBP (female) (3), (4)
PC600-8

ENG
Voltage
Between (33) (38)
4.75 5.25 V
45
SEN00449-02
40 Troubleshooting
Circuit diagram related to bypass valve solenoid & lift sensor
46
PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA1632] BP Valve Pos Sens Low Error

Action code
Failure code
E11
CA1632
Trouble

Contents of trouble
Signal voltage in bypass valve lift sensor circuit is abnormally low.


Output drops.
on machine
Related information
Possible causes and
PC600-8
Signal voltage of bypass valve lift sensor can be checked with monitoring function.
(Code: 18200 Bypass valve lift sensor voltage)
Cause

47
SEN00449-02
40 Troubleshooting
Failure code [CA1633] KOMNET Datalink Timeout Error

Action code
Failure Code
E0E
CA1633
Failure content
Failure
phenomenon

Abnormality occurred in circuit of KOMNET communication with machine monitor.
Response from
Operates in default mode or maintains condition when abnormality occurs.
monitor panel
Phenomenon
occurring on
machine
Relative
information
Cause

a Prepare with starting switch OFF and hold it in the OFF position during the
troubleshooting.
harness
Wiring harness between CM03 (female) (16) and CE02

(female) (47) or between CM03 (female) (16) and CP02
(female) (22)
Resistance
value
Max. 1 z

(female) (32)
Resistance
value
Max. 1 z
Presumed cause and

troubleshooting.
Ground fault of wiring
harness
2
(Contact with ground
circuit)
Resistance
value
Min. 1 Mz

and CE02 (female) (46) or between CM03 (female) (15)
and CP02 (female) (32) or between CM03 (female) (15)
and related circuits and ground
Resistance
value
Min. 1 Mz
a Prepare with starting switch OFF and hold it in the ON position during the
troubleshooting.
Short-circuiting of wiring
3 harness
(Contact with 24 V circuit)
CAN terminal resistor

defective
Machine monitor, engine

5 controller, or pump
controller defective
48


Voltage
Max. 1 V

Voltage
Max. 1 V
troubleshooting.
K02 (male), K03 (male)
Voltage
Between (1) and (2)
40 80 z
If causes 1 4 are not detected, machine monitor, engine controller, or pump controller may be defective. (Since trouble is in those devices, troubleshooting cannot be
carried out.)
PC600-8
40 Troubleshooting
SEN00449-02
Electrical circuit diagram related to CAN communication
PC600-8
49
SEN00449-02
50
40 Troubleshooting
PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA1642] EGR Inlet Press Sens Low Error

Serial numbers : 30001 30070
Action code
Failure code
E11
CA1642
Trouble

Contents of trouble
Signal voltage in EGR inlet pressure sensor circuit is abnormally low.
Sets EGR inlet pressure to default value (102 kPa {1.0 kg/cm2}) and continues operation.

Output drops.
on machine
Related information
Possible causes and
PC600-8
Signal voltage of EGR inlet pressure sensor can be checked with monitoring function.
(Code: 18001 EGR inlet sensor voltage)
Cause

51
SEN00449-02
40 Troubleshooting
Failure code [CA1653] EGR Inlet Press Sens High Error

Serial numbers : 30001 30070
Action code
Failure code
E11
CA1653
Trouble

Contents of trouble
Signal voltage in EGR inlet pressure sensor circuit is abnormally high.
Sets EGR inlet pressure to default value (102 kPa {1.0 kg/cm2}) and continues operation.

Output drops.
on machine
Related information
Signal voltage of EGR inlet pressure sensor can be checked with monitoring function.
(Code: 18001 EGR inlet pressure sensor voltage)
Cause
1

supply

Defective EGR inlet pres2 sure sensor (Internal

trouble)
PEVA
Between (1) (2)
Voltage
Power supply
4.75 5.25 V

3
Possible causes and


(37) PEVA (female) (1)
Resistance Max. 1 z

Resistance

Resistance Max. 1 z
Max. 1z
with GND circuit)

PEVA (female) (1) and chassis ground

(37) PEVA (female) (1) and between
Short circuit in wiring har- ENG (female) (47) PEVA (female) (2)
harness)
ENG (female) (20) PEVA (female) (3)
ENG (female) (20) PEVA (female) (3)

ler
ENG
Voltage
Between (37) (47)
52
4.75 5.25 V
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to EGR inlet pressure sensor
PC600-8
53
SEN00449-02
40 Troubleshooting
Failure code [CA2185] Throt Sens Sup Volt High Error

Action code
Failure code
E14
CA2185
Trouble

Contents of trouble
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
Sets throttle angle with signal other than throttle sensor signal and continues operation.
on machine
Related information
Cause

Defective accelerator
pedal (Internal trouble)
Disconnect devices at right

in order. If failure code
disappears when a device
is disconnected, that
device has a defect in it.
Fuel
control dial
P20 connector

Possible causes and

wiring harness)
Wiring harness between CE02 (female)

(22) P20 (female) (1) and between
CE02 (female) (23) P20 (female) (3)


3 with 24V circuit) in wiring harness

(22) P20 (female) (1) and chassis
ground
Voltage
Max. 1 V

(23) P20 (female) (3) and chassis
ground
Voltage
Max. 1 V

4
54
CE02
Voltage
Between (22) (23)
4.75 5.25 V
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to throttle sensor of fuel control dial type
PC600-8
55
SEN00449-02
40 Troubleshooting
Failure code [CA2186] Throt Sens Sup Volt Low Error

Action code
Failure code
E14
CA2186
Trouble

Contents of trouble
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low.
Sets throttle angle with signal other than throttle sensor signal and continues operation.
on machine
Related information
Possible causes and
56
Cause

PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA2249] Rail Press Very Low Error

Action code
Failure code
E11
CA2249
Trouble

Contents of trouble
Supply pump does not feed fuel (level 2).
Limits common rail pressure.

Output drops.
on machine
Related information
Possible causes and
PC600-8
Cause

57
SEN00449-02
40 Troubleshooting
Failure code [CA2271] EGR Valve Pos Sens High Error

Action code
Failure code
E11
CA2271
Trouble

Contents of trouble
Signal voltage in EGR valve lift sensor circuit is abnormally high.


Output drops.
on machine
Related information
Signal voltage of EGR valve lift sensor can be checked with monitoring function.
(Code: 18101 EGR valve lift sensor voltage)
Cause
Defective sensor
1
power supply

Defective EGR valve

2 lift sensor (Internal
trouble)
SEGR
Between (1) (2)
Voltage
Power supply
4.75 5.25V

Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
harness (Disconnec3 tion in wiring or defective contact in
connector)

Resistance Max. 1 z
SEGR (female) (1)
Resistance Max. 1 z
SEGR (female) (2)
Resistance Max. 1 z
SEGR (female) (3), (4)
Possible causes and


with GND circuit)

SEGR (female) (1) and chassis ground
SEGR (female) (2) and chassis ground
SEGR (female) (3), (4) and chassis
ground

wiring harness)

SEGR (female) (1) and between ENG
(female) (47) SEGR (female) (2)
(female) (19) SEGR (female) (3), (4)
(female) (19) SEGR (female) (3), (4)
58

ENG
Voltage
Between (37) (47)
4.75 5.25 V
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to EGR valve solenoid & lift sensor
PC600-8
59
SEN00449-02
40 Troubleshooting
Failure code [CA2272] EGR Valve Pos Sens Low Error

Action code
Failure code
E11
CA2272
Trouble

Contents of trouble
Signal voltage in EGR valve lift sensor circuit is abnormally low.


Output drops.
on machine
Related information
Possible causes and
60
Signal voltage of EGR valve lift sensor can be checked with monitoring function.
(Code: 18101 EGR valve lift sensor voltage)
Cause

PC600-8
40 Troubleshooting
PC600-8
SEN00449-02
61
SEN00449-02
40 Troubleshooting
Failure code [CA2351] EGR Valve Sol Current High Error

Action code
Failure code
E11
CA2351
Trouble

Contents of trouble
There is short circuit in drive circuit of EGR valve solenoid.


Output drops.
on machine
Related information
Cause
Defective EGR valve
1
solenoid (Internal trouble)

EGR (male)
Resistance
Between (1) (2)
10 21 z
2
Resistance Max. 1 z
in wiring or defective con- (22) EGR (female) (1)
tact in connector)
Resistance Max. 1 z
(11) EGR (female) (2)
Possible causes and

with GND circuit)

(22) EGR (female) (1) and chassis
ground

ground

ground
harness
ground
Voltage
Max. 1 V
Voltage
Max. 1 V
ler
ENG (female)
Resistance
Between (22) (11)
62
10 21 z
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to EGR valve solenoid & lift sensor
PC600-8
63
SEN00449-02
40 Troubleshooting
Failure code [CA2352] EGR Valve Sol Current Low Error

Action code
Failure code
E11
CA2352
Trouble

Contents of trouble
There is disconnection in drive current of EGR valve solenoid.


Output drops.
on machine
Related information
Possible causes and
64
Cause

PC600-8
SEN00449-02
40 Troubleshooting
Failure code [CA2555] Grid Htr Relay Volt Low Error

Action code
Failure code
E15
CA2555
Trouble
Grid Htr Relay Volt Low Error

Contents of trouble
There is low voltage error in intake air heater relay circuit.
None in particular.

Engine does not start easily at low temperature.
on machine
Related information
Possible causes and
PC600-8
Cause

65
SEN00449-02
40 Troubleshooting
Failure code [CA2556] Grid Htr Relay Volt High Error

Action code
Failure code
E15
CA2556
Trouble
Grid Htr Relay Volt High Error

Contents of trouble
There is high voltage error in intake air heater relay circuit.
None in particular.

Engine does not start easily at low temperature.
on machine
Related information
Cause
Defective intake air
1 heater relay (Internal
trouble)

R18 (male)
Resistance
Between (1) (2)
200 400 z
harness (Disconnection Wiring harness between CE02 (female)
2
in wiring or defective con- (40) R18 (female) (1)
tact in connector)
(42) R18 (female) (2)
Possible causes and
Resistance Max. 1 z
Resistance Max. 1 z
with GND circuit)

(40) R18 (female) (1) and chassis
ground

(42) R18 (female) (2) and chassis
ground

4
CE02
Between (40) (42)
66
Heater relay
Voltage
Under operating
condition
Max. 1 V
Under stopping
condition
20 30 V
PC600-8
40 Troubleshooting
SEN00449-02
Circuit diagram related to intake air heater
PC600-8
67
SEN00449-02
40 Troubleshooting

2009 KOMATSU
All Rights Reserved
68
SEN00450-02
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up
40 Troubleshooting
Failure code [D110KB] Battery Relay Drive S/C .................................................................................................. 4
Failure code [D163KB] Flash Light Relay S/C ..................................................................................................... 6
Failure code [D195KB] Step Light Relay S/C....................................................................................................... 8
Failure code [DA22KK] Pump Solenoid Power Low Error ................................................................................. 10
Failure code [DA25KP] Press. Sensor Power Abnormality................................................................................ 12
Failure code [DA2SKQ] Model Selection Abnormality ....................................................................................... 14
Failure code [DA80MA] Auto. Lub Abnormal ..................................................................................................... 16
Failure code [DA2RMC] Pump Comm. Abnormality .......................................................................................... 18
Failure code [DAFRMC] Monitor Comm. Abnormality ....................................................................................... 20
Failure code [DGE5KY] Ambi. Temp. Sensor S/C ............................................................................................. 22
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C ........................................................................................ 23
Failure code [DHPAMA] F pump P. Sensor Abnormality.................................................................................... 24
Failure code [DHPBMA] R pump P. Sensor Abnormality ................................................................................... 26
Failure code [DV20KB] Travel Alarm S/C .......................................................................................................... 28
Failure code [DW43KA] Travel Speed Sol. Disc. ............................................................................................... 30
Failure code [DW43KB] Travel Speed Sol. S/C ................................................................................................. 32
Failure code [DW45KA] Swing Brake Sol. Disc. ................................................................................................ 34
Failure code [DW45KB] Swing Brake Sol. S/C .................................................................................................. 36
Failure code [DW48KA] CO Cancel Sol. Disc.................................................................................................... 38
Failure code [DW48KB] CO Cancel Sol. S/C..................................................................................................... 40
PC600-8
SEN00450-02
40 Troubleshooting
Failure code [DW7BKA] Fan Reverse Sol. Disc. ............................................................................................... 42

Failure code [DW7BKB] Fan Reverse Sol. S/C ................................................................................................. 43
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc.................................................................................. 44
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C................................................................................... 46
Failure code [DWK0KA] 2-stage Relief Sol. Disc. .............................................................................................. 48
Failure code [DWK0KB] 2-stage Relief Sol. S/C ................................................................................................ 50
Failure code [DX16KA] Fan Pump EPC Sol. Disc. ............................................................................................ 52
Failure code [DX16KB] Fan Pump EPC Sol. S/C .............................................................................................. 54
Failure code [DXA0KA] TVC Sol. Disc............................................................................................................... 56
Failure code [DXA0KB] TVC Sol. S/C................................................................................................................ 58
Failure code [DY20KA] Wiper Working Abnormality .......................................................................................... 60
Failure code [DY20MA] Wiper Parking Abnormality .......................................................................................... 62
Failure code [DY2CKB] Washer Drive S/C ........................................................................................................ 66
Failure code [DY2DKB] Wiper Drive (For) S/C .................................................................................................. 68
Failure code [DY2EKB] Wiper Drive (Rev) S/C.................................................................................................. 72
PC600-8
40 Troubleshooting
PC600-8
SEN00450-02
SEN00450-02
40 Troubleshooting
Failure code [D110KB] Battery Relay Drive S/C

Action code
Failure code
D110KB
Failure content
Failure
phenomenon

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

Cause
Battery relay defective

1 (Internal short-circuiting
or grounding fault)

harness
2
circuit)

Battery relay (Unit)
Resistance value
Between BR and E
Approx. 100 z
Between BR and grounding
Min. 1 Mz
Between wiring harness between CP03 (female) (4),
D01, J01, battery relay terminal BR or between CP03
(female) (4) and starting switch terminal BR or between
CP03 (female) (4) and D01 (female) (2) and grounding
Resistance
value
Min. 1 Mz
3
Pump controller
defective
CP03 (female)
Starting switch
Voltage
ON o OFF
20 30 V
(For 0.5 sec)
a S/C: Short circuit
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to battery relay drive
PC600-8
SEN00450-02
40 Troubleshooting
Failure code [D163KB] Flash Light Relay S/C

Action code
Failure code
D163KB
Failure content
Failure
phenomenon

Abnormal current flowed in the flash light relay circuit (the primary circuit of the relay), when power is
supplied to the circuit.
The controller turns OFF the output to the coil circuit of the flash light relay.
Response from
Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
The flash light does not flash.
Relative
information
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
Presumed cause and

Flash light relay defective
1
R10 (male)
Resistance value

harness
2
circuit)
Between wiring harness between CP03 (female) (18)

and R10 (female) (1) and grounding
Resistance
valve
Min. 1 Mz
3
250 350 z
Between (1) and (2)
Pump controller
defective
CP03
Horn switch
Voltage
Between (18) and

grounding
ON
20 30 V
Max. 1 V
(at constant cycle,
5 seconds)
OFF
Max. 1 V
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to horn and flash light
PC600-8
SEN00450-02
40 Troubleshooting
Failure code [D195KB] Step Light Relay S/C

Action code
Failure code
D195KB
Failure content
Failure
phenomenon

Abnormal current flowed in the step light relay circuit (the primary circuit of the relay), when power is
supplied to the circuit.
Power to the step light relay circuit is switched OFF.

Response from
controller
Phenomenon
occurring on
machine
Step light does not light up.
Relative
information
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
Presumed cause and

Step light relay defective


harness
2
circuit)
R09 (male)
Resistance value
Between (2) and (1)
250 350 z
and R09 (female) (2) and grounding
Resistance
value
Min. 1 Mz
3 Pump controller defective

CP02
Step light switch
Voltage
Between (19) and

grounding
ON
20 30 V
(Kept for 60 sec)
OFF
Max. 1 V
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to step light
PC600-8
SEN00450-02
40 Troubleshooting
Failure code [DA22KK] Pump Solenoid Power Low Error

Action code
Failure code
E0E
DA22KK
Failure content
Failure
phenomenon
Pump Solenoid Power Low Error

Pump controller solenoid power supply voltage is below 20 V.
Response from
Limits engine speed to 1,400 rpm.
controller
Phenomenon
occurring on
machine
If solenoid power supply voltage lowers extremely, work equipment, swing system and travel system do
not operate.
Engine speed does not rise above 1,400 rpm.
Hydraulic fan cannot be rotated in reverse.
Relative
information
If D110KB is displayed, carry out troubleshooting for it first.

Cause
Defective circuit breaker

No. 4

If circuit breaker No. 4 is turned OFF, circuit probably has ground fault etc. (See
cause 3.)
starting switch ON.
Presumed cause and

Wiring harness between CP03 (female) (2), (12), (22)

J07 (female) (2), (3), (4)
Wiring harness between J07 (female) (1) B24
2
in wiring or defective con- Wiring harness between battery relay terminal M B14
tact in connector)
Wiring harness between starting switch terminal BR
battery relay terminal BR
J08 ground
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
starting switch ON.
3 harness (Contact with
GND circuit)
4 Defective pump controller

J07 (female) (2), (3), (4) ground
Resistance
Min. 1 Mz
Wiring harness between J07 (female) (1) B24

ground
Resistance
Min. 1 Mz
Wiring harness between battery relay terminal M B14

ground
Resistance
Min. 1 Mz
troubleshooting.
Between CP03 (2), (12), (22) (31), (32) (33)
10
Resistance
Voltage
20 30 V
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to power supply of pump controller
PC600-8
11
SEN00450-02
40 Troubleshooting
Failure code [DA25KP] Press. Sensor Power Abnormality

Action code
Failure code
DA25KP
Failure content
Failure
phenomenon
Press. Sensor Power Abnormality

Abnormal current flowed in the pressure sensor power supply (5 V) circuit.
Response from Power to the power supply (5 V) circuit is switched OFF.

controller
Phenomenon
occurring on
machine
The pressure sensor signal is not input normally.

The error code of abnormality in the pressure sensor is displayed, too.
Relative
information
Cause

a Disconnect the connector when the engine starting switch is in OFF, and hold it in
the ON position during the troubleshooting.
Presumed cause and

Pressure sensor
1 defective
Disconnect the parts

shown at right in order.
If the error code goes off
when one of those parts is
disconnected, that part is
defective.
Front pump
pressure sensor
Connector P25
Rear pump
pressure sensor
Connector P26
harness
2
circuit)

A06, and P25 (female) (B) and grounding
[Front pump pressure sensor system]
Resistance
value
Min. 1 Mz

A06, and P26 (female) (B) and grounding
[Rear pump pressure sensor system]
Resistance
value
Min. 1 Mz
12
CP01
Voltage
4.5 5.5 V
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to pressure sensor power supply
PC600-8
13
SEN00450-02
40 Troubleshooting
Failure code [DA2SKQ] Model Selection Abnormality

Action code
Failure code
DA2SKQ
Failure content
Failure
phenomenon
Model Selection Abnormality

A model code signal was inputted which indicates another model that is not registered in the controller.
The controller treats it as a default-set model (PC600).

Response from
Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
None in particular with PC600 model
Relative
information
Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
function. (Code No. 00200: Controller Model Code)
a Input of model selecting signals (ON or OFF) can be confirmed in the monitoring function.
(Code No. 02201: Switch Input 2)
Cause
Presumed cause and

Model selection connector defective

1
(Internal disconnection or
short-circuiting)
harness

S30 (male)
Resistance value
Between (2), (3), (4) and (8)
Min. 1 Mz
Between (1) and (8)
Max. 1 z
Wiring harness between CP02 (female) (37) and S30
(male) (1)
Resistance
value
Max. 1 z
Between wiring harness between S30 (male) (8) to J05,

A07, J14, J15 and grounding
Resistance
value
Max. 1 z
harness
3
circuit)

and S30 (male) (2) and grounding
Resistance
value
Min. 1 Mz

and S30 (male) (3) and grounding
Resistance
value
Min. 1 Mz
Between wiring harness between CP02 (female) (7) and

S30 (male) (4) and grounding
Resistance
value
Min. 1 Mz
14
CP02
Voltage
Between (7), (17), (27) and grounding
20 30 V
Max. 1 V
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to model selection connector (for pump controller)
PC600-8
15
SEN00450-02
40 Troubleshooting
Failure code [DA80MA] Auto. Lub Abnormal

a This failure code is applicable only when the auto grease device is installed.
16
PC600-8
40 Troubleshooting
PC600-8
SEN00450-02
17
SEN00450-02
40 Troubleshooting
Failure code [DA2RMC] Pump Comm. Abnormality

Action code
Failure code
E0E
DA2RMC
Failure content
Failure
phenomenon
Pump Comm. Abnormality

The pump controller detected communication failure in the CAN communication circuit to the machine
monitor or engine controller.
Response from The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
controller
Phenomenon
occurring on
machine
The output lowers (The pump absorption torque is reduced).

If the working load increases, the engine may stall.
Relative
information
Cause

harness

(female) (22)
Resistance
value
Max. 1 z

(female) (32)
Resistance
value
Max. 1 z
Presumed cause and

harness
2
circuit)

and related circuits and grounding
Resistance
value
Min. 1 Mz

Resistance
value
Min. 1 Mz
3 harness

defective

Voltage
Max. 1 V

Voltage
Max. 1 V
Resistance value
Between (A) and (B)
120 12 z
If causes 1 4 are not detected, machine monitor, engine controller, or pump controlMonitor panel,
ler may be defective. (Since trouble is in those devices, troubleshooting cannot be
5 engine controller, or
pump controller defective carried out.)
18
PC600-8
40 Troubleshooting
SEN00450-02
PC600-8
19
SEN00450-02
40 Troubleshooting
Failure code [DAFRMC] Monitor Comm. Abnormality

Action code
Failure code
E0E
DAFRMC
Failure content
Failure
phenomenon
Monitor Comm. Abnormality

The machine monitor detected communication failure in the CAN communication circuit to the engine
controller or pump controller.
Response from The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
machine monitor When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
The output lowers (The pump absorption torque is reduced).

If the working load increases, the engine may stall.
Relative
information
Cause

harness

(female) (22)
Resistance
value
Max. 1 z

(female) (32)
Resistance
value
Max. 1 z
Presumed cause and

harness
2
circuit)
Resistance
value
Min. 1 Mz

Resistance
value
Min. 1 Mz
3 harness

defective
Machine monitor, engine

5 controller, or pump
controller defective
20


Voltage
Max. 1 V

Voltage
Max. 1 V
Voltage
Between (A) and (B)
120 12 z
If causes 1 4 are not detected, machine monitor, engine controller, or pump controller may be defective. (Since trouble is in those devices, troubleshooting cannot be
carried out.)
PC600-8
40 Troubleshooting
SEN00450-02
PC600-8
21
SEN00450-02
40 Troubleshooting
Failure code [DGE5KY] Ambi. Temp. Sensor S/C

Action code
Failure code
DGE5KY
Failure content
Failure
phenomenon
Ambi. Temp. Sensor S/C

Abnormal current flowed in ambient temperature sensor circuit.
Response from None in particular.

controller
Phenomenon
occurring on
machine
Fan rotation speed rises.
Relative
information
Cause
Presumed cause and

Defective ambient
temperature sensor

starting switch ON.
P29 (male)
Ambient temperature
Resistance
Between (1) (2)
20C
4 6 kz
starting switch ON.
Wiring harness between CP01 (female) (9) P29
2
in wiring or defective con- (female) (1)
tact in connector)
(female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
troubleshooting.
3 with 24 V circuit) in wiring
Wiring
harness between CP01 (female) (9) P29
harness
Voltage
Max. 1 V
(female) (1)
starting switch ON.
P29 (male)
Ambient temperature
Resistance
Between (1) (2)
20C
4 6 kz
Circuit diagram related to ambient temperature sensor
22
PC600-8
SEN00450-02
40 Troubleshooting
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C

Action code
Failure code
DGH2KB
Failure content
Failure
phenomenon
Hydr. Oil Temp. Sensor S/C

While engine was running, signal of hydraulic oil temperature sensor rose above 102C.
Response from
None in particular.
machine monitor
Phenomenon
occurring on
machine
If machine is operated as it is, hydraulic components may be damaged.
Relative
information
If hydraulic oil temperature monitor of monitor panel lights up red while engine is running, this failure
code is recorded.
Input (temperature) from hydraulic oil temperature sensor can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature, 04402: Hydraulic oil temperature sensor voltage)
Cause
Overheating of hydraulic
1 oil (When system is normal)

Hydraulic oil may have been overheated. Remove cause and repair damaged
hydraulic parts.
Presumed cause and

starting switch ON.
Defective hydraulic oil
2 temperature sensor
(Internal defect)
P22 (male)
Between (1)
chassis ground

GND circuit)
Between (1) (2)
Resistance
90 3.5 kz
10 100C
Min. 1 Mz
starting switch ON.
Wiring harness between CM02 (female) (12) P22
(female) (1) and chassis ground
Resistance
Min. 1 Mz
starting switch ON.
4
Defective machine monitor
CM02 (female)
Between (12) (13)

Between (12)
chassis ground
Resistance
90 3.5 kz
10 100C
Min. 1 Mz
Electric circuit diagram related to hydraulic oil temperature sensor
PC600-8
23
SEN00450-02
40 Troubleshooting
Failure code [DHPAMA] F pump P. Sensor Abnormality

Action code
Failure code
DHPAMA
Failure content
Failure
phenomenon
F pump P. Sensor Abnormality

Signal voltage from the front pump pressure sensor is Max. 0.3 V or Min. 4.42 V.
Response from
controller
Phenomenon
occurring on
machine
The travel speed does not shift automatically (The travel load pressure cannot be detected).
Relative
information
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure
sensor will be broken. Accordingly, take extreme care when checking.
Input from the front pump pressure sensor (pressure) can be checked in the monitoring function. (Code
No. 01100: Front pump pressure)
Cause
Sensor power supply

system defective

If failure code [DA25KP] is displayed, carry out troubleshooting for it first.
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
P25
Front pump pressure

2 sensor defective
(Internal defect)
Voltage
Between (B) and (A)
Power supply
4.5 5.5 V
Between (C) and (A)
Signal
0.5 4.5 V
The pressure sensor voltage is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,
for another cause of the trouble, and then judge.
Presumed cause and

harness

harness
4
circuit)
Wiring harness between CP01 (female) (22), A06, J25,

and P25 (female) (B)
Resistance
value
Max. 1 z
Wiring harness between CP01 (female) (10), A06, and

P25 (female) (A)
Resistance
value
Max. 1 z
Wiring harness between CP01 (female) (8) and P25

(female) (C)
Resistance
value
Max. 1 z
P25 (female) (C) and grounding
Resistance
value
Min. 1 Mz
Hot short
5 (Short circuit with 24 V
circuit) in wiring harness

A06, J25, and P25 (female) (B) and grounding
Voltage
Max. 1 V
Between wiring harness between C01 (female) (8) and

P25 (female) (C) and grounding
Voltage
Max. 1 V
24
CP01
Voltage
4.5 5.5 V
0.5 4.5 V
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to front pump pressure sensor
PC600-8
25
SEN00450-02
40 Troubleshooting
Failure code [DHPBMA] R pump P. Sensor Abnormality

Action code
Failure code
DHPBMA
Failure content
Failure
phenomenon
R pump P. Sensor Abnormality

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

supply system

If failure code [DA25KP] is displayed, perform troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON and start engine and
carry out troubleshooting in each case.
P26
Defective R pump pres2 sure sensor (Internal

defect)
Voltage
Between (B) and (A)
Power supply
4.5 5.5 V
Between (C) and (A)
Signal
0.5 4.5 V
Pressure sensor voltage is measured with wiring harness connected. Accordingly, if

voltage is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.
Presumed cause and

starting switch ON.
3
or defective contact with
connector)

GND circuit)
Wiring harness between CP01 (female) (22) A06

J25 P26 (female) (B)
Resistance
value
Max. 1 z
Wiring harness between CP01 (female) (10) J08

A06 P26 (female) (A)
Resistance
value
Max. 1 z

(female) (C)
Resistance
value
Max. 1 z
starting switch ON.
(female) (C) and chassis ground
Resistance
value
Min. 1 Mz
troubleshooting.
Wiring harness between CP01 (female) (22) A06
J25 P26 (female) (B)
harness
(female) (C) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON and start engine and
carry out troubleshooting in each case.
26
CP01
Voltage
4.5 5.5 V
0.5 4.5 V
PC600-8
40 Troubleshooting
SEN00450-02
Circuit diagram related to R pump pressure sensor
PC600-8
27
SEN00450-02
40 Troubleshooting
Failure code [DV20KB] Travel Alarm S/C

Action code
Failure code
DV20KB
Failure content
Failure
phenomenon
Travel Alarm S/C

Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit.
Power to the travel alarm circuit is switched OFF.

Response from
controller
Phenomenon
occurring on
machine
The travel alarm does not sound.
Relative
information
Operation of the travel alarm (ON or OFF) can be checked in the monitoring function.
(Code No. 03701: Controller output 2)
Cause

Presumed cause and

M14 (female)
1
Travel alarm defective

(Internal defect)
Between (1) and (2)
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.
harness
2
circuit)
M14 (female) (1) and grounding
Resistance
value
Min. 1 Mz
CP03
28
Travel lever
Travel lever
Voltage
Neutral
Max. 1 V
Operated
20 30 V
PC600-8
40 Troubleshooting
SEN00450-02
Circuit diagram related to travel alarm
PC600-8
29
SEN00450-02
40 Troubleshooting
Failure code [DW43KA] Travel Speed Sol. Disc.

Action code
Failure code
DW43KA
Failure content
Failure
phenomenon
Travel Speed Sol. Disc.

No current flows to the travel speed select solenoid circuit, when power is supplied to the circuit.
Response from None in particular (The solenoid does not function as there is no current flowing to it)
controller
Phenomenon
occurring on
machine
The travel speed does not shift to Hi.

(The swash plate angle of the travel motor is not minimized.)
Relative
information
The travel speed select solenoid is not turned ON when the engine speed is below 1,200 rpm.
Operation of the travel speed select solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 02300: Solenoid 1)
Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or
OFF, refer to the troubleshooting under failure code [DW43KB].)
Cause
Presumed cause and

Travel speed select

1 solenoid defective
harness

V04 (male)
Resistance value
Between (2) and (1)
20 60 z
Wiring harness from CP03 (female) (27) to A05 and V04
(female) (2)
Resistance
value
Max. 1 z
Wiring harness between V04 (female) (1) to J23, A05,

J08, CP03 (female) (3), (13), (23), J23 and grounding
Resistance
value
Max. 1 z
Between
wiring harness between CP03 (female) (27),
harness
Voltage
Max. 1 V
A05, and V04 (female) (2) and grounding
30
CP03 (female)
Resistance value
20 60 z
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to travel speed select solenoid
PC600-8
31
SEN00450-02
40 Troubleshooting
Failure code [DW43KB] Travel Speed Sol. S/C

Action code
Failure code
DW43KB
Failure content
Failure
phenomenon
Travel Speed Sol. S/C

Abnormal current flew to the travel speed select solenoid, when power was supplied to the circuit.
Power supply to the travel speed select solenoid circuit is switched OFF.
Response from
controller
Phenomenon
occurring on
machine
The travel speed does not turn to Hi.

(The swash plate angle of the travel motor is not minimized.)
Relative
information
The travel speed select solenoid is not turned ON when the engine speed is below 1,200 rpm.
Operation of the travel speed select solenoid (ON or OFF) can be checked in the monitoring function.
Presumed cause and

Cause
Travel speed select
solenoid defective
1
(Internal short-circuiting
or grounding fault)
harness
2
circuit)
V04 (male)
Resistance value
Between (2) and (1)
20 60 z
Min. 1 Mz
Resistance
value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in high idling
during the troubleshooting.
32
CP03
Travel speed select switch
Voltage
Between (27) and

grounding
Lo
Max. 1 V
Hi
20 30 V
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to travel speed select solenoid
PC600-8
33
SEN00450-02
40 Troubleshooting
Failure code [DW45KA] Swing Brake Sol. Disc.

Action code
Failure code
DW45KA
Failure content
Failure
phenomenon
Swing Brake Sol. Disc.

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

Assembled-type diode
2 D01 defective
Swing lock switch

Presumed cause and
3 defective

V05 (male)
Resistance value
Between (2) and (1)
20 60 z
D01 (male)
Digital tester
Continuity
Between (7) and (3)
Diode mode
Continued
S04 (female)
Between (3) and (4)
Swing lock switch
Resistance value
OFF
Max. 1 z
LOCK
Min. 1 Mz
harness
Wiring harness between CP03 (female) (37) and D01

(female) (7)
Resistance
value
Max. 1 z
Wiring harness between D01 (female) (3), J04, and S04

(male) (3)
Resistance
value
Max. 1 z
Wiring harness between S04 (male) (4), V05 (female)

(2)
Resistance
value
Max. 1 z
Wiring harness between V05 (female) (1), J23, A05, J08

and CP03 (female) (3), (13) and (23)
Resistance
value
Max. 1 z
harness
Voltage
Max. 1 V
and D01 (female) (7)
CP03 (female)
Between (37) and
grounding
34
Disconnect D01 and

directly connect pins (3)
and (7) on the female side.
Resistance value
20 60 z
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to swing holding brake solenoid
PC600-8
35
SEN00450-02
40 Troubleshooting
Failure code [DW45KB] Swing Brake Sol. S/C

Action code
Failure code
DW45KB
Failure content
Failure
phenomenon
Swing Brake Sol. S/C

Abnormal current flowed in the swing holding brake solenoid circuit, when power is supplied to the circuit.
Power to the swing holding brake solenoid circuit is switched OFF.

Response from
controller
Phenomenon
occurring on
machine
The machine cannot swing (The swing holding brake cannot be released).
Relative
information
Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding
brake release switch in the RELEASE position (The parking brake does not operate when the machine
stops, however).
Cause
Presumed cause and

Swing holding brake

solenoid defective
1
or grounding fault)
2 D01 defective
harness
3
circuit)

V05 (male)
Resistance value
Between (2) and (1)
20 60 z
Min. 1 Mz
D01 (male)
Resistance value (Continuitiy)
Between (3) and (7)
Min. 1 Mz (No continuitiy)
D01, J04, S04, and V05 (female) (2) and grounding
Min. 1 Mz
CP03
Work equipment
control lever
Voltage
All levers in neutral
Max. 1 V
(5 sec after setting
in neutral)
Work equipment or
swing operated
20 30 V

Between (37) and
grounding
36
Resistance
value
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to swing holding brake solenoid
PC600-8
37
SEN00450-02
40 Troubleshooting
Failure code [DW48KA] CO Cancel Sol. Disc.

Action code
Failure code
DW48KA
Failure content
Failure
phenomenon
CO Cancel Sol. Disc.

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

CO cancel
harness
V07 (male)
Resistance value
Between (2) and (1)
20 60 z
(female) (2)
Resistance
value
Max. 1 z

J08, CP03 (female) (3), (13), (23)
Resistance
value
Max. 1 z
harness
Voltage
Max. 1 V
38
Pump controller
defective
CP03 (female)
Resistance value
20 60 z
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to CO cancel solenoid
PC600-8
39
SEN00450-02
40 Troubleshooting
Failure code [DW48KB] CO Cancel Sol. S/C

Action code
Failure code
DW48KB
Failure content
Failure
phenomenon
CO Cancel Sol. S/C

Abnormal current flew to the CO cancel solenoid circuit, when power was supplied to the circuit.
Power supply to the CO cancel solenoid circuit is switched OFF.

Response from
Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
When the boom is raised and the machine travels, power is low (The pump CO function cannot be cancelled).
Relative
information
Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function.
Presumed cause and

Cause
CO cancel solenoid
defective
1
or grounding fault)
harness
2
circuit)

V07 (male)
Resistance value
Between (2) and (1)
20 60 z
Min. 1 Mz
A05 and V08 (female) (2) and grounding
Resistance
value
Min. 1 Mz
3
Pump controller
defective
CP03
Swing lock switch
Voltage
Between (28) and

grounding
OFF
Max. 1 V
ON (Note)
20 30 V
Note: May be measured under the condition of "Power max. switch ON (for 8.5 seconds)" or "Single boom
RAISE operation" or "Travel operation".
40
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to CO cancel solenoid
PC600-8
41
SEN00450-02
40 Troubleshooting
Failure code [DW7BKA] Fan Reverse Sol. Disc.

Action code
Failure code
DW7BKA
Failure content
Failure
phenomenon
Fan Reverse Sol. Disc.

When signal is output to hydraulic drive solenoid circuit, no current flows.
Response from None in particular (Since no current flows, solenoid does not operate).
monitor panel
Phenomenon
occurring on
machine
Fan does not rotate in reverse.
Relative
information
Since disconnection of solenoid is detected while output is ON, be sure to turn output ON when checking for reproduction of failure after repair.
Cause
Presumed cause and

Defective hydraulic fan

1 reverse solenoid (Internal
disconnection)

starting switch ON.
V17 (male)
Resistance
Between (1) (2)
20 60 z
starting switch ON.
Wiring harness between CP03 (female) (25) V17
2
tact in connector)
Wiring harness between V17 (female) (2) CP03
(female) (3), (13), (23)
Resistance
Max. 1 z
Resistance
Max. 1 z
troubleshooting.
Wiring
harness between CP03 (female) (25) V17
harness
Voltage
Max. 1 V
starting switch ON.
CP03 (female)
Resistance
Between (25) chassis ground
20 60 z
Circuit diagram related to hydraulic fan
42
PC600-8
SEN00450-02
40 Troubleshooting
Failure code [DW7BKB] Fan Reverse Sol. S/C

Action code
Failure code
DW7BKB
Failure content
Failure
phenomenon
Fan Reverse Sol. S/C

When signal was output to hydraulic fan reverse solenoid circuit, abnormal current flowed.
Response from Turns output to hydraulic fan reverse solenoid circuit OFF.
monitor panel
Phenomenon
occurring on
machine
Fan does not rotate in reverse.
Relative
information
Operating condition (ON-OFF) of hydraulic fan reverse solenoid can be checked with monitoring function.
Presumed cause and

Cause
reverse solenoid (Internal
1
short circuit or ground
fault)

GND circuit)

starting switch ON.
V17 (male)
Resistance
Between (1) (2)
20 60 z
Min. 1 Mz
starting switch ON.
Resistance
Min. 1 Mz
troubleshooting.
CP03
Working mode
Voltage
Between (25)
chassis ground
Other than L-mode
Max. 1 V
L-mode
20 30 V
PC600-8
43
SEN00450-02
40 Troubleshooting
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc.

Action code
Failure code
DW4XKA
Failure content
Failure
phenomenon
Bucket Curl Hi Cancel Sol. Disc.

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

Bucket Curl Hi cancel

2
connector)

V03 (male)
Resistance value
Between (2) and (1)
20 60 z
Wiring harness between CP03 (female) (38), A05, and
V03 (female) (2)
Resistance
value
Max. 1 z
Wiring harness between CP03 (female) (3), J08, and

V03 (female) (1)
Resistance
value
Max. 1 z
Between
wiring harness between CP03 (female) (38),
harness
Voltage
Max. 1 V
44
CP03 (female)
Resistance value
20 60 z
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to bucket curl Hi cancel solenoid
PC600-8
45
SEN00450-02
40 Troubleshooting
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C

Action code
Failure code
DW4XKB
Failure content
Failure
phenomenon
Bucket Curl Hi Cancel Sol. S/C

Abnormal current flowed to the bucket Curl Hi cancel solenoid circuit, when power was supplied to the
circuit.
Power supply to the bucket Curl Hi cancel solenoid circuit is switched OFF.
Response from
Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
When the bucket and other work equipment are operated simultaneously, the speed of the other work
equipment is low (The bucket Curl Hi function is not cancelled).
Relative
information
Operation of the bucket Curl Hi cancel solenoid (ON or OFF) can be checked in the monitoring function.
Cause
Presumed cause and

Bucket Curl Hi cancel

solenoid defective
1
or grounding fault)

grounding circuit)

V03 (male)
Resistance value
Between (2) and (1)
20 60 z
Min. 1 Mz
Min. 1 Mz
CP03
46
Resistance
value
Work equipment
control lever
Voltage
Max. 1 V
Bucket Curl
+
Other work equipment
operation
20 30 V
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to bucket curl Hi cancel solenoid
PC600-8
47
SEN00450-02
40 Troubleshooting
Failure code [DWK0KA] 2-stage Relief Sol. Disc.

Action code
Failure code
DWK0KA
Failure content
Failure
phenomenon
2-stage Relief Sol. Disc.

No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from None in particular (The solenoid does not function as there is no current flowing to it)
controller
Phenomenon
occurring on
machine
The heavy-lift function does not work.

Travel power is low (The main relief valve is not set in the HIGH PRESSURE position).
Relative
information
Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
OFF, refer to the troubleshooting under failure code [DWK0KB].)
Cause
Presumed cause and


1 defective
harness

V08 (male)
Resistance value
Between (2) and (1)
20 60 z
(female) (2)
Resistance
value
Max. 1 z

J08, CP03 (female) (3), (13), (23)
Resistance
value
Max. 1 z
harness
Voltage
Max. 1 V
48
CP03 (female)
Resistance value
20 60 z
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to 2-stage relief solenoid
PC600-8
49
SEN00450-02
40 Troubleshooting
Failure code [DWK0KB] 2-stage Relief Sol. S/C

Action code
Failure code
DWK0KB
Failure content
Failure
phenomenon
2-stage Relief Sol. S/C

Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
Power supply to the 2-stage relief solenoid circuit is switched OFF.

Response from
controller
Phenomenon
occurring on
machine
Travel power is low (The main relief valve is not set in the HIGH PRESSURE position).
Relative
information
Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
Presumed cause and

Cause
defective
1
or grounding fault)
harness
2
circuit)
50
V08 (male)
Resistance value
Between (2) and (1)
20 60 z
Min. 1 Mz
Resistance
value
Min. 1 Mz
Note:
CP03
Voltage
Between (17) and

grounding
Neutral
Max. 1 V
Travel operation (Note)
20 30 V
May be measured under the condition of "Power max. switch ON (for 8.5 seconds)" or "Single boom
RAISE operation".
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to 2-stage relief solenoid
PC600-8
51
SEN00450-02
40 Troubleshooting
Failure code [DX16KA] Fan Pump EPC Sol. Disc.

Action code
Failure code
DX16KA
Failure content
Failure
phenomenon
Fan Pump EPC Sol. Disc.

No current flows in hydraulic fan EPC solenoid circuit.
Response from Fan pump is set to maximum swash plate angle and fan may rotate at excessive speed. Accordingly,
controller
protection mode is selected to lower engine speed.
Phenomenon
occurring on
machine
Fan motor speed cannot be controlled.
Relative
information
If fan EPC solenoid system has disconnection or short circuit, fan cannot be reversed.
Output (current) to hydraulic fan EPC solenoid can be checked with monitoring function.
(Code No. 31623: Hydraulic fan EPC solenoid current)
Cause
Presumed cause and


1 EPC solenoid (Internal
disconnection)

starting switch ON.
V13 (male)
Resistance
Between (1) (2)
7 14 z
starting switch ON.
2
tact in connector)
(female) (3), (13), (23)
Resistance
Max. 1 z
Resistance
Max. 1 z
troubleshooting.
harness
(female) (3), (13), (23)
Voltage
Max. 1 V
Voltage
Max. 1 V
starting switch ON.
52
CP03 (female)
Resistance
Between (35) (3), (13), (23)
7 14 z
PC600-8
40 Troubleshooting
SEN00450-02
PC600-8
53
SEN00450-02
40 Troubleshooting
Failure code [DX16KB] Fan Pump EPC Sol. S/C

Action code
Failure code
DX16KB
Failure content
Failure
phenomenon
Fan Pump EPC Sol. S/C

Abnormal current flowed in hydraulic fan EPC solenoid circuit.
Response from Fan pump is set to maximum swash plate angle and fan may rotate at excessive speed. Accordingly,
controller
protection mode is selected to lower engine speed.
Phenomenon
occurring on
machine
Fan motor speed cannot be controlled.
Relative
information
If fan EPC solenoid system has disconnection or short circuit, fan cannot be reversed.
Output (current) to hydraulic fan EPC solenoid can be checked with monitoring function.
(Code No. 31623: Hydraulic fan EPC solenoid current)
Presumed cause and

Cause
EPC solenoid (Internal
1
short circuit or ground
fault)

GND circuit)

starting switch ON.
V13 (male)
Resistance
Between (1) (2)
7 14 z
Min. 1 Mz
starting switch ON.
Resistance
Min. 1 Mz
starting switch ON.
CP03 (female)
Resistance
Between (35) (3), (12), (23)
7 14 z
Min. 1 Mz
54
PC600-8
40 Troubleshooting
PC600-8
SEN00450-02
55
SEN00450-02
40 Troubleshooting
Failure code [DXA0KA] TVC Sol. Disc.

Action code
Failure code
E02
DXA0KA
Failure content
Failure
phenomenon
TVC Sol. Disc.

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


V11 (male)
Resistance value
Between (1) and (2)
10 22 z
Presumed cause and

Emergency pump drive

2 switch defective
Emergency pump
drive switch
Resistance value
NORML position
Max. 1 z
EMERGENCY position
Min. 1 Mz
NORML position
Max. 1 z
EMERGENCY position
Min. 1 Mz
S25 (male)
Between (2) and (3)
Between (5) and (6)
harness

(female) (3)
Resistance
value
Max. 1 z
Wiring harness between S25 (female) (2) and V11

(female) (1)
Resistance
value
Max. 1 z

(female) (6)
Resistance
value
Max. 1 z
Wiring harness between S25 (female) (5) and V11

(female) (2)
Resistance
value
Max. 1 z
and S25 (female) (3) and grounding
harness
Between wiring harness between S25 (female) (2) and
V11 (female) (1) and grounding
Voltage
Max. 1 V
Voltage
Max. 1 V
56
CP03 (female)
Resistance value
10 22 z
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to TVC solenoid
PC600-8
57
SEN00450-02
40 Troubleshooting
Failure code [DXA0KB] TVC Sol. S/C

Action code
Failure code
E02
DXA0KB
Failure content
Failure
phenomenon
TVC Sol. S/C

Abnormal current flowed in the TVC solenoid circuit.
Power to the TVC solenoid circuit is switched OFF.

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

TVC solenoid defective

or grounding fault)
Emergency pump drive

switch defective
2
or grounding fault)

V11 (male)
Resistance value
Between (1) and (2)
10 22 z
Min. 1 Mz
S25 (male)
Between (3) and (4)

harness
3
circuit)
Emergency pump
drive switch
NORML position
Resistance value
Min. 1 Mz
Min. 1 Mz
and S25 (female) (3) and grounding
Resistance
value
Min. 1 Mz

V11 (female) (1) and grounding
Resistance
value
Min. 1 Mz
58
CP03 (female)
Resistance value
10 22 z
Min. 1 Mz
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to TVC solenoid
PC600-8
59
SEN00450-02
40 Troubleshooting
Failure code [DY20KA] Wiper Working Abnormality

Single wiper specification
Action code
Failure code
DY20KA
Failure content
Failure
phenomenon
Wiper Working Abnormality

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

Presumed cause and

Wiper motor defective

M05 (female)
Between (6) and (5)
harness
2
(Disconnection or faulty
contact with connector)
Resistance value
At upper end of operation

range
Max. 1 z
Outside upper end of

operation range
Min. 1 Mz
Wiring harness between CM01 (female) (5) and M05
(male) (6)
Resistance
value
Max. 1 z
Wiring harness between M05 (male) (5) and grounding
Resistance
value
Max. 1 z
3
Machine monitor
defective
CM01
60
Windshield wiper blade
Wiper blade
Voltage
At upper end of
operation range
Max. 1 V
Outside upper end of

operation range
20 30 V
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to wiper motor (Single wiper specification.)
PC600-8
61
SEN00450-02
40 Troubleshooting
Failure code [DY20MA] Wiper Parking Abnormality

Double wiper specification
Action code
Failure code
DY20MA
Failure content
Failure
phenomenon
Wiper Parking Abnormality

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

1 defective

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

(male) (4)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z

(male) (4)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Machine monitor
defective
CM01
Upper wiper blade
Between (12) and

grounding
Retraction range
Max. 1 V
Operation range
20 30 V
CM01
Lower wiper blade
Voltage
Retraction range
Max. 1 V
Operation range
20 30 V
62
Voltage
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to wiper motor (Double wiper specification.)
PC600-8
63
SEN00450-02
40 Troubleshooting

Action code
Failure code
DY20MA
Failure content
Failure
phenomenon
Wiper Parking Abnormality

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

Presumed cause and

M05 (female)
Between (4) and (5)
harness
Wiper blade
Resistance value
Retraction range
Max. 1 z
Operation range
Min. 1 Mz
(male) (4)
Resistance
value
Max. 1 z
Between wiring harness M05 (male) (5) and grounding
Resistance
value
Max. 1 z
3
64

Machine monitor
defective
CM01
Wiper blade
Voltage
Between (12) and

grounding
Retraction range
Max. 1V
Operation range
20 30 V
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to wiper motor (Single wiper specification.)
PC600-8
65
SEN00450-02
40 Troubleshooting
Failure code [DY2CKB] Washer Drive S/C

Action code
Failure code
DY2CKB
Failure content
Failure
phenomenon
Washer Drive S/C

Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power
was switched ON.
Response from
Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on
machine
The window washer stopped moving.
Relative
information
Presumed cause and

Cause
Window washer drive
1 motor defective

position for the troubleshooting.
M06 (male)
Resistance value
Between (1) and (2)
5 20 z
2 with 24 V circuit) in wiring Between wiring harness from CM01 (female) (3) and
harness
M06 (female) (2), or between wiring harness between
Voltage
Max. 1 V
CM01 (female) (3) and D04 (female) (6) and grounding
3
Machine monitor
defective
CM01
66
Voltage
OFF
20 30 V
ON
Max. 1 V
PC600-8
40 Troubleshooting
SEN00450-02
Electrical circuit diagram related to window washer motor
PC600-8
67
SEN00450-02
40 Troubleshooting
Failure code [DY2DKB] Wiper Drive (For) S/C

Action code
Failure code
DY2DKB
Failure content
Failure
phenomenon
Wiper Drive (For) S/C

Abnormal current flowed in the wiper motor forward rotation circuit, when power is supplied to the circuit.
Response from
Power to the wiper motor forward rotation circuit is switched OFF.
monitor panel
Phenomenon
occurring on
machine
The wiper stops.
Relative
information
Cause
Upper wiper motor

defective
1
or grounding fault)
Presumed cause and

Lower wiper motor

defective
2
or grounding fault)
3 D04 defective

M05 (female)
Continuity and resistance value
Between (3) and (1)
Continued
Min. 1 Mz
M15 (female)
Between (3) and (1)
Continued
Min. 1 Mz
D04 (male)
Between (3) and (7)
Between (4) and (8)
harness
4
circuit)
Machine monitor
defective
(Upper wiper motor)

and M05 (male) (3) or between CM01 (female) (9) and
D04 (female) (3) and grounding
Resistance
value
Min. 1 Mz
Between wiring harness between CM01 (female) (5),

M15 (male) (3) or between CM01 (female) (5) and D04
(female) (4) and grounding
Resistance
value
Min. 1 Mz
CM01
5
Machine monitor
defective
(Lower wiper motor)
68
Voltage
OFF
Max. 3 V
ON
20 30 V (Note)
CM01
Note:
Upper wiper switch
Lower wiper switch
Voltage
OFF
Max. 3 V
ON
20 30 V (Note)
When the upper wiper and lower wiper are operated simultaneously: Max. 3 V
intervals)
20 30 V (at regular
PC600-8
40 Troubleshooting
SEN00450-02
Electrical Circuit diagram related to wiper motor (Double wiper specification)
PC600-8
69
SEN00450-02
40 Troubleshooting

Action code
Failure code
DY2DKB
Failure content
Failure
phenomenon
Wiper Drive (For) S/C

Abnormal current flowed in the wiper motor forward rotation circuit, when power is supplied to the circuit.
Response from
Power to the wiper motor forward rotation circuit is switched OFF.
monitor panel
Phenomenon
occurring on
machine
The wiper stops.
Relative
information
Presumed cause and

Cause

or grounding fault)

harness
2
circuit)

M05 (female)
Between (3) and (1)
Continued
Min. 1 Mz
and M05 (male) (3) and grounding
Min. 1 Mz
3
Machine monitor
defective
CM01
70
Resistance
value
Wiper switch
Voltage
OFF
Max. 3 V
ON
Max. 3 V
20 30 V
(at constant cycle)
PC600-8
40 Troubleshooting
SEN00450-02
Electric circuit diagram related to wiper motor (Single wiper specification.)
PC600-8
71
SEN00450-02
40 Troubleshooting
Failure code [DY2EKB] Wiper Drive (Rev) S/C

Action code
Failure code
DY2EKB
Failure content
Failure
phenomenon
Wiper Drive (Rev) S/C

Abnormal current flowed in the wiper motor reverse rotation circuit, when power is supplied to the circuit.
Response from
Power to the wiper motor reverse rotation circuit is switched OFF.
monitor panel
Phenomenon
occurring on
machine
The wiper stops.
Relative
information
Presumed cause and

Cause

or grounding fault)

harness
2
circuit)

position for the troubleshooting.
M05 (female)
Between (1) and (3)
Continued
Min. 1 Mz
and M05 (male) (1) and grounding
Min. 1 Mz
3
Machine monitor
defective
CM01
Between (10) and
grounding
72
Resistance
value
Wiper switch
Voltage
OFF
Max. 3 V
ON
Max. 3 V
20 30 V
(at constant cycle)
PC600-8
SEN00451-03
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up
40 Troubleshooting
E-1 Engine does not start (Engine does not rotate) ............................................................................................. 3
E-2 Preheater does not operate........................................................................................................................... 6
E-3 Auto engine warm-up device does not work ................................................................................................. 8
E-4 Auto-decelerator does not operate ................................................................................................................ 9
E-5 All work equipment, swing and travel do not move ..................................................................................... 10
E-6 Power max. function does not operate ........................................................................................................ 12
E-7 Machine push-up function does not operate normally................................................................................. 13
E-8 Any item is not displayed on machine monitor ............................................................................................ 15
E-9 Part of display on machine monitor is missing ............................................................................................ 16
E-10 Machine monitor displays contents irrelevant to the model....................................................................... 16
E-11 Fuel level monitor red lamp lights up while engine is running ................................................................... 17
E-12 Engine coolant temperature gauge does not display correctly.................................................................. 18
E-13 Hydraulic oil temperature gauge does not display correctly ...................................................................... 20
E-14 Fuel gauge does not display correctly ....................................................................................................... 21
E-15 Swing lock monitor does not display correctly........................................................................................... 22
E-16 When monitor switch is operated, nothing is displayed............................................................................. 24
E-17 Wiper and window washer do not work ..................................................................................................... 26
E-18 "Boom Raise" is not correctly displayed in monitoring function................................................................. 34
E-19 "Boom Lower" is not correctly displayed in monitoring function ................................................................ 36
E-20 "Arm IN" is not correctly displayed in monitoring function ......................................................................... 38
E-21 "Arm OUT" is not correctly displayed in monitoring function ..................................................................... 39
E-22 "Bucket CURL" is not correctly displayed in monitoring function............................................................... 40
PC600-8
SEN00451-03
40 Troubleshooting
E-23 "Bucket DUMP" is not correctly displayed in monitoring function .............................................................. 41

E-24 "Swing" is not correctly displayed in monitoring function........................................................................... 42
E-25 "Travel" is not correctly displayed in monitoring function........................................................................... 44
E-26 Air conditioner does not work .................................................................................................................... 46
E-27 Step light does not light up or go off .......................................................................................................... 48
E-28 Electric grease gun does not operate........................................................................................................ 52
E-29 Travel alarm does not sound or does not stop sounding........................................................................... 54
E-30 Horn does not sound ................................................................................................................................. 56
E-31 Bottom dump does not move..................................................................................................................... 58
PC600-8
SEN00451-03
40 Troubleshooting
E-1 Engine does not start (Engine does not rotate)

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

Battery voltage
Electrolyte specific gravity
Min. 24 V
Min. 1.26
Circuit breakers No. 1 or If a circuit breaker is turned OFF or a fuse is broken, the circuit probably has ground6 or fuse 2, 3, 6 defective ing fault (See cause 9).
position or start the engine during the troubleshooting.
Starting switch defective

M06 (male)
Starting switch
Resistance value
OFF
Min. 1 Mz
ON
Max. 1 z
Presumed cause and

Between (1) and (4)
Work equipment lock

4 switch defective
S14 (female)
Work equipment lock lever
Resistance value
FREE
Min. 1 Mz
LOCK
Max. 1 z
Between (1) and (3)
Starting motor cut-out
5 relay defective
(Internal defect)
R06 (female) and R07 (female)
Resistance value
Between (1) and (2)
100 500 z
Between (3) and (5)
Min. 1 Mz
Between (3) and (6)
Max. 1 z
a Turn the engine starting switch OFF for the preparations (with the wiring harness
connected), and start the engine for troubleshooting.
Starting motor
Starting motor defective

6
(Internal defect)
Voltage
Between B and grounding
B (Power
supply)
20 30 V
Between ST (1)
and grounding
S (Start)
20 30 V
Between ST (2)
and grounding
R (Charge)
Max. 1 V
If the above voltages are normal and the starting motor does not rotate, the starting
motor has a defect in it or the engine is defective.
Alternator defective
7
PC600-8
a Turn the engine starting switch OFF for the preparations (with only wiring harness
R disconnected), and hold it in the ON position during the troubleshooting.
Alternator
Voltage
Between terminal R and grounding
Max. 1 V
SEN00451-03
40 Troubleshooting
Cause

Presumed cause and

harness
Wiring harness between battery relay terminal B and

B16
Resistance
value
Max. 1 z
Wiring harness between B26 and H06 (female) (1)
Resistance
value
Max. 1 z
Wiring harness between H06 (female) (4) and R06

(female) (5)
Resistance
value
Max. 1 z
Wiring harness between R06 (female) (3) and ST

(female) (1)
Resistance
value
Max. 1 z
Wiring harness between F01-3 and S14 (male) (1)
Resistance
value
Max. 1 z
Wiring harness between S14 (male) (3) and R06

(female) (1)
Resistance
value
Max. 1 z
Wiring harness between R06 (female) (2) and R07

(female) (6)
Resistance
value
Max. 1 z
Wiring harness between R07 (female) (3), J04, A07 and

grounding
Resistance
value
Max. 1 z

harness
9
circuit)
Between wiring harness between B26 and H06 (female)

(1) and grounding
Resistance
value
Min. 1 Mz
Between wiring harness between H06 (female) (4) and

R06 (female) (5) and grounding
Resistance
value
Min. 1 Mz
Between wiring harness between R06 (female) (3) and

ST (female) (1) and grounding
Resistance
value
Min. 1 Mz
Between wiring harness between F01-3 and S14 (male)

(1) and grounding
Resistance
value
Min. 1 Mz
Between wiring harness between S14 (male) (3) and

Resistance
value
Min. 1 Mz

Resistance
value
Min. 1 Mz

CM02 (female) (14) and grounding
Resistance
value
Min. 1 Mz

10 with 24 V circuit) in wiring Between wiring harness between ST (female) (2) and
alternator terminal R or between ST (female) (2), J02
harness
and D01 (female) (6) or between ST (female) (2) and
CM02 (female) (11) and grounding
Voltage
Max. 1 V
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram for engine preheating, starting, charging
PC600-8
SEN00451-03
40 Troubleshooting
E-2 Preheater does not operate

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

Cause
(1) When the starting switch is turned to the HEAT position, the preheating monitor does not light up.
Starting switch system

1
defective
If the preheater does not operate (the heater unit is not warmed), carry out troubleshooting (2).
harness
Wiring harness between CM02 (female) (18) and J02
(male) (7)
Resistance
value
Max. 1 z
a Turn the engine starting switch OFF for the preparations , and hold it in the OFF or
HEAT position during troubleshooting.
3
Machine monitor
defective
CM02
Starting switch
Voltage
Between (18) and

grounding
OFF
Max. 1 V
HEAT
20 30 V
Failure
information
The preheater does not operate.
Relative
information
Check that the starting motor rotates normally.

(If the starting motor does not rotate, carry out troubleshooting in "Engine does not start".)
Cause
(2) When the starting switch is turned to the HEAT

position, the heater unit is not warmed.

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF or
HEAT position during troubleshooting.
Starting switch defective

H06 (male)
Between (1) and (3)
Starting switch
Resistance value
OFF
Min. 1 Mz
HEAT
Max. 1 z
Presumed cause and

a Turn the engine starting switch OFF for the preparations (with the wiring harness
connected), and hold it in the OFF or HEAT position during troubleshooting.
2
Heater relay defective

Intake air heater

3 defective
Heater relay
Starting switch
Continuity and
resistance value
Between coil terminal

and grounding
OFF
Continued
Between contact terminals
HEAT
Max. 1 z
Intake air heater
Between terminals
harness
Continuity
Continued
Wiring harness between H06 (female) (3), J02, and

heater relay terminal R17
Resistance
value
Max. 1 z
Wiring harness between battery relay terminal B and

heater relay R15
Resistance
value
Max. 1 z
Wiring harness between heater relay terminal R16 and

intake air heater
Resistance
value
Max. 1 z
Wiring harness between intake air heater and engine
Resistance
value
Max. 1 z
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram for engine preheating, starting, charging
PC600-8
SEN00451-03
40 Troubleshooting
E-3 Auto engine warm-up device does not work

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

Cause

a Turn the starting switch ON for the troubleshooting (monitoring).
Monitoring code
Engine coolant
temperature signal fault
04107
Item
Normal display
Compare the monitor

Engine coolant temperature
indication with the actual
(low temperature)
engine coolant temperature.
If the display on the machine monitor is abnormal, carry out troubleshooting in "E-12
Engine coolant temperature gauge does not display correctly".
2
Engine controller
defective
If cause 1 is not detected, the engine controller may be defective. (Since trouble is in
the engine controller, troubleshooting cannot be carried out.)
PC600-8
SEN00451-03
40 Troubleshooting
E-4 Auto-decelerator does not operate

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

defective
Boom LOWER signal

2
defective
3 Arm IN signal defective
Presumed cause and

4 Arm OUT signal defective
Bucket CURL signal

defective
Bucket DUMP signal

6
defective
7 Swing signal defective
8 Travel signal defective
9 Service signal defective

11
PC600-8
Engine controller
defective

Monitoring code
Item
Normal display
01900
Pressure switch 1
Boom RAISE
Lever operated: ON
Lever in neutral: OFF
Monitoring code
Item
Normal display
01900
Pressure switch 1
Boom LOWER
Lever operated: ON
Monitoring code
Item
Normal display
01900
Pressure switch 1
Arm IN
Lever operated: ON
Monitoring code
Item
Normal display
01900
Pressure switch 1
Arm OUT
Lever operated: ON
Monitoring code
Item
Normal display
01901
Pressure switch 2
Bucket CURL
Lever operated: ON
Monitoring code
Item
Normal display
01901
Pressure switch 2
Bucket DUMP
Lever operated: ON
Monitoring code
Item
Normal display
01900
Pressure switch 1
Swing
Lever operated: ON
Monitoring code
Item
Normal display
01900
Pressure switch 1
Right travel
Lever operated: ON
Monitoring code
Item
Normal display
01901
Pressure switch 2
Service
Lever operated: ON
If causes 1 9 are not detected, the pump controller may be defective.

(Since trouble is in the pump controller, troubleshooting cannot be carried out.)
If causes 1 9 are not detected, the engine controller may be defective.
(Since trouble is in the pump controller, troubleshooting cannot be carried out.)
SEN00451-03
40 Troubleshooting
E-5 All work equipment, swing and travel do not move

Failure
information
All the work equipment, swing and travel do not move.
Relative
information
Cause
1 Fuse No. 3 fault
Safety lock switch

2 defective

If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. (See cause 6.)
S14 (female)
Safety lock lever
Presumed cause and

Between (1) and (2)

PPC lock solenoid defective
3 (Internal disconnection,
short-circuiting, or
grounding fault)
4 D01 defective
Resistance value
Free
Max. 1 z
Lock
Min. 1 Mz
V01 (male)
Resistance value
Between (2) and (1)
20 60 z
Min. 1 Mz
D01 (male)
Between (4) and (8)
harness
Wiring harness between F01-3 outlet and S14 (male) (1)
Resistance
value
Max. 1 z
Wiring harness from S14 (male) (2) and V01 (female)

(2)
Resistance
value
Max. 1 z
Wiring harness between V01 (female) (1) and grounding
Resistance
value
Max. 1 z
harness
6
circuit)
10
Between wiring harness between F01-3 outlet and S14

(male) (1) and grounding
Resistance
value
Min. 1 Mz
Wiring harness from S14 (male) (2) to V01 (female) (2),

or between wiring harness between S14 (male) (2) and
Resistance
value
Min. 1 Mz
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram for PPC lock solenoid
PC600-8
11
SEN00451-03
40 Troubleshooting
E-6 Power max. function does not operate

Failure
information
Power max. function does not operate
Relative
information
If the power max. switch is pressed while the engine is running, the power max. monitor is displayed on
the monitor panel.
Input condition of the power max. switch (left knob switch) (ON or OFF) can be checked in the monitoring function. (Code No. 02200: Switch input 1)
Cause
1 Fuse No. 9 defective
Power max. switch defec2 tive (Internal disconnection)

If the fuse is broken, there is a big possibility that grounding fault occurred in the circuit. (See cause 4.)
M23 (male)
Presumed cause and

Between (1) and (2)

3
connector)
Power max. switch
Resistance value
Released
Min. 1 Mz
Pressed
Max. 1 z
Wiring harness between F01-9 outlet and S11 (female)
(1)
Resistance
value
Max. 1 z
grounding circuit)

Resistance
value
Min. 1 Mz

CP01 (female) (11) and grounding
Resistance
value
Min. 1 Mz
CP01
Power max. switch
Voltage
Between (11) and

grounding
Released
Max. 1 V
Pressed
20 30 V
Electrical circuit diagram related to power max. switch
12
PC600-8
SEN00451-03
40 Troubleshooting
E-7 Machine push-up function does not operate normally

Failure
information
Machine push-up function does not operate

normally.
Relative
information
When the machine push-up function is set in the high pressure position, the solenoid is turned OFF.
Presumed cause and

Cause
Machine push-up switch

1 defective
(1) The machine push-up function does not operate.

S05 (female)
Between (1) and (2)
Resistance value
Low pressure position
Max. 1 z
High pressure position
Min. 1 Mz
position during troubleshooting.
2 with 24 V circuit) in wiring Between wiring harness between S05 (male) (2), J01
harness
and V06 (female) (2) or between S05 (male) (2) and
Voltage
Max. 1 V
Electrical circuit diagram related to machine push-up solenoid
PC600-8
13
SEN00451-03
40 Troubleshooting
Failure
information
Machine push-up function does not operate

normally.
Relative
information
When the machine push-up function is set in the low pressure position, the solenoid is turned ON.
Cause

2 defective
(2) The machine push-up function is not turned OFF.

If the fuse is broken, the circuit probably has grounding fault (See cause 6).
S05 (female)
Resistance value
Low pressure position
Max. 1 z
High pressure position
Min. 1 Mz
Presumed cause and

Between (1) and (2)

Machine push-up
solenoid defective
short-circuiting or
grounding fault)
4 D03 defective
V06 (male)
Resistance value
Between (2) and (1)
20 60 z
Min. 1 Mz
position during troubleshooting.
D03 (male)
Between (1) and (5)
harness
Wiring harness between F01-2 outlet and S05 (male) (1)
Resistance
value
Max. 1 z
Wiring harness between S05 (male) (2), J01 and V06

(female) (2)
Resistance
value
Max. 1 z
Wiring harness between V06 (female) (1) and grounding
Resistance
value
Max. 1 z
harness
6
circuit)
14

(male) (1) or between F01-2 outlet and related circuits
and grounding
Resistance
value
Min. 1 Mz
Between wiring harness between S05 (male) (2), J01

and V06 (female) (2) or between S05 (male) (2) and
Resistance
value
Min. 1 Mz
PC600-8
SEN00451-03
40 Troubleshooting
E-8 Any item is not displayed on machine monitor

Failure
information
Any item is not displayed on the machine

monitor.
When the starting switch is turned ON, any item is not

displayed on the machine monitor.
Relative
information
Cause
1
Circuit breaker No. 1 or

fuse No. 10 defective

If the circuit breaker is turned OFF or the fuse is broken, the circuit probably has
grounding fault (See cause 3).
Presumed cause and

harness

harness
3
circuit)
Wiring harness between CM01 (female) (1), (2) and

F01-10 outlet
Resistance
value
Max. 1 z
Wiring harness between F01 inlet and B21
Resistance
value
Max. 1 z
Wiring harness between B11 and battery relay terminal

M
Resistance
value
Max. 1 z
Between wiring harness between CM01 (female) (1), (2)
and F01-10 outlet and grounding
Resistance
value
Min. 1 Mz
Between wiring harness between F01 inlet and B21 and

grounding
Resistance
value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON or
OFF position during troubleshooting.
Machine monitor
4
defective
CM01 (female)
Starting switch
Voltage, Resistance value
Between (1), (2)

and grounding
ON
Voltage: 20 30 V
Between (6), (7)

and grounding
OFF
Resistance value:
Max. 1 z
Electrical circuit diagram related to machine monitor power supply
PC600-8
15
SEN00451-03
40 Troubleshooting
E-9 Part of display on machine monitor is missing

Part of display on machine monitor is missing
Relative
information
Presumed cause and

Failure
information
Cause
Part of the display in the machine monitor is missing

during starting switch in ON.

a Turn the starting switch ON during the troubleshooting.
Machine monitor LCD

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

The machine monitor displays contents that have nothing to do with the model on which it is installed.
Relative
information
Presumed cause and

Failure
information
16
Cause

a Turn the starting switch in ON during the troubleshooting (monitoring).
Model code signal fault

(Internal failure)
Monitoring code
Item
Normal display
00200
Controller model code
PC600-a
If the display on the monitor panel is normal, troubleshoot failure code [DA2SKQ].
2
Machine monitor
defective
If cause 1 is not detected, the machine monitor may be defective. (Since trouble is in
the machine monitor, troubleshooting cannot be carried out.)
PC600-8
SEN00451-03
40 Troubleshooting
E-11 Fuel level monitor red lamp lights up while engine is running
Failure
information
Fuel level monitor red lamp lighted up while the engine was running.
Relative
information
If the fuel gauge shows in a red range on the machine monitor, the fuel level monitor lamp lights up red.
Cause
Presumed cause and

Fuel level lowered

1 (system in normal
condition)

Check the fuel level in the fuel tank. If it is low, add fuel.
Fuel level sensor fault

P21 (male)
harness
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 110 z
(female) (1)
Resistance
value
Max. 1 z
4
Machine monitor
defective
CM02 (female)
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 110 z
Electrical circuit diagram related to fuel level sensor
PC600-8
17
SEN00451-03
40 Troubleshooting
E-12 Engine coolant temperature gauge does not display correctly

(1) While the engine coolant temperature rises normally,
the temperature gauge does not rise above the white
range (C).
(2) While the engine coolant temperature is stabilized
normally, the temperature gauge rises up to the red
range (H).
Failure
information
Engine coolant temperature gauge does not

display correctly
Relative
information
The signal of the engine coolant high temperature sensor for the coolant temperature gauge is received
from the engine controller through the communication line.
If the engine coolant high temperature sensor system becomes defective, failure code [CA144] may be
displayed.
Input from the engine coolant high temperature sensor (voltage and temperature) can be checked in the
monitoring function. (Code No. 04106: Engine coolant sensor voltage Hi, Code No. 04102: Engine
coolant temperature (High temperature))
Cause
Presumed cause and

Engine coolant high

temperature sensor
defective
1
(Internal disconnection,
short-circuiting or
grounding fault)
harness
harness
3
circuit)

TWTR (male)
Resistance value
Between (A) and (B)
3.5 k 90 kz
Between (A), (B) and grounding
Min. 1 Mz
Wiring harness between ENG (female) (15) and TWTR
(female) (1)
Resistance
value
Max. 1 z
Wiring harness between ENG (female) (38), JM03 and

TWTR (female) (2)
Resistance
value
Max. 1 z
Between wiring harness between ENG (female) (15)
and TWTR (female) (1) and grounding
Resistance
value
Min. 1 Mz
Between
wiring harness between ENG (female) (15)
harness
Voltage
Max. 1 V
and TWTR (female) (1) and grounding
5
18
Engine controller
defective
Machine monitor
defective
ENG (female)
Resistance value
3.5 k 90 kz
Between (15), (38) and grounding
Min. 1 Mz
If causes 1 5 are not detected, the monitor panel may be defective. (Since trouble
is in the monitor panel, troubleshooting cannot be carried out.)
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to engine coolant high temperature sensor
PC600-8
19
SEN00451-03
40 Troubleshooting
E-13 Hydraulic oil temperature gauge does not display correctly

Failure
information
Hydraulic oil temperature rises normally, but the dis Hydraulic oil temperature gauge does not display does not exceed the white range (C).
play correctly
Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Relative
information
Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
(Code No. 04401: Hydraulic oil temperature)
Presumed cause and standard value in normalcy
Cause
sensor defective
P22 (male)
Resistance value
short-circuiting or
Between (1) and (2)
90 3.5 kz
10 100C
grounding fault)
Min. 1 Mz
harness
harness
3
(GND) circuit)
(female) (1)
Resistance
value
Max. 1 z

(female) (2)
Resistance
value
Max. 1 z
Resistance
value
Min. 1 Mz
harness
Voltage
Max. 1 V
5
Machine monitor
defective
CM02 (female)

Between (12) and
grounding
Resistance value
90 3.5 kz
10 100C
Min. 1 Mz
Electrical circuit diagram related to hydraulic oil temperature sensor
20
PC600-8
SEN00451-03
40 Troubleshooting
E-14 Fuel gauge does not display correctly

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

Presumed cause and

Fuel level sensor defective

P21 (male)
1
grounding fault)
harness
harness
3
(GND) circuit)
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 110 z
(female) (1)
Resistance
value
Max. 1 z
Between wiring harness between CM02 (female) (2) and
P21 (female) (1) and grounding
Resistance
value
Min. 1 Mz
Between
wiring harness between CM02 (female) (2) and
harness
Voltage
Max. 1 V
5
Machine monitor
defective
CM02 (female)
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 110 z
Electrical circuit diagram related to fuel level sensor
PC600-8
21
SEN00451-03
40 Troubleshooting
E-15 Swing lock monitor does not display correctly

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

Swing lock switch defective

1
short-circuiting)
harness

harness
3
(GND) circuit)

S04 (female)
Between (1) and (2)
Swing lock switch
Resistance value
OFF
Min. 1 Mz
ON
Max. 1 z
Wiring harness from CM02 (female) (17) to J07 and S04
(male) (1)
Resistance
value
Max. 1 z
Wiring harness from S04 (male) (2) to J03 and grounding
Resistance
value
Max. 1 z
Between wiring harness from CM02 (female) (17) to J07
and S04 (male) (1), or between CM02 (female) (17) to
Resistance
value
Min. 1 Mz

4 with 24 V circuit) in wiring Between wiring harness from CM02 (female) (17) to J07
harness
and S04 (male) (1), or between CM02 (female) (17) to
Voltage
Max. 1 V
5
22
Machine monitor
defective
CM02
Swing lock switch
Voltage
Between (17) and

grounding
OFF
20 30 V
ON
Max. 1 V
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to swing holding brake
PC600-8
23
SEN00451-03
40 Troubleshooting
E-16 When monitor switch is operated, nothing is displayed

Failure
information
When monitor switch is operated, nothing is (1) When mode selector switch is operated, working
displayed.
mode monitor is not displayed.
Relative
information
Presumed
cause and
standard value
in normalcy
Cause
1
Machine monitor
defective

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

Failure
information
When monitor switch is operated, nothing is (3) When maintenance switch is operated, item selecdisplayed.
tion screen is not displayed.
Relative
information
Presumed
cause and
standard value
in normalcy
Cause
1
Machine monitor
defective

Failure
information
When monitor switch is operated, nothing is (4) When auto-deceleration switch is operated, autodisplayed.
matic deceleration monitor is not displayed.
Relative
information
When the automatic decelerator does not operate either, conduct the troubleshooting for "Auto-decelertor does not operate".
Presumed
cause and
standard value
in normalcy
Failure
information
Cause
1
Machine monitor
defective

When monitor switch is operated, nothing is (5) When travel speed selector switch is operated,
displayed.
travel speed monitor is not displayed.
Relative
information
Presumed
cause and
standard value
in normalcy
24
Cause
1
Machine monitor
defective

PC600-8
SEN00451-03
40 Troubleshooting
Failure
information
When monitor switch is operated, nothing is (6) When wiper switch is operated, wiper monitor is not
displayed.
displayed.
Relative
information
When the wiper does not operate either, conduct the troubleshooting for "Windshield wiper and window
washer do not work".
Presumed
cause and
standard value
in normalcy
PC600-8
Cause
1
Machine monitor
defective

25
SEN00451-03
40 Troubleshooting
E-17 Wiper and window washer do not work

Failure
information
Wiper and window washer do not work
Relative
information
Presumed cause and

Cause
Upper wiper motor
1 defective
harness

M05 (female)
Between (3) and (1)
Continued
(male) (3)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
3
Machine monitor
defective
CM01
Note:
26
(1) Upper wiper does not operate
Wiper switch
Voltage
OFF
Max. 3 V
ON
20 30 V (Note)
intervals)
20 30 V (at regular
PC600-8
40 Troubleshooting
PC600-8
SEN00451-03
27
SEN00451-03
40 Troubleshooting

Failure
information
Wiper and window washer do not work
Relative
information
Cause
Lower wiper switch

1 defective

S08 (female)
Between (1) and (2)
Presumed cause and

Lower wiper motor

2 defective
harness
4
Machine monitor defective (Lower wiper motor
system)
28
Lowe wiper switch
Resistance value
OFF
Min. 1 Mz
ON
Max. 1 z
M15 (female)
Between (3) and (1)
Continued
Machine monitor defective (Lower wiper switch

system)
Note:
(2) Lower wiper does not operate.
Wiring harness between CM02 (female) (15) and S08

(male) (1)
Resistance
value
Max. 1 z
Wiring harness between S08 (male) (2), J05 and

grounding
Resistance
value
Max. 1 z
Wiring harness between CM01 (female) (10), J02 and

M15 (male) (3)
Resistance
value
Max. 1 z
Wiring harness between M15 (male) (1), J05 and

grounding
Resistance
value
Max. 1 z
CM02
Lower wiper switch
Voltage
Between (15) and

grounding
OFF
20 30 V
ON
Max. 1 V
CM01
Lower wiper switch
Between (10) and

grounding
OFF
Max. 3 V
ON
20 30 V (Note)
intervals)
Voltage
20 30 V (at regular
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to wiper motor (double wiper specification)
PC600-8
29
SEN00451-03
40 Troubleshooting

Failure
information
Wiper and window washer do not work.
Relative
information
Cause
Window rear limit switch

defective
1
short-circuiting)
Presumed cause and


harness
harness
4
circuit)
Machine monitor
defective
(Window rear limit switch
system)

S12 (female)
Between (1) and (2)
Front window
Resistance value
When installed at front
Min. 1 Mz
When retracted at rear
Max. 1 z
M05 (female)
Between (3) and (1)
Continued
Wiring harness between CM01 (male) (9) and M05
(female) (3)
Resistance
value
Max. 1 z
Wiring harness between CM01 (male) (10) and M05

(female) (1)
Resistance
value
Max. 1 z
and S12 (male) (2)
Resistance
value
Min. 1 Mz
CM02
Front window
Voltage
Between (15) and

grounding
When installed at front
20 30 V
When retracted at rear
Max. 1 V
5
Machine monitor
defective
(Wiper motor system)
30
(3) Wiper does not work.
CM01
Wiper switch
Voltage
Between (9) and grounding,

Between (10) and
grounding
OFF
Max. 3 V
ON
Max. 3 V
20 30 V
(Constant cycle)
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to wiper motor (Single wiper specification)
PC600-8
31
SEN00451-03
40 Troubleshooting
Failure
information
Wiper and window washer do not work.
Relative
information
Cause
Presumed cause and

Washer motor defective

2 (Internal disconnection or
grounding fault)
harness

harness
4
circuit)
(4) Window washer does not operate.

If fuse is broken, the circuit probably has grounding fault, etc. (See cause 4.)
M06 (male)
Resistance value
Between (1) and (2)
5 20 z
Min. 1 Mz
Wiring harness from F01-4 outlet to J02 and M06
(female) (1)
Resistance
value
Max. 1 z
Wiring harness from M06 (female) (2) and CM01

(female) (3)
Resistance
value
Max. 1 z
Between wiring harness from F01-4 outlet to J04 and
M06 (female) (1), or F01-4 outlet to D04 (female) (2),
and to other relative circuits and grounding
Resistance
value
Min. 1 Mz
5
Machine monitor
defective
CM01
32
Washer switch
Voltage
OFF
20 30 V
ON
Max. 1 V
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to window washer motor
PC600-8
33
SEN00451-03
40 Troubleshooting
E-18 "Boom Raise" is not correctly displayed in monitoring function

Failure
information
"Boom Raise" is not correctly displayed in the moni "Boom Raise" is not correctly displayed in monitoring function (special function) on the machine
toring function
monitor.
Relative
information
Cause
Boom Raise PPC pressure switch defective

1
short-circuiting)

P06 (male)
Presumed cause and

Between (2) and (1)
harness
harness
3
circuit)
R.H. work equipment

control lever
Resistance value
NEUTRAL
Min. 1 Mz
Boom RAISE
Max. 1 z
(female) (2)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Resistance
value
Min. 1 Mz
harness
Voltage
Max. 1 V
a Turn the engine starting switch OFF for the preparations, and start the engine
CP03
Between (10) and
grounding
R.H. work equipment

control lever
Voltage
NEUTRAL
20 30 V
Boom RAISE
Max. 1 V
Electrical circuit diagram related to boom Raise PPC pressure switch
34
PC600-8
40 Troubleshooting
PC600-8
SEN00451-03
35
SEN00451-03
40 Troubleshooting
E-19 "Boom Lower" is not correctly displayed in monitoring function

Failure
information
"Boom Lower" is not correctly displayed in the moni "Boom Lower" is not correctly displayed in monitoring function (special function) on the machine
toring function
monitor.
Relative
information
Cause
Boom Lower PPC pressure switch defective

1
short-circuiting)

P02 (male)
Presumed cause and

Between (2) and (1)
harness
harness
3
circuit)
R.H. work equipment

control lever
Resistance value
NEUTRAL
Min. 1 Mz
Boom LOWER
Max. 1 z
(female) (2)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Resistance
value
Min. 1 Mz
harness
Voltage
Max. 1 V
CP03
Between (20) and
grounding
36
R.H. work equipment

control lever
Voltage
NEUTRAL
20 30 V
Boom LOWER
Max. 1 V
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to boom Lower PPC pressure switch
PC600-8
37
SEN00451-03
40 Troubleshooting
E-20 "Arm IN" is not correctly displayed in monitoring function

Failure
information
"Arm IN" is not correctly displayed in monitoring

function
Relative
information
Cause
Arm IN PPC pressure

switch defective
1
short-circuiting)

P04 (male)
Presumed cause and

Between (2) and (1)
harness
harness
3
circuit)
"Arm IN" is not correctly displayed in the monitoring

function (special function) on the machine monitor.
L.H. work equipment

control lever
Resistance value
NEUTRAL
Min. 1 Mz
Arm IN
Max. 1 z
(female) (2)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Resistance
value
Min. 1 Mz
Between
wiring harness between CP03 (female) (30)
harness
Voltage
Max. 1 V
CP03
L.H. work equipment

control lever
Voltage
NEUTRAL
20 30 V
Arm IN
Max. 1 V
Electrical circuit diagram related to arm IN PPC pressure switch
38
PC600-8
SEN00451-03
40 Troubleshooting
E-21 "Arm OUT" is not correctly displayed in monitoring function

Failure
information
"Arm OUT" is not correctly displayed in monitor- "Arm OUT" is not correctly displayed in the monitoring
ing function
Relative
information
Cause
Arm OUT PPC pressure

switch defective
1
(Internal disconnection
and short-circuiting)

P08 (male)
Presumed cause and

Between (2) and (1)
harness
harness
3
circuit)
L.H. work equipment

control lever
Resistance value
NEUTRAL
Min. 1 Mz
Arm OUT
Max. 1 z
(female) (2)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Resistance
value
Min. 1 Mz
Between
wiring harness between CP03 (female) (40)
harness
Voltage
Max. 1 V
CP03
Between (40) and
grounding
L.H. work equipment

control lever
Voltage
NEUTRAL
20 30 V
Arm OUT
Max. 1 V
Electrical circuit diagram related to arm OUT PPC pressure switch
PC600-8
39
SEN00451-03
40 Troubleshooting
E-22 "Bucket CURL" is not correctly displayed in monitoring function

Failure
information
"Bucket CURL" is not correctly displayed in

monitoring function
Relative
information
Cause
Bucket CURL PPC pressure switch defective

1

P01 (male)
Presumed cause and

Between (2) and (1)
harness
harness
3
circuit)
"Bucket CURL" is not correctly displayed in the monitoring function (special function) on the machine
monitor.
R.H. work equipment

control lever
Resistance value
NEUTRAL
Min. 1 Mz
Bucket CURL
Max. 1 z
(female) (2)
Resistance
value
Max. 1 z
Wiring harness between P01 (female) (1) to J12 and

grounding
Resistance
value
Max. 1 z
Resistance
value
Min. 1 Mz
harness
Voltage
Max. 1 V
CP03
R.H. work equipment

control lever
Voltage
NEUTRAL
20 30 V
Bucket CURL
Max. 1 V
Electrical circuit diagram related to bucket CURL PPC pressure switch
40
PC600-8
SEN00451-03
40 Troubleshooting
E-23 "Bucket DUMP" is not correctly displayed in monitoring function

Failure
information
"Bucket DUMP" is not correctly displayed in the mon"Bucket DUMP" is not correctly displayed in moniitoring function (special function) on the machine
toring function
monitor.
Relative
information
Cause
Bucket DUMP PPC pressure switch defective

1

P05 (male)
Presumed cause and

Between (2) and (1)
harness
harness
3
circuit)
R.H. work equipment

control lever
Resistance value
NEUTRAL
Min. 1 Mz
Bucket DUMP
Max. 1 z
(female) (2)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Resistance
value
Min. 1 Mz
harness
Voltage
Max. 1 V
CP03
Between (19) and
grounding
R.H. work equipment

control lever
Voltage
NEUTRAL
20 30 V
Bucket DUMP
Max. 1 V
Electrical circuit diagram related to bucket DUMP PPC pressure switch
PC600-8
41
SEN00451-03
40 Troubleshooting
E-24 "Swing" is not correctly displayed in monitoring function

Failure
information
"Swing" is not correctly displayed in monitoring

function
Relative
information
Cause
Swing PPC pressure

switch defective
1
short-circuiting)

P03 (male)
Presumed cause and

Between (2) and (1)
harness
harness
3
(GND) circuit)
"Swing" is not correctly displayed in the monitoring

R.H. work equipment

control lever
Resistance value
NEUTRAL
Min. 1 Mz
Swing operated
Max. 1 z
(female) (2)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Resistance
value
Min. 1 Mz
Wiring
harness between CP03 (female) (29) and P03
harness
Voltage
Max. 1 V
CP03
Between (29) and
grounding
42
R.H. work equipment

control lever
Voltage
NEUTRAL
20 30 V
Swing operated
Max. 1 V
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to swing PPC pressure switch
PC600-8
43
SEN00451-03
40 Troubleshooting
E-25 "Travel" is not correctly displayed in monitoring function

Failure
information
"Travel" is not correctly displayed in the monitor- "Travel" is not correctly displayed in the monitoring
ing function.
function (special function) of the machine monitor.
Relative
information
Cause
Presumed cause and

Travel PPC pressure

switch defective
1
short-circuiting)
harness
harness
3
circuit)

P09 (male)
Between (2) and (1)
Travel lever
Resistance value
Neutral
Min. 1 Mz
Operated
Max. 1 z
(female) (2)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Resistance
value
Min. 1 Mz
harness
Voltage
Max. 1 V
44
CP03
Travel lever
Voltage
Between (39) and

grounding
Neutral
20 30 V
Operated
Max. 1 V
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to travel PPC pressure switch
PC600-8
45
SEN00451-03
40 Troubleshooting
E-26 Air conditioner does not work

Failure
information
Air conditioner does not work.
Relative
information
Cause
Presumed cause and


harness
harness
3
(GND) circuit)

When fuse is blown, there is a big possibility that grounding fault occurred in the circuit. (See Cause 3.)
Wiring harness between F01-11 outlet and M26 (male)
(5)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Between wiring harness between F01-11 outlet and M26
Voltage
Min. 1 Mz
4

defective
M26
Voltage
Between (5) and (8)
20 30 V
If the above voltages are normal and the air conditioner does not operate, the air conditioner unit is defective.
Electrical circuit diagram related to air conditioner
46
PC600-8
40 Troubleshooting
PC600-8
SEN00451-03
47
SEN00451-03
40 Troubleshooting
E-27 Step light does not light up or go off

Failure
information
Relative
information
Cause
1 Defective fuse No. 20
If fuse is broken, circuit probably has ground fault (See cause 6).
2 Defective step light
Step light may be defective. Check bulb directly for breakage.
Defective step light

3 switch (Internal disconnection)
starting switch ON.
S13 (male)
Between (1) (2)
Presumed cause and

Defective step light relay

4
(Internal defect)
Step light switch
Resistance
Released
Min. 1 Mz
Pressed
Max. 1 z
starting switch ON.
When step light relay is replaced with another relay, if condition
becomes normal, step light relay is defective.
R09
starting switch ON.
5
48
(1) When switch is pressed, light does not light up for

1 minute.
Wiring harness between F01-20 outlet J06 (female)

(19)
Resistance
Max. 1 z
Wiring harness between J06 (female) (20) S13

(female) (2)
Resistance
Max. 1 z
Wiring harness between J06 (female) (17), (18) R09

(female) (1), (3)
Resistance
Max. 1 z
Wiring harness between S13 (female) (1) J06 (female)

(3)
Resistance
Max. 1 z
Wiring harness between J06 (female) (2) CP01

(female) (24)
Resistance
Max. 1 z
Wiring harness between J06 (female) (1) D03 J07

(female) (11), (12) CP03 (female) (14), (24)
Resistance
Max. 1 z
Wiring harness between R09 (female) (2) CP02

(female) (19)
Resistance
Max. 1 z
Wiring harness between R09 (female) (5) L06

(female) (1)
Resistance
Max. 1 z
Wiring harness between L06 (female) (2) chassis

ground
Resistance
Max. 1 z
PC600-8
SEN00451-03
40 Troubleshooting
Cause
Presumed cause and

starting switch ON.

GND circuit)
Defective pump controller

(Step light switch input
system)
7
(Step light relay output
system)
PC600-8
Wiring harness between F01-20 outlet J06 S13

(female) (2), or R09 (female) (2), (3) chassis ground
Resistance
Min. 1 Mz
Wiring harness between S13 (female) (1) J06 CP01

(female) (24), or D03 J07 CP03 (female) (14), (24)
chassis ground
Resistance
Min. 1 Mz
Wiring harness between R09 (female) (5) H02 L06

Resistance
Min. 1 Mz
Wiring harness between R09 (female) (2) CP02

Resistance
Min. 1 Mz
starting switch ON.
CP01
Step light switch
Voltage
Between (24)
chassis ground
Released
Max. 1 V
Pressed
20 30 V
starting switch ON.
CP02
Step light switch
Voltage
Between (19)
chassis ground
Released
Max. 1 V
Pressed
20 30 V (60 seconds)
49
SEN00451-03
40 Troubleshooting
Failure
information
Relative
information
Cause
(2) While switch is not pressed, light lights up.

starting switch ON.
Defective step light

(Internal short circuit)
S13 (male)
Between (1) (2)
Presumed cause and

Defective step light relay

2
(Internal defect)
Resistance
Released
Min. 1 Mz
Pressed
Max. 1 z
starting switch ON.
When step light relay is replaced with another relay, if condition
becomes normal, step light relay is defective.
R09
troubleshooting.
Wiring harness between S13 (female) (1) J06 CP01
3 with 24 V circuit) in wiring (female) (24), or D03 J07 CP03 (female) (14), (24)
harness
chassis ground
Wiring harness between CP02 (female) (19) R09

(Step light switch input
system)
4
(Step light relay output
system)
50
Step light switch
Voltage
Max. 1 V
Voltage
Max. 1 V
starting switch ON.
CP01
Step light switch
Voltage
Between (24) chassis

ground
Released
Max. 1 V
Pressed
20 30 V
starting switch ON.
CP02
Step light switch
Voltage
Between (19) chassis

ground
Released
Max. 1 V
Pressed
20 30 V (60 seconds)
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to step light
PC600-8
51
SEN00451-03
40 Troubleshooting
E-28 Electric grease gun does not operate

Failure
information
Electric grease gun does not operate.
Relative
information
Cause
Presumed cause and

Circuit breaker No. 3

defective
harness
harness
3
circuit)
4 Grease pump defective

If the circuit breaker is turned OFF, there is a big possibility that grounding fault
occurred in the circuit (See cause 3).
Wiring harness between B01 (female) (F) and M16
(male) (1)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Wiring harness between B01 (female) (F) and M16
Resistance
value
Min. 1 Mz
If causes 1 3 are not detected, the grease pump may be defective. (Since trouble
is in the grease pump, troubleshooting cannot be carried out.)
Electrical circuit diagram related to electric grease gun
52
PC600-8
40 Troubleshooting
PC600-8
SEN00451-03
53
SEN00451-03
40 Troubleshooting
E-29 Travel alarm does not sound or does not stop sounding
Failure
information
Travel alarm does not sound or does not stop

sounding.
Relative
information
Cause
(1) The alarm does not sound while the machine is traveling.
(2) The alarm sounds while the machine is stopped.

1 Travel signal defective
Monitoring code
Item
Normal display
01900
Pressure switch 1
Travel
Lever operated: ON
If the display on the monitor panel is abnormal, carry out troubleshooting in "
not displayed normally in monitoring function".
is
Presumed cause and
M14 (female)
Travel alarm defective
2
(Internal defective)
Between (1) and (2)
Travel lever
Voltage
Neutral
Max. 1 V
Operated
20 30 V
If the above voltages are normal and the travel alarm does not sound, the travel
alarm is defective.
harness
Wiring harness between CP03 (female) (8) and M14
(female) (1)
Resistance
value
Max. 1 z
Wiring harness between M14 (female) (2) and grounding
Resistance
value
Max. 1 z
harness
Voltage
Max. 1 V
M14 (female) (1) and grounding
CP03
54
Travel lever
Voltage
Neutral
Max. 1 V
Operated
20 30 V
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to travel alarm
PC600-8
55
SEN00451-03
40 Troubleshooting
E-30 Horn does not sound

Failure
information
Horn does not sound.
Relative
information
Cause
1 Defective fuse No. 5
If fuse is broken, circuit probably has ground fault. (See Cause 6)
2 Defective horn relay
If the horn sounds after replacing the relay, the relay was defective.
troubleshooting.
Between M07 (1) chassis ground (with horn switch
turned ON)
3 Defective high tone horn
Voltage
20 30 V
starting switch ON.
Between M07 (female) (2) chassis ground
Resistance
value
Max. 1 z
If above is normal, the horn is defective.
Presumed cause and

troubleshooting.
Between M08 (1) chassis ground (with horn switch
turned ON)
4 Defective low tone horn
Voltage
20 30 V
starting switch ON.
Between M08 (female) (2) chassis ground
Resistance
value
Max. 1 z
If above is normal, the horn is defective.

starting switch ON.
harness
5 (Disconnection in wiring
or defective contact in
connector)
Wiring harness between F01 (5) S10 (female) R08

(female) (3)
Resistance
value
Max. 1 z
Wiring harness between S10 (2) R08 M07 (female)

(1)
Resistance
value
Max. 1 z
Wiring harness between R08 (female) (4) M08

(female) (1)
Resistance
value
Max. 1 z
starting switch ON.
harness
6
(Short circuit with GND
circuit)
56
Wiring harness between F01 (5) S10 (female) R08

Resistance
value
Min. 1 Mz
Wiring harness between S10 (female) (2) R08

(female) M07 (female) (1) and chassis ground
Resistance
value
Min. 1 Mz
Wiring harness between R08 (female) (4) M08

Resistance
value
Min. 1 Mz
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to horn
PC600-8
57
SEN00451-03
40 Troubleshooting
E-31 Bottom dump does not move

Failure
information
Bottom dump does not move.
Relative
information
Cause
Defective fuse
1
No. 5, No. 9
2
Presumed cause and

Defective bottom dump

open
close

If fuse is broken, circuit probably has ground fault. (See Cause 6)
troubleshooting.
Between S10 (1) (2)
Voltage
20 30 V
troubleshooting.
Between S11 (1) (3)
Voltage
20 30 V
troubleshooting.
4

close solenoid valve
Between V20 (1) (2)
Voltage
20 30 V
troubleshooting.
Between V20 (1) chassis ground
Resistance
value
Min. 1 Mz
troubleshooting.
5

open solenoid valve
Between V21 (1) (2)
Voltage
20 30 V
troubleshooting.
Between V21 (2) chassis ground
Resistance
value
Min. 1 Mz
troubleshooting.
6 Defective wiring harness
Failure
information
Between S10 (2) A11 V21 (1)
Resistance
value
Max. 1 z
Between S11 (3) A11 V20 (1)
Resistance
value
Max. 1 z
Bottom dump does not move.
Presumed cause and

Relative
information
Cause

troubleshooting.

1
pressure switch
Between P13 (2) A09 CP02 (35)
Resistance
value
Max. 1 z
troubleshooting.
Between P13 (2) chassis ground
Resistance
value
Min. 1 Mz
a Solenoid valve and bottom dump pressure switch are connected by hydraulic line.
58
PC600-8
40 Troubleshooting
SEN00451-03
Electrical circuit diagram related to bottom dump
PC600-8
59
SEN00451-03
40 Troubleshooting

2009 KOMATSU
All Rights Reserved
60
SEN00452-02
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up
40 Troubleshooting
Troubleshooting of hydraulic and
mechanical system (H-mode)
Before troubleshooting H-mode ........................................................................................................................... 3
Information in troubleshooting table ..................................................................................................................... 8
H-1 Speed or power of all work equipment, travel, and swing is low ................................................................. 10
H-2 Engine speed lowers remarkably or engine stalls ....................................................................................... 12
H-3 All work equipment, travel, and swing systems do not work ....................................................................... 14
H-4 Abnormal sound is heard from around pump .............................................................................................. 16
H-5 Auto-decelerator is not reset ....................................................................................................................... 17
H-6 Boom speed or power is low ....................................................................................................................... 18
H-7 Arm speed or power is low .......................................................................................................................... 20
H-8 Bucket speed or power is low ..................................................................................................................... 21
H-9 Boom does not move .................................................................................................................................. 22
H-10 Arm does not move ................................................................................................................................... 22
H-11 Bucket does not move ............................................................................................................................... 23
H-12 Bottom dump does not move .................................................................................................................... 23
H-13 Hydraulic drift of work equipment is large ................................................................................................. 24
H-14 Time lag of work equipment is large.......................................................................................................... 25
H-15 Power max. function does not operate or stop.......................................................................................... 26
H-16 Machine push-up function does not operate or stop ................................................................................. 26
H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is low.......................... 27
PC600-8
SEN00452-02
40 Troubleshooting
H-18 When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel speed
is low............................................................................................................................................................. 27
H-19 When arm and swing are operated simultaneously, swing speed is low................................................... 28
H-20 Machine deviates in one direction ............................................................................................................. 29
H-21 Machine deviates largely at start............................................................................................................... 31
H-22 Travel deviation is large during compound operation................................................................................ 32
H-23 Travel speed or power is low..................................................................................................................... 33
H-24 Machine does not travel (only one track) .................................................................................................. 34
H-25 Travel speed does not change .................................................................................................................. 35
H-26 Upper structure does not swing................................................................................................................. 36
H-27 Swing speed or acceleration is low ........................................................................................................... 37
H-28 Upper structure overruns excessively when it stops swinging .................................................................. 38
H-29 Large shock is made when upper structure stops swinging ...................................................................... 39
H-30 Large abnormal sound is made when upper structure stops swinging ..................................................... 40
H-31 Hydraulic drift of swing is large.................................................................................................................. 41
PC600-8
40 Troubleshooting
SEN00452-02
Before troubleshooting H-mode
PC600-8
SEN00452-02
1. Combination and operation of hydraulic
pumps
For the work equipment, travel, and swing
circuits, 2 tandem pumps (4 pump units) of
the No. 1 pump (HPV95+95) and the No. 2
pump (HPV95+95) are used.
The oil from the No. 1 front pump and that
from the No. 2 front pump merge together
and flow in the right side 5-spool valve. The
oil from the No. 1 rear pump and that from
the No. 2 rear pump merge together and flow
in the left side 4-spool valve.
The TVC valve installed on the No. 1 rear
pump carries out the TVC control of the No.
1 pump and No. 2 pump similarly.
The CO, NC valve installed on the No. 1 front
pump and the jet sensor installed to the right
side 5-spool valve carry out the CO, NC control of the No. 1 front pump and No. 2 front
pump similarly.
The CO, NC valve installed on the No. 1 rear
pump and the jet sensor installed to the left
side 4-spool valve carry out the CO, NC control of the No. 1 rear pump and No. 2 rear
pump similarly.
40 Troubleshooting
2. Finding cause of trouble that "work equipment speed is low and machine deviates to
right"
The possible causes of this trouble are as
follows:
1) The main relief valve of the right side 5spool valve is defective.
2) The jet sensor of the right side 5-spool
valve is defective.
3) The CO, NC valve of the No. 1 front
pump is defective.
4) The servo valve of the No. 1 front pump
is defective.
5) The No. 1 front pump is defective.
6) The servo valve of the No. 2 front pump
is defective.
7) The No. 2 front pump is defective.
Whether the main relief valve, jet sensor,
and CO, NC valve are good or not can be
judged by measuring the relief pressure, differential pressure, and output pressure respectively.
Since the oil from the No. 1 front pump and
that from the No. 2 front pump merge together as explained in 1 above, exchange the
outlet hoses of the No. 2 front and rear
pumps and check the phenomenon of the
machine to find out a defective system in the
servo valves and pump units of the No. 1 and
No. 2 front pumps.
1) If the machine still deviates to the right
(If deviation does not change), the No. 1
front pump system is defective.
2) If the machine deviates to the left (If
deviation changes), the No. 2 front
pump system is defective.
3) If the travel speed lowers, the jet sensor
or the CO, NC valve is defective (when
the right and left relief pressures are
normal).
To judge the condition of the servo valve and
pump unit, remove the servo valve and test it
or measure the stroke of the servo piston.
a Actually, judge the condition according "4.
Judgment matrix for trouble that work equipment speed is low and machine deviates".
PC600-8
40 Troubleshooting
3. Finding cause of trouble that "work equipment speed is low and machine deviates to
left"
The possible causes of this trouble are as
follows:
1) The main relief valve of the left side 4spool valve is defective.
2) The jet sensor of the left side 4-spool
valve is defective.
3) The CO, NC valve of the No. 1 rear
pump is defective.
4) The servo valve of the No. 1 rear pump
is defective.
5) The No. 1 rear pump is defective.
6) The servo valve of the No. 2 rear pump
is defective.
7) The No. 2 rear pump is defective.
Whether the main relief valve, jet sensor,
and CO, NC valve are good or not can be
judged by measuring the relief pressure, differential pressure, and output pressure respectively.
Since the oil from the No. 1 rear pump and
that from the No. 2 rear pump merge together as explained in 1 above, exchange the
outlet hoses of the No. 2 front and rear
pumps and check the phenomenon of the
machine to find out a defective system in the
servo valves and pump units of the No. 1 and
No. 2 rear pumps.
1) If the machine still deviates to the left (If
deviation does not change), the No. 1
rear pump system is defective.
2) If the machine deviates to the right (If
deviation changes), the No. 2 rear pump
system is defective.
3) If the travel speed lowers, the jet sensor
or the CO, NC valve is defective (when
the right and left relief pressures are
normal).
To judge the condition of the servo valve and
pump unit, remove the servo valve and test it
or measure the stroke of the servo piston.
a Actually, judge the condition according "4.
Judgment matrix for trouble that work equipment speed is low and machine deviates".
PC600-8
SEN00452-02
4. Judgment matrix for trouble that work equipment speed is low and machine deviates (on
the next page)
a Carry out diagnosis in order from the top line
and judge the factor having the most black
points (q) to be the cause of the trouble.
1) To judge the servo valve, remove it and test
it or measure the stroke of the servo piston.
a Perform the test on the servo piston unit
in the specified maintenance shop.
2) If the speed lowers extremely and the pump
seems to be abnormal, check the line filter
too.
3) If the speed lowers little but cannot be set to
the normal level by adjusting each device,
check the line filter too.
4) To check the operation of the servo piston,
remove the caps from both sides of it and
move the servo piston with the hand.
SEN00452-02
40 Troubleshooting
Causes
Front
pump
Rear
pump
CONC valve defective
Servo valve defective
Pump unit defective
Pump unit defective
Pump unit defective
Main relief valve defective
Jet sensor defective
Main relief valve defective
Jet sensor defective
L.H. travel motor
R.H. travel motor
Diagnosis
Rear pump
Pump unit defective
Remedy
No.
Front pump
Remedy A: Adjust
Remedy X: Repair or replace
Left
Right
4-spool 5-spool
valve
valve
No. 2 pump
CONC valve defective
No. 1 pump
A
X
A
X
A
X
A
X
A
X
A
X
Machine "deviates to right" and work equipment speed

and swing speed are low.
q q q
q q
q q
Machine "deviates to right" and single swing speed is

particularly low.
q q q
q q
Machine "deviates to right" and single swing speed is

normal.
Travel relief pressure of front pump circuit is low.
5
6
7
8
Machine "deviates to right"
q
q
q q

(Deviation does not change).
When result of 4 is normal, exchange front and Machine "deviates to left"

rear outlet hoses of No. 2 (Deviation changes).
pump.
Speed of both travel motors
is low.
q
q q
q
q
When phenomenon of 5 occurs, servo valve of No. 1

front pump is normal.

front pump is normal.
10
When phenomenon of 7 occurs, jet sensor differential

pressure of right side 5-spool valve is abnormal.
11
When result of 10 is normal, No. 1 front NC valve output

pressure is abnormal.
12
Machine "deviates to left" and work equipment speed is

low.
q q q
q q q q
13
Machine "deviates to left" and bucket dump speed is

particularly low.
q q q
q q
14
Machine "deviates to left" and bucket dump speed is

normal.
15
Travel relief pressure of rear pump circuit is low.
16
17
18
19
Machine "deviates to left"
When result of 15 is normal, exchange front and

rear outlet hoses of No. 2
pump.
q
q q
q
q

rear pump is normal.
rear pump is normal.
21
When phenomenon of 18 occurs, jet sensor differential

pressure of left side 4-spool valve is abnormal.
22
When result of 18 is normal, No. 1 front NC valve output

pressure is abnormal.
q
q q

(Deviation changes).
Speed of both travel motors
is low.
q
q
Machine "deviates to left"

(Deviation does not change).
20
q
q
q
PC600-8
40 Troubleshooting
SEN00452-02
How to exchange outlet hoses of No. 2 pump and hydraulic circuit diagram after they are exchanged
PC600-8
SEN00452-02
40 Troubleshooting
Information in troubleshooting table

a Tables and related circuit diagrams concerning troubleshooting contains the following information. Please
understand the contents sufficiently before carrying out troubleshooting.
Failure
Phenomenon
Phenomena on machine
Related
Information
Information concerning to failure or troubleshooting.

Cause
Presumed cause and

Causes for presumed

failure
(The attached No. for filing and reference purpose only. It does not
stand for any priority)
<Contents>
Standard values for judgement of possible causes.
Remarks for judgement
PC600-8
40 Troubleshooting
PC600-8
SEN00452-02
SEN00452-02
40 Troubleshooting
H-1 Speed or power of all work equipment, travel, and swing is low
Failure
information
Speed or power of all work equipment, travel, and swing is low
Relative
information
Measure the speed of the work equipment, travel, and swing speed and check that all of them are slow
(or their power is low).
Check that abnormal sound is not heard from around the pump.
(If abnormal sound is heard, carry out the related troubleshooting.)
Check that the machine does not deviate.
(If the machine deviates, carry out the related troubleshooting.)
Carry out all the troubleshooting in working mode P.
Cause

a Run the engine at high idle during troubleshooting.
1 Engine unit defective
PTO defective internally

2 (Control pump drive
system)
Presumed cause and

Control pump defective

internally
Power max. switch and right work

equipment control lever
Engine speed
Power max. switch OFF +

Boom RAISE relief
Above 1,780 rpm
Power max. switch ON + Boom RAISE relief
Above 1,730 rpm
a Keep the engine stopped for the preparations and troubleshooting.

Disconnect the control pump outlet hose and rotate the crankshaft. If oil flows out of
the pump outlet, PTO is normal.
Control pump may be defective internally. Check inside of pilot filter for metal dust,
etc.
a Keep the engine stopped for the preparations, and run it at high idle during
troubleshooting.
Control levers
Wrong adjustment or
4 malfunction of control
relief valve
Control relief pressure

+0.39
MPa
0
+4
{32 0 kg/cm2}
3.14
If the oil pressure is still abnormal after adjustment, check cause 5. If cause 5 is not
detected, the control relief valve operation may be defective. Check the control relief
valve directly.
a Stop the engine and block (1) (7) in Fig. 1 in order. Run the engine at high idle
and check.
5
Leakage in control
system devices
Control levers

+0.39
MPa
0
+4
{32 0 kg/cm2}
3.14
troubleshooting.
Wrong adjustment or
6 malfunction of main relief
valve
Right work equipment control lever
Main relief pressure
Boom RAISE relief

(Normal)
31.87 0.98 MPa
+1.47
+15
{325 10 kg/cm2}
If the oil pressure is still abnormal after adjustment, the main relief valve (on the lowpressure set side and high-pressure set side) may be defective. Check the main
relief valve directly.
10
PC600-8
SEN00452-02
40 Troubleshooting
Cause
Presumed cause and

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

{Min. 18 kg/cm2}
+0.20
Boom RAISE relief
1.05 0.53 MPa

+2.0
{10.7 5.4 kg/cm2}

If the oil pressure is still abnormal after adjustment, the TVC valve may be defective.
Check the TVC valve directly.
troubleshooting.
8
Malfunction of CO
cancel solenoid valve
Swing lock switch
Solenoid valve outlet pressure
ON
Min. 2.74 MPa

{Min. 28 kg/cm2}
OFF
0 MPa {0 kg/cm2}
Fig. 1: Control system devices
PC600-8
11
SEN00452-02
40 Troubleshooting
H-2 Engine speed lowers remarkably or engine stalls

Failure
Phenomenon
Engine speed lowers remarkably or engine stalls
Related
Information

Cause
Presumed cause and

a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
Defective adjustment or
1
malfunction of TVC valve
R.H. work equipment control lever
TVC valve output pressure
All control levers in neutral
Min. 1.76 MPa

{Min. 18 kg/cm2}
Boom relieved in RAISE position
1.05 0.53 MPa
+0.20
+2.0
{10.7 5.4
kg/cm2}
If the oil pressure cannot be set normally by adjustment, the TVC valve may have a
malfunction. Check the TVC valve directly.
high idle. (Check cause 1 and confirm that the result is normal before
troubleshooting.)
2 malfunction of CO, NC
valve
CO, NC valve output pressure
Boom relieved in RAISE position
1.05 0.53 MPa
+0.20
+2.0
{10.7 5.4 kg/cm2}

If the oil pressure cannot be set normally by adjustment, the CO, NC valve may have
a malfunction. Check the CO, NC valve directly.
3 Defective engine
12
If the results of check of causes 1 and 2 are normal, the engine may be defective.
Check the engine
PC600-8
40 Troubleshooting
PC600-8
SEN00452-02
13
SEN00452-02
40 Troubleshooting
H-3 All work equipment, travel, and swing systems do not work
Failure
information
All work equipment, travel, and swing systems do not work
Relative
information

Cause

1 (Main pump drive
system)
2 (Control pump drive
system)
Presumed cause and

Control pump defective

internally

Disconnect the main pump oil pressure pickup coupler and rotate the crankshaft. If
oil flows out of the pump outlet, PTO is normal.
Disconnect the control pump outlet hose and rotate the crankshaft. If oil flows out of
the pump outlet, PTO is normal.
Control pump may be defective internally. Check inside of pilot filter for metal dust,
etc.
troubleshooting.
Control levers
Wrong adjustment or
4 malfunction of control
relief valve

+0.39
MPa
0
+4
{32 0 kg/cm2}
3.14
If the oil pressure is still abnormal after adjustment, check cause 5. If cause 5 is not
detected, the control relief valve operation may be defective. Check the control relief
valve directly.
a Stop the engine and block (1) (9) in Fig. 1 in order. Run the engine at high idle
and check.
5
Leakage in control
system devices
Control levers

+0.39
MPa
0
+4
{32 0 kg/cm2}
3.14
troubleshooting.
6
14
Malfunction of PPC lock

solenoid valve
Work equipment lock lever
FREE
Min. 2.74 MPa

{28 kg/cm2}
LOCK
0 MPa {0 kg/cm2}
PC600-8
40 Troubleshooting
SEN00452-02
Fig. 1: Control system devices
PC600-8
15
SEN00452-02
40 Troubleshooting
H-4 Abnormal sound is heard from around pump

Abnormal sound is heard from around pump
Related
Information
Presumed cause and standard

value in normalcy
Failure
Phenomenon
16
Cause
1 Low hydraulic oil level
Since the hydraulic oil level may be low, check it directly.
2 Loosened piping clamp
Since a piping clamp between the hydraulic tank and hydraulic pump may be loosened, check it directly.
Clogged hydraulic tank

strainer
Internal defect of hydrauSince the hydraulic pump may have a defect in it, check it directly.
lic pump
5 Observation of condition
Since the hydraulic tank strainer may be clogged, check it directly.
If a cause cannot be found by troubleshooting, operate the machine as it is for a

while and observe the condition for change.
PC600-8
SEN00452-02
40 Troubleshooting
H-5 Auto-decelerator is not reset

Auto-decelerator is not reset
Relative
information
The signal pressure of the swing PPC circuit is input through the armswing PPC shuttle valve (swing
side) to the swing PPC pressure switch.
Carry out all troubleshooting in working mode P.
Presumed cause and

Failure
information
Cause
(1) When machine swings, auto-decelerator is not reset.

a Stop the engine for the preparations, and keep it running at high idle during the
troubleshooting.
Malfunction of arm, swing

1 PPC shuttle valve
(swing side)
L.H. work equipment control lever
Shuttle valve outlet pressure
Neutral
0 MPa
{0 kg/cm2}
Swing left right stroke end
Min. 2.74 MPa

{Min. 28 kg/cm2}
Auto-decelerator is not reset
Relative
information
The signal pressure of the travel PPC circuit is input through the travel PPC shuttle valve (in the travel
PPC valve) to the travel PPC pressure switch.
Presumed cause and

Failure
information
Cause
(2) When machine travels, auto-decelerator is not reset.

a Stop the engine for the preparations (measure at the travel PPC pressure switch),
and keep it running at high idle during the troubleshooting.
Malfunction of travel PPC

1 valve
(internal shuttle valve)
PC600-8
Travel lever
PPC valve output pressure
0 MPa
{0 kg/cm2}
R.H. and L.H. forward-reverse stroke end
Min. 2.74 MPa

{Min. 28 kg/cm2}
17
SEN00452-02
40 Troubleshooting
H-6 Boom speed or power is low

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

troubleshooting.
Presumed cause and

Boom RAISE, LOWER full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
Malfunction of boom
control valve (spool)
Malfunction of boom con- The main unit of the boom control valve (Lo, Hi) may be malfunctioning. Check it
trol valve (main unit)
directly.
The spool of the boom control valve (Lo, Hi) may be malfunctioning. Check it directly.
The safety & suction valve of the boom lock valve may be malfunctioning. Check it
Malfunction of boom lock
directly. (The safety & suction valve may be checked by exchanging it with a valve of
4 valve
another work equipment circuit. After finishing check, however, be sure to return the
(safety & suction valve)
safety-suction valve since its set pressure and structure are different from others.)
Malfunction of boom
5 regeneration valve
18
Malfunction of right PPC

valve (boom circuit)
Defective seal of boom

cylinder
The safety & suction valve of the boom regeneration valve may be malfunctioning.
Check it directly. (When checking the safety & suction valve by exchanging it with a
valve of another work equipment circuit, stop the hose of the machine push-up solenoid securely. After finishing check, be sure to return the safety & suction valve since
its set pressure and structure are different from others.)
troubleshooting.
Leakage from cylinder
Boom RAISE relief
Max. 20 cc/min
PC600-8
SEN00452-02
40 Troubleshooting
Failure
information
Relative
information
Check that the other work equipment, travel, and swing are normal. (If any of them is abnormal, carry
out troubleshooting related to it.)
Check that the machine does not deviate. (If it deviates, carry out troubleshooting related to deviation.)
Cause
(2) Boom raise speed or power is low in L-mode.

troubleshooting.
Presumed cause and

Malfunction of CO
Neutral
0 MPa {0 kg/cm2}
Single boom RAISE operation
Min. 2.74 MPa

{Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idling during
troubleshooting.
2
Malfunction of 2-stage
relief solenoid valve
Neutral
0 MPa {0 kg/cm2}
Min. 2.74 MPa

{Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idling during
troubleshooting.
Wrong adjustment or
valve
Main relief pressure

+1.5
37.2 2.0 MPa

+15
{380 20 kg/cm2}
If the main relief valve is still abnormal after adjustment, its operation (on the high
pressure set side) may be defective. Check it directly.
Failure
information
Relative
information
The machine push-up mode is the state that the machine push-up switch is turned ON.
Check that the other work equipment, travel, and swing are normal. (If any of them is abnormal, carry
out troubleshooting related to it.)
Check that the machine does not deviate. (If it deviates, carry out troubleshooting related to deviation.)
Presumed cause and

Cause
(3) Boom lower speed or power is low in the machine

push-up mode.

troubleshooting.
Malfunction of machine
push-up solenoid valve
Malfunction of boom
2 regeneration valve
PC600-8
OFF
Min. 2.74 MPa

{Min. 28 kg/cm2}
ON
0 MPa {0 kg/cm2}
The safety & suction valve of the boom regeneration valve (on the high pressure set
side) may malfunction. Check it directly.
19
SEN00452-02
40 Troubleshooting
H-7 Arm speed or power is low

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

high idle.
Presumed cause and

Malfunction of arm
Malfunction of arm
3 control valve
4
20
Malfunction of left PPC

valve (arm circuit)
Defective arm control

valve (body)
Defective seal of arm
cylinder
Arm IN, OUT

full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it
directly.
The safety-suction valve of the arm control valve (Lo) may malfunction. Check it
directly. (After checking the safety-suction valve by exchanging it with a valve of
another work equipment circuit, be sure to return it since its set pressure is different
from others.)
Since the body of the arm control valve (Lo, Hi) may have a malfunction, check it
directly.
high idle.
Relieved in arm CURL position
Max. 20 cc/min
PC600-8
SEN00452-02
40 Troubleshooting
H-8 Bucket speed or power is low

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

high idle.
Presumed cause and


valve (bucket circuit)
Bucket CURL, DUMP

full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
Malfunction of bucket
Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it
directly.
3 control valve
Since the safety & suction valve of the bucket control valve (Lo, Hi) may have a malfunction, check it directly. (The safety & suction valve may be checked by replacing it
with one of another work equipment circuit. After checking, however, be sure to
return the safety & suction valve since its set pressure and structure are different
from the others.)
Defective bucket control

valve (body)
Defective seal of bucket

5
cylinder
PC600-8
Since the body of the bucket control valve (Lo, Hi) may have a malfunction, check it
directly.
high idle.
Relieved in bucket CURL position
Max. 20 cc/min
21
SEN00452-02
40 Troubleshooting
H-9 Boom does not move

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

value in normalcy
Failure
Phenomenon
Cause
1 valve
(boom circuit)
Malfunction of boom

high idle.
Boom RAISE, LOWER

full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
Since the spool of the boom control valve (Lo, Hi) may have a malfunction, check it
directly.
H-10 Arm does not move

Arm does not move
Related
Information

value in normalcy
Failure
Phenomenon
22
Cause

high idle.

valve (arm circuit)
Malfunction of arm
Arm IN, OUT

full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it
directly.
PC600-8
SEN00452-02
40 Troubleshooting
H-11 Bucket does not move

Bucket does not move
Related
Information

value in normalcy
Failure
Phenomenon
Cause

high idle.

Bucket CURL, DUMP

full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
directly.
H-12 Bottom dump does not move

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

value in normalcy
Cause

high idle.


2 valve (bottom dump
circuit)
PC600-8
Bucket DUMP full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
high idle.
Bottom dump OPEN, CLOSE full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
Since the spool of the bucket control valve (Hi) may have a malfunction, check it
directly.
23
SEN00452-02
40 Troubleshooting
H-13 Hydraulic drift of work equipment is large

Related
Information

value in normalcy
Failure
Phenomenon
Cause
1

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

Since the safety & suction valve of the boom lock valve may have a malfunction,
2 valve (safety & suction
check it directly.
valve)
Defective seal of boom
3
cylinder
high idle.
Relieved in boom RAISE position
Max. 20 cc/min
Failure
Phenomenon
Related
Information

value in normalcy
Cause
1

Malfunction of arm
2 control valve

cylinder
Since the spool of the arm control valve (Lo) may have a malfunction, check it
directly.
Since the safety & suction valve (head side) of the arm control valve (Lo) may have a
malfunction, check it directly. (The safety & suction valve may be checked by replacing it with one of another work equipment circuit. After checking, however, be sure to
return the safety & suction valve since its set pressure and structure are different
from the others.)
high idle.
Relieved in arm IN position
Max. 20 cc/min
Related
Information

value in normalcy
Cause
1

2 control valve

cylinder
(2) Hydraulic drift of arm is large
Failure
Phenomenon
24
(1) Hydraulic drift of boom is large
(3) Hydraulic drift of bucket is large

directly.
Since the safety & suction valve (bottom side) of the bucket control valve (Lo, Hi)
may have a malfunction, check it directly. (The safety & suction valve may be
checked by replacing it with one of another work equipment circuit. After checking,
however, be sure to return the safety & suction valve since its set pressure and structure are different from the others.)
high idle.
Relieved in bucket CURL position
Max. 20 cc/min
PC600-8
SEN00452-02
40 Troubleshooting
H-14 Time lag of work equipment is large

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

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

Cause

a Stop the engine for the preparations, and keep it running at high idle during
the troubleshooting.
Presumed
cause and
standard value
in normalcy
Malfunction of
2-stage relief
solenoid valve
Malfunction of main
relief valve
Power max. switch
OFF
0 MPa
{0 kg/cm2}
ON
Min. 2.74 MPa

{Min. 28 kg/cm2}
The main relief valve of the control valve may malfunction. Check it directly.
H-16 Machine push-up function does not operate or stop

Failure
Phenomenon
Machine push-up function does not operate or stop
Related
Information
Presumed
cause and
standard value
in normalcy
26
Cause
1

Check by (3) in "H-6 Boom speed or power is low".
PC600-8
SEN00452-02
40 Troubleshooting
H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is
low
Failure
Phenomenon
When arm and boom, bucket are operated simultaneously, boom, bucket speed is low
Related
Information
Check that all the operations are normal when performed singly. (If any of them is abnormal, carry out
troubleshooting related to it.)
Cause

Presumed
cause and
standard value
in normalcy
Malfunction of boom,
bucket PPC shuttle
valve
NEUTRAL
0 MPa
{0 kg/cm2}
Boom or bucket full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
Malfunction of control
valve
The arm throttle valve of the control valve may malfunction. Check it directly.
(arm throttle valve)
H-18 When bucket and boom, arm, swing, travel are operated simultaneously, boom,
arm, swing, travel speed is low
Failure
Phenomenon
When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel
speed is low
Related
Information
Check that all the operations are normal when performed singly. (If any of them is abnormal, carry out
Cause

Presumed
cause and
standard value
in normalcy
PC600-8
CURL Hi cancel
solenoid valve
L.H. and R.H. work equipment control

levers and travel lever
Single operation of bucket CURL
Min. 2.35 MPa

{Min. 24 kg/cm2}
Operations other than single

operation of bucket CURL
0 MPa
{0 kg/cm2}
27
SEN00452-02
40 Troubleshooting
H-19 When arm and swing are operated simultaneously, swing speed is low
Failure
Phenomenon
When arm and swing are operated simultaneously, swing speed is low
Related
Information
Check that both operations are normal when performed singly. (If either of them is abnormal, carry out
Cause

Presumed
cause and
standard value
in normalcy
28
Malfunction of arm,
swing PPC shuttle
valve (arm side)
Neutral
0 MPa
{0 kg/cm2}
Arm IN or OUT full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
The swing priority valve of the control valve may malfunction. Check it
valve (swing priority
directly.
valve)
PC600-8
SEN00452-02
40 Troubleshooting
H-20 Machine deviates in one direction

Related
Information
Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.)
Carry out all the troubleshooting in working mode A.
Presumed cause and standard value in normalcy
Failure
Phenomenon
(1) Machine deviates in the same direction, regardless

of its travel direction
Cause
Troubleshooting with
judgment matrix
Carry out troubleshooting by using the judgment matrix in Before troubleshooting Hmode.
Wrong adjustment of
main pump
See Testing and adjusting, Testing and adjusting travel deviation.

high idle.

valve
Travel lever
FORWARD, REVERSE
Full stroke
2.74 MPa
{28 kg/cm2}
Malfunction of travel
Since the spool of the travel control valve may have a malfunction, check it directly.
Defective travel control

valve (body)
Since the body of the travel control valve may have a malfunction, check it directly.
high idle.
Defective seal of center

swivel joint
Travel lever
Leakage from swivel joint
Relieved on one side
Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 2.

high idle.
7 Leakage in travel motor
8 Defective travel motor

9
Internal defect of final

drive
Travel lever
Leakage from travel motor
Max. 20 l/min
Since the travel motor may be defective, check it directly.

Since the final drive may have a defect in it, check it directly. (The defect can be
judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.)
Fig. 2 Defective seals in center swivel joint and travel deviation directions
PC600-8
29
SEN00452-02
40 Troubleshooting
Failure
Phenomenon
Related
Information
Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.)
Cause
(2) Machine deviates in different directions, depending

on its travel direction

high idle.
Presumed cause and

PPC valve
Travel lever
FORWARD, REVERSE
full stroke
2.74 MPa
{28 kg/cm2}
high idle.

swivel joint
Travel lever
Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 2.

high idle.
4
Low set pressure of

travel motor safety valve
Travel lever
35.3 1.47 MPa

{360 15 kg/cm2}
Fig. 2 Defective seals in center swivel joint and travel deviation directions
30
PC600-8
SEN00452-02
40 Troubleshooting
H-21 Machine deviates largely at start

Failure
Phenomenon
Related
Information
Check that the machine does not deviate during constant-speed travel.
(If the machine deviates even during constant-speed travel, carry out the related troubleshooting.)

value in normalcy
Cause
(1) Machine deviates only when started with travel lever

at full stroke
Malfunction of main
pump servo-valve
Since the servo valve of main pumps (No. 1 & No. 2) may have a malfunction, check
it directly. (Test the servo valve unit or measure its stroke.)

3
swivel joint
Internal defect of travel

motor (body)
troubleshooting.
Travel lever
Either side relief
Max. 100 cc/min
Since the travel motor may have a defect in it, check it directly.
Failure
Phenomenon
Related
Information
Check that the machine does not deviate during constant-speed travel.
(If the machine deviates even during constant-speed travel, carry out the related troubleshooting.)
Cause
(2) Machine deviates when started, regardless of travel

lever stroke
Presumed cause and

high idle. (Check cause 3 and confirm that the result is normal before
troubleshooting.)
1 malfunction of CO, NC
valve
Travel lever
CO, NC valve output pressure
Neutral
Max. 0.55 MPa

{Max. 5.5 kg/cm2}
Full stroke on one side (Idle travel)
Min. 1.7 MPa

{Min. 17 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the CO, NC valve may have
a malfunction or may be adjusted defectively. Check the CO, NC valve directly.
2
Malfunction of main
pump servo-valve
Since the servo-valve of main pump may have a malfunction, check it directly.
(Test the servo-valve unit or measure its stroke.)
high idle.
malfunction of jet sensor
Travel lever
Differential pressure of jet sensor
Neutral
Min. 1.5 MPa

{Min. 15 kg/cm2}
Full stroke on one side (Idle travel)
Max. 0.2 MPa

{Max. 2 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the relief valve may have a
malfunction or the orifice may be defective. Check the relief valve and orifice directly.
PC600-8
31
SEN00452-02
40 Troubleshooting
H-22 Travel deviation is large during compound operation

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

troubleshooting.

value in normalcy
32
Malfunction of boom,
bucket PPC shuttle valve
Neutral
0 MPa
{0 kg/cm2}
Boom or bucket full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
troubleshooting.
2 PPC shuttle valve (arm
side)
Neutral
0 MPa
{0 kg/cm2}
Arm CURL DUMP full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
troubleshooting.
3 PPC shuttle valve (swing
side)
Left work equipment control lever
Neutral
0 MPa
{0 kg/cm2}
Swing LEFT, RIGHT full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
4 valve
(travel shuttle valve)
The travel shuttle valve of the control valve may malfunction. Check it directly.
5 valve
(straight travel valve)
The straight travel valve of the control valve may malfunction. Check it directly.
PC600-8
SEN00452-02
40 Troubleshooting
H-23 Travel speed or power is low

Failure
Phenomenon
Travel speed or power is low
Related
Information

Cause

troubleshooting.

valve
Travel lever
FORWARD, REVERSE full stroke
Min. 2.74 MPa

{Min. 28 kg/cm2}
Presumed cause and

troubleshooting.
2
Malfunction of CO
Travel lever
Neutral
0 MPa {0 kg/cm2}
Operated
Min. 2.74 MPa

{Min. 28 kg/cm2}
troubleshooting.
3
Malfunction of 2-stage
relief solenoid valve
Travel lever
Neutral
0 MPa {0 kg/cm2}
Operated
Min. 2.74 MPa

{Min. 28 kg/cm2}
troubleshooting.
Wrong adjustment or
valve
Travel lever
Either side relieved
35.3 1.47 MPa

{360 15 kg/cm2}
If the main relief valve is still abnormal after adjustment, its operation (on the high
pressure set side) may be defective. Check it directly.
PC600-8
33
SEN00452-02
40 Troubleshooting
H-24 Machine does not travel (only one track)

Related
Information
Presumed cause and

Failure
Phenomenon
(1) Machine does not travel in either direction.
Cause
motor (parking brake)
Since the parking brake of the travel motor may have a malfunction, check it directly.
Internal defect of travel

motor (body)
Since the travel motor may have a defect in it, check it directly.
Internal defect of final

drive
Since the final drive may have a defect in it, check it directly. (The defect can be
judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.)
Failure
Phenomenon
Related
Information

Cause
(2) Machine does not travel forward or in reverse

high idle.
Presumed cause and


valve

Min. 2.74 MPa
{Min. 28 kg/cm2}
Defective travel control

valve (suction valve)
Since the suction valve of the travel control valve may have a malfunction, check it
directly. (The suction valve can be checked by replacing it with normal one.)
high idle.
motor (safety valve)
5 motor
(counterbalance valve)
34
Travel levers
FORWARD, REVERSE
full stroke
Travel levers

(Direction in which machine does not travel)
35.3 1.47 MPa

{360 15 kg/cm2}
Since the counterbalance valve of the travel motor may have a malfunction, check it
directly.
PC600-8
SEN00452-02
40 Troubleshooting
H-25 Travel speed does not change

Travel speed does not change
Related
Information
Check that the Lo and Hi travel speeds are normal.

The travel speed selection system has the automatic speed changing function. If the oil pressure rises
above 33.4 MPa {340 kg/cm2} during travel, the travel speed is changed to Lo even while the machine
is traveling at Hi (Hi is still displayed on the monitor panel).
Presumed cause and

Failure
Phenomenon
Cause

high idle.
1 speed select solenoid
valve
PC600-8
Travel speed select switch
Lo
0 MPa {0 kg/cm2}
Hi
Min. 2.74 MPa

{Min.28 kg/cm2}
Since the servo mechanism of the travel motor may have a malfunction, check it
motor (servo mechanism) directly.
35
SEN00452-02
40 Troubleshooting
H-26 Upper structure does not swing

Failure
Phenomenon
Related
Information
Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out
When carrying out the following troubleshooting, set the swing lock switch in OFF and the working
mode in the P mode.
Cause
(1) Upper structure swings in neither direction.

troubleshooting.
Presumed cause and

Malfunction of swing
1 holding brake solenoid
valve
Neutral (after 10 seconds or more)
0 MPa {0 kg/cm2}
Operated to swing
(in either direction)
Min. 2.74 MPa

{Min. 28 kg/cm2}
The parking brake of the swing motor may malfunction. Check it directly.
troubleshooting.
Wrong adjustment or
3 malfunction of swing
Swing relief
29.91 0.98 MPa

{305 10 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction.
check the safety valve directly.
4
Swing motor (motor unit)

defective internally
The motor unit of the swing motor may have a defect in it. Check it directly.
Swing machinery
Swing machinery may have a defect in it. Check it directly. (The swing machinery can
be checked by abnormal sound, abnormal heating, metal dust in the drained oil, etc.)
Failure
Phenomenon
Related
Information
When carrying out the following troubleshooting, set the swing lock switch in OFF and the working
mode in the P mode.
Cause
(2) Upper structure does not swing in only one direction.

troubleshooting.
Presumed cause and

36

valve (swing circuit)
3 control valve
(suction valve)
Swing RIGHT, LEFT full stroke
Min. 2.74 MPa

{Min.28 kg/cm2}
The spool of the swing control valve may malfunction. Check it directly.
The suction valve of the swing control valve may malfunction. Check it directly.
(The suction valves of the right and left swing control valves can be checked by
exchanging them with each other and seeing the change of the phenomenon.)
motor (suction valve)
The suction valve of the swing motor may malfunction. Check it directly.
(The suction valves of the right and left swing motors can be checked by exchanging
them with each other and seeing the change of the phenomenon.)
motor (check valve)
The check valve of the swing motor may malfunction. Check it directly.
(The check valves of the right and left swing motors can be checked by exchanging
PC600-8
SEN00452-02
40 Troubleshooting
H-27 Swing speed or acceleration is low

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

troubleshooting.
Presumed cause and

1 Leakage in swing motor
2
Leakage from swing motor
Swing relief (in either direction)
Max. 10 l/min
troubleshooting.
Wrong adjustment or
Swing relief
29.91 0.91 MPa

{305 10 kg/cm2}
4

Swing machinery
Swing machinery may have a defect in it. Check it directly. (The swing machinery
can be checked by abnormal sound, abnormal heating, metal dust in the drained oil,
etc.)
Failure
Phenomenon
Related
Information
Cause
(2) Swing speed or acceleration is low in only one direction.

troubleshooting.
Presumed cause and


Min. 2.74 MPa

{Min. 28 kg/cm2}
3 control valve
(suction valve)
The suction valve of the swing control valve may malfunction. Check it directly. (The
suction valves of the right and left swing control valves can be checked by exchanging them with each other and seeing the change of the phenomenon.)
motor (check valve)
PC600-8
37
SEN00452-02
40 Troubleshooting
H-28 Upper structure overruns excessively when it stops swinging

Failure
Phenomenon
Upper structure overruns excessively when it (1) Upper structure overruns excessively when it stops
stops swinging
swinging in both directions.
Related
Information
Presumed cause and

Cause

troubleshooting.
Wrong adjustment or
Swing relief
29.91 0.98 MPa

{305 10 kg/cm2}
troubleshooting.
2 Leakage in swing motor
Failure
Phenomenon
Leakage from swing motor
Max. 10 l/min
Upper structure overruns excessively when it (2) Upper structure overruns excessively when it stops
stops swinging
swinging in only one direction.
Related
Information
Cause

troubleshooting.
Presumed cause and

38

Min. 2.74 MPa

{Min. 28 kg/cm2}
Malfunction of swing con(The suction valves of the right and left swing control valves can be checked by
trol valve (suction valve)
motor (check valve)
PC600-8
SEN00452-02
40 Troubleshooting
H-29 Large shock is made when upper structure stops swinging

Failure
Phenomenon
Large shock is made when upper structure

stops swinging
Related
Information
Cause
(1) Large shock is made when the upper structure stops

swinging in both directions.

troubleshooting.
Presumed cause and

valve
Neutral (After 7 seconds or more)
0 MPa {0 kg/cm2}
Operated to swing (in either direction)
Min. 2.74 MPa

{Min. 28 kg/cm2}
troubleshooting.
Wrong adjustment or
29.91 0.98 MPa

{305 10 kg/cm2}
Check the safety valve directly.
4

Swing machinery
etc.)
Failure
Phenomenon
Large shock is made when the upper structure stops swinging.
Related
Information
Presumed cause and

Cause
(2) Large shock is made when the upper structure stops

swinging in only one direction.

troubleshooting.

Neutral
0 MPa {0 kg/cm2}
Min. 2.74 MPa

{Min. 28 kg/cm2}
PC600-8
39
SEN00452-02
40 Troubleshooting
H-30 Large abnormal sound is made when upper structure stops swinging
Failure
Phenomenon
Large abnormal sound is made when upper

structure stops swinging
Related
Information
Presumed cause and

Cause
Malfunction of back
1 pressure compensation
valve

The back pressure compensation valve may malfunction. Check it directly.
troubleshooting.
Wrong adjustment or
29.91 0.98 MPa

{305 10 kg/cm2}
Check the safety valve directly.
3
Swing machinery
etc.)
Large abnormal sound is made when upper

structure stops swinging
Related
Information
Presumed cause and

Failure
Phenomenon
40
(1) Large abnormal sound is made when the upper

structure stops swinging in both directions.
Cause
1 control valve
(suction valve)
(2) Large abnormal sound is made when the upper

structure stops swinging in only one direction.

(The suction valves of the right and left swing control valves can be checked by
PC600-8
SEN00452-02
40 Troubleshooting
H-31 Hydraulic drift of swing is large

Related
Information
When carrying out the following troubleshooting, set the working mode in the P mode.
Presumed cause and

Failure
Phenomenon
Cause

troubleshooting.
valve
Neutral (After 5 seconds or more)
0 MPa {0 kg/cm2}
Operated to swing (in either direction)
Min. 2.74 MPa

{Min. 28 kg/cm2}
Failure
Phenomenon
Related
Information
Cause
Presumed cause and

(1) While the swing holding brake is applied.
2 control valve
(suction valve)
(2) While the swing holding brake is released.

The safety valve of the swing motor may malfunction. Check it directly.
motor (check valve)
PC600-8
41
SEN00452-02
40 Troubleshooting

2009 KOMATSU
All Rights Reserved
42
SEN00453-02
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up
40 Troubleshooting
Method of using troubleshooting chart ................................................................................................................. 3
S-1 Starting performance is poor ......................................................................................................................... 6
S-2 Engine does not start..................................................................................................................................... 8
S-3 Engine does not pick up smoothly............................................................................................................... 12
S-4 Engine stops during operations ................................................................................................................... 13
S-5 Engine does not rotate smoothly ................................................................................................................. 14
S-6 Engine lacks output (or lacks power) .......................................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion)....................................................................................... 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................................... 17
S-9 Oil becomes contaminated quickly .............................................................................................................. 18
S-10 Fuel consumption is excessive.................................................................................................................. 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................................ 20
S-12 Oil pressure drops ..................................................................................................................................... 21
S-13 Oil level rises (Entry of coolant or fuel)...................................................................................................... 22
S-14 Coolant temperature becomes too high (overheating) .............................................................................. 24
S-15 Abnormal noise is made ............................................................................................................................ 25
S-16 Vibration is excessive ................................................................................................................................ 26
PC600-8
SEN00453-02
40 Troubleshooting
PC600-8
40 Troubleshooting
SEN00453-02
Method of using troubleshooting chart

The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right. The items in A are basic ones. The items
in B can be drawn from the user or operator,
depending on their level.
[Check items]
Simple check items used by the serviceman to
narrow the causes. They correspond to C in the
chart on the right.
[Causes]
Items to be narrowed from the questions and
check items. The serviceman narrows down the
probable causes from A, B, and C.
[Troubleshooting]
Items used to find out the true cause by verifying
the narrowed causes finally in order from the
most probable one by applying troubleshooting
tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the
causes cannot be narrowed, however, you may apply them.)
PC600-8
SEN00453-02
40 Troubleshooting
<Example of troubleshooting> Exhaust gas color is black (incomplete combustion)

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

General causes why starting performance is poor
Causes
Clogged air cleaner element

Cracked EGR cooler (Coolant in exhaust pipe)
Defective contact of valve, vale seat
Worn piston ring, cylinder
Clogged air breather hole of fuel tank cap
Leaking or clogged fuel piping, entry of air
Clogged fuel filter, element
Clogged feed pump gauze filter
Stuck, seized supply pump plunger
Defective injector
Defective intake air heater system
Defective alternator (regulator section)
Defective alternator (generator section)
Defective, deteriorated battery

Insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel
Coolant in exhaust pipe
Confirm recent repair history

Degree of use of
Operated for long period
machine
Became worse gradually
Starting performance
Engine starts easily when warm
Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation and Maintenance Manual
Engine oil must be added more frequently
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally
During operation, charge level monitor indicates abnormal charge
Dust indicator is red
Air breather hole of fuel tank cap is clogged
Fuel is leaking from fuel piping
When priming pump is operated, it makes no reaction or it is heavy
Starting motor cranks engine slowly
If air bleeding plug of fuel filter is removed, fuel does not
While engine is
flow out
cranked with starting
motor
If spill hose from injector is disconnected, little fuel spills
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
Engine does not pick up smoothly and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
EE
Q Q w w
Q Q
Remedy
Q Q Q Q
w
w w Q Q
w
w
w w
w
Q
w
Q
w Q Q
w w
w
w
Q Q
w
Inspect air cleaner directly

q
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows
q
out (*1)
When compression pressure is measured, it is found to be low
q q
When air is bled from fuel system, air comes out
Inspect fuel filter directly
Inspect feed pump gauze filter directly
Carry out troubleshooting according to No-pressure feed by supply pump (*2)
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
When starting switch is turned to HEAT, intake air heater mount does not become
warm
Yes
Is voltage 20 30 V between alternator terminal R and terminal E with
engine at low idle?
No
When specific gravity of electrolyte and voltage of battery are measured, they are low
For *1 and *2, see the next page.
EE
Q Q
q
q
q
q
Clean
Replace
Correct
Replace
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Replace
Replace
Troubleshooting
Check items
Questions
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.
PC600-8
40 Troubleshooting
SEN00453-02
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out.
A little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.
*2: See failure codes [CA559] and [CA2249] in troubleshooting by failure code (display of codes) (Part 2).
PC600-8
SEN00453-02
40 Troubleshooting
S-2 Engine does not start
Defective hydraulic pump or PTO
Defective starting circuit wiring
Defective starting motor (motor section)
Defective starting motor (safety relay section)
Defective starting switch
Defective connection of battery terminal
Water hammer caused by coolant which entered cylinder
Defective or deteriorated battery
Internal parts of engine seized

See S-4 Engine stops during operations.
Broken flywheel ring gear
Cracked EGR cooler (Coolant in exhaust pipe)
General causes why engine does not turn
Defective battery relay
Causes
a) Engine does not turn
EEE
Condition of horn when Horn does not sound

starting switch is turned
Horn volume is low
ON
Battery electrolyte is low
w
w
Battery terminal is loose
Q
Q
w
When starting switch is turned to START, starting pinion does not move out
Speed of rotation is low
Makes grating noise
w
w
Q
Soon disengages again
Makes rattling noise and does not turn
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1).
There is not voltage (20 30 V) between battery relay terminal M and

terminal E
Turn starting switch
OFF, connect cord, and
carry out troubleshooting at ON
When terminal B and terminal C of starting switch are connected,

engine starts
When terminal B and terminal C at safety relay outlet are connected,

engine starts
Even if terminal B and terminal C at safety relay outlet are connected,

engine does not start
Replace
Replace
Replace
Correct
Replace
Replace
Remedy
Replace
For *1, see the next page.
Carry out troubleshooting on H-mode
Inspect flywheel ring gear directly
Troubleshooting
Carry out troubleshooting on E-mode
Check items
When starting switch is turned ON, there is no operating sound from battery relay
When starting switch is

turned to START, starting pinion moves out,
but
Degree of use of
machine
Replace
Questions
PC600-8
40 Troubleshooting
SEN00453-02

PC600-8
SEN00453-02
40 Troubleshooting
Use of improper fuel

Insufficient fuel in tank
Clogged fuel filter element
Fuel is not being supplied

Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)

Seized, abnormally worn feed pump
Broken supply pump shaft, key
Defective supply pump PCV
General causes why engine turns but no exhaust smoke comes out
Wrong connection of supply pump PCV

Defective operation of overflow valve (Does not close)
Defective operation of flow damper
Defective fuel injector
Causes
b) Engine turns but no exhaust smoke comes out
Degree of use of
machine
EEE
w Q w w w
Exhaust smoke suddenly stopped coming out (when starting again)

w w
Q Q Q
w
w
w Q Q
Rust and water are found when fuel tank is drained
When fuel filter is removed, there is not fuel in it

Check items
w
Q w
When fuel tank is inspected, it is found to be empty

If air bleeding plug of fuel filter is removed, fuel does not flow
While engine is
cranked with start- out
ing motor
Q Q
w Q
w w w w
Inspect fuel filter directly

Troubleshooting
EE
Inspect feed pump directly
q q

Carry out troubleshooting according to Abnormality in PCV1 (*2) or Abnormality in
PCV2 (*3)
q
q
q
Inspect overflow valve directly
q q
Clean
Replace
Replace
Replace
Replace
Remedy
Replace
Add
Correct
Correct
Replace
Engine can be started in reduced cylinder mode
Correct
Replace
Replace
Replace
Questions
*1: Failure code [CA559] and failure code [CA2249]

10
PC600-8
SEN00453-02
40 Troubleshooting
Causes
Worn dynamic valve system (Valve, rocker lever, etc.)
Worn piston ring, cylinder liner
Leaking or clogged fuel system, entry of air
Clogged fuel filter, strainer
Clogged injector, defective spray
Defective, deteriorated battery
Defective coolant temperature sensor, wiring harness
Defective intake air heater system
c) Exhaust smoke comes out but engine does not start (fuel is being injected)
General causes why exhaust smoke comes out but engine does not start
Lack of rotating force due to defective electrical system
Questions
Degree of use of machine Operated for long period
EE
Suddenly failed to start

Replacement of filters has not been carried out according to Operation and Maintenance
Manual
E
w
QQ
ww
w

When engine is preheated or when temperature is low, preheating monitor does not indicate
normally
w
w
ww
When fuel filter is removed, there is not fuel in it
w
wQQ

w
w
When engine is cranked, abnormal sound is generated around cylinder head

While engine is cranked
with starting motor,
ww
w
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low
w
q
Inspect dynamic valve system directly

Troubleshooting
If air bleeding plug of fuel filter is removed, fuel does not flow out
Inspect fuel filter, strainer directly
When injector unit is tested, spray condition is bad

Coolant temperature gauge does not indicate normally (if coolant temperature gauge is
installed)
When starting switch is turned to HEAT, intake air heater mount does not become warm
Remedy
q
q
q
Clean
Replace
Replace
Replace
Clean
Correct
Clean
Clean
Replace
Clean
Replace
Replace
Replace
Check items
Starting motor cranks engine slowly
PC600-8
11
SEN00453-02
40 Troubleshooting
S-3 Engine does not pick up smoothly

General causes why engine does not pick up smoothly
EGR valve is stuck open

(There is much EGR gas and intake of air is insufficient)l
Improper valve clearance
Controller is controlling in derate mode (limiting injection rate (output)

because of an error in electrical system)
Stuck EGR valve
Defective contact of valve and valve seat
Defective condition of fuel spray
Seized turbocharger, interference of turbocharger
Clogged injector, defective spray
Defective operation of flow damper (Large leakage from injector)
Causes
EEE
Engine pick-up suddenly became worse
EE
Q Q
w w
w
Oil must be added more frequently
w w
w
w Q Q

Check items

Color of exhaust
gas
Blue under light load
Black
When engine is cranked, interference sound is generated around turbocharger
Q
Q
High idle speed under no load is normal, but speed suddenly drops when load is applied
w w
Q w
Carry out troubleshooting according to Abnormality in EGR valve servo (*1)

Troubleshooting
Q
w
w w w
q
q
Inspect valve clearance directly
When turbocharger is rotated by hand, it is found to be heavy

not change
Clean
Replace
Clean
Correct
Clean
Replace
Replace
Replace
Adjust
Replace
Clean
Remedy
q q
Correct
Degree of use of
machine
Replace
Questions

12
PC600-8
SEN00453-02
40 Troubleshooting
S-4 Engine stops during operations

General causes why engine stops during operations
Seized parts inside engine
There is overheating
Broken dynamic valve system (valve, rocker arm, etc.)

Broken, seized piston, connecting rod
Broken, seized crankshaft bearing
Broken, seized gear train
Leaking, clogged fuel piping
Broken, seized feed pump
Broken supply pump shaft, key
Causes
EE
w
w Q
Engine stopped slowly

There was hunting and engine stopped

w w
w
w
Fuel level monitor indicates low level

w
w Q Q
w w
Q Q

Check items
Q Q
Q Q Q
Q Q Q
w w
w w
Metal particles are found when oil is drained

Does not turn at all
When engine is cranked Turns in opposite direction

by hand
Moves by amount of gear backlash
w
w
Supply pump shaft does not turn
Engine turns, but stops when load is applied to machine
q
q
Inspect crankshaft bearing directly
Inspect gear train directly
Inspect feed pump directly
q q

Remedy
Replace
Replace
Replace
Replace
Add
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Troubleshooting
Inspect piston, connecting rod directly
Carry out troubleshooting on H-mode
Condition when engine

stopped
Q w Q w
w Q
Engine overheated and stopped
Questions
Abnormal noise was heard and engine stopped suddenly w w w w
PC600-8
13
SEN00453-02
40 Troubleshooting
S-5 Engine does not rotate smoothly

General causes why engine does not rotate smoothly
Defective speed sensor (Error at degree that it is not indicated)

Defective EGR valve
Defective Ne speed sensor, wiring harness
Defective G speed sensor, wiring harness
Q
Q
Q
Q
Q
Q Q Q Q Q Q
Q
Q
w
Q
Defective operation of bypass valve
Defective operation of EGR valve
Low setting of low idle speed
Clogged injector, defective spray (dirt in injector)
Air in fuel system
Defective operation of flow damper (Large leakage from injector)
Causes
EE
Q Q Q
w
Q Q
Occurs at a certain speed range

Condition of hunting
Occurs at low idle

Occurs even when speed is raised
Occurs on slopes
EE
w w
w
Check items
Q Q
w
w Q Q

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

not change
q q
Carry out troubleshooting according to Abnormality in engine Ne speed sensor

(*3)
Carry out troubleshooting according to Abnormality in engine Bkup speed sensor

(*4)
Correct
Correct
Replace
Replace
Replace
Replace
Clean
Add
Replace
Replace
Correct
Remedy
q
Correct
Questions

*3: Failure code [CA689]
*4: Failure code [CA778]
14
PC600-8
SEN00453-02
40 Troubleshooting
S-6 Engine lacks output (or lacks power)

General causes why engine lacks output
Q Q Q
Q
Defective fuel temperature sensor, wiring harness
Defective drive of injector (signal, solenoid)
Defective charge pressure sensor, wiring harness
Clogged injector, defective spray (dirt in injector)
Leaking, clogged fuel piping
Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
Air leakage from air intake piping
See S-14 Coolant temperature becomes too high (Overheating)
Defective spray condition of fuel
Defective installation of charge pressure sensor (air leakage)
Causes
Power was lost
E E
Q Q
Q Q
Suddenly
Gradually

w
Q Q Q
Output becomes insufficient after short stop of operation

Color of exhaust gas
w w
Black
Check items

w
w
High idle speed is too high

High idle speed under no load is normal, but speed suddenly drops when load is
applied
w w Q
w
Q Q
Q Q Q Q

Inspect air intake piping directly
q
q q q
When boost pressure is measured, it is found to be low

Troubleshooting
q
q

not change
q q
q
Inspect charge pressure sensor mount directly
Carry out troubleshooting according to Abnormality in charge pressure sensor (*2)
q
Replace
Correct
Replace
Replace
Replace
Clean
Replace
Correct
Clean
Replace
Adjust
Replace
Replace
Correct
Remedy
Clean
Carry out troubleshooting according to Abnormality in fuel temperature sensor (*3)
Replace
Questions
Degree of use of
machine

PC600-8
15
SEN00453-02
40 Troubleshooting
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black
Improper fuel injection pressure
Improper fuel injection timing
Clogged fuel spill piping (on cylinder head side)
Abnormally worn injector
Clogged, seized injector
EGR valve is stuck open (There is much EGR gas and intake of air is
insufficient)
Crushed, clogged muffler
Controller is controlling in derate mode (limiting injection rate

(output) because of an error in electrical system)
See S-14 Coolant temperature becomes too high (Overheating)
Defective condition of fuel injection
Stuck EGR valve
Excessive injection of fuel
Leakage of air between turbocharger and cylinder head
Causes
Gradually became black
Q
w
Q Q

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

Q w
w
Q Q
Torque converter stall speed or pump relief speed is high (Fuel is injected excessively)
Exhaust noise is abnormal
Q Q
Q Q Q
Q w
w
If spill hose from injector is disconnected, abnormally much fuel spills
When turbocharger is rotated by hand, it is found to be heavy
Troubleshooting
q
q
When muffler is removed, exhaust sound improves

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
q
q
q
Inspect fuel spill piping (on cylinder head side) directly
q
Adjust
Adjust
Correct
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Replace
Replace
Replace
Remedy
Clean
Carry out troubleshooting according to Abnormality in coolant temperature sensor (*3)
Replace
Questions
Color of exhaust gas
E E
w Q
Suddenly became black

16
PC600-8
SEN00453-02
40 Troubleshooting
S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive
Abnormal consumption of oil
Long-time operation of engine at low idle or high idle (Do not run engine
at idle for more than 20 minutes continuously)
External leakage of oil

Degree of use of
machine
Oil consumption suddenly increased
Oil becomes contaminated quickly
Outside of engine is dirty with oil
There are loose piping clamps in intake system
Inside of turbocharger intake outlet pipe is dirty with oil
Inside of turbocharger exhaust outlet pipe is dirty with oil
There is oil in coolant
Oil level in damper chamber of machine is high
Exhaust smoke is blue under light load
Excessive
Amount of blow-by
gas
None
EEEE
E
w
Q
Q
w
Q Q w
w w w w
w
w
Q w
w
w
Q
Q
w w
w w
Q
w
When intake manifold is removed, dust is found inside

q
When intake manifold is removed, inside is found to be dirty abnorq
mally
Excessive play of turbocharger shaft
q q
When EGR valve is removed, exhaust port is found to be dirty with oil
q
Check breather and breather hose directly
q
q q
Inspect rear oil seal directly
q
Pressure-tightness test of oil cooler shows there is leakage
q q
There is external leakage of oil from engine
q q q
Remedy
PC600-8
Correct
Correct
Replace
Replace
Replace
Clean
Replace
Replace
Correct
Replace
Replace
Correct
Correct
Correct
Correct
Troubleshooting
Check items
Questions
Wear of parts in lubrication system
Dust sucked in from intake system

Worn, damaged valve (stem, guide, seal)
Worn seal at turbocharger end
Turbocharger
Worn seal at blower end
Oil leakage from EGR valve stem
Clogged breather, breather hose
Broken piston ring
Worn, damaged rear oil seal
Broken oil cooler
Oil leakage from oil cooler
Oil leakage from oil filter
Oil leakage from oil piping
Oil leakage from oil drain plug
Oil leakage from oil pan, cylinder head, etc.
Causes
17
SEN00453-02
40 Troubleshooting
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
Defective turbocharger turbine side seal

Worn EGR valve guide
Worn valve, valve guide
Clogged breather, breather hose
Clogged oil cooler
Clogged oil filter
Defective oil filter safety valve
Clogged turbocharger lubrication drain tube
Exhaust smoke is bad
Causes

Use of improper oil
Troubleshooting
Check items
Questions
Operation under excessive load

Degree of use of
machine
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging
Metal particles are found when oil is drained
Inside of exhaust pipe is dirty with oil
Engine oil temperature rises quickly
Color of exhaust gas Blue under light load
color
Black
Excessive
Amount of blow-by gas
None
Excessive play of turbocharger shaft
When EGR valve is removed, exhaust port is found to be dirty with oil
Inspect breather and breather hose directly
Inspect oil cooler directly
Inspect oil filter directly
Spring of oil filter safety valve is hitched or broken
Inspect turbocharger lubrication drain tube directly
Remedy
18
E E E E
Q
Q
w
w
Q Q
w
w
w
w
w
Q
Q w
Q
w
q
q
q q
See S-7
Clogging of lubrication passage
q
q
q
q
q
Replace
Replace
Replace
Replace
Clean
Clean
Replace
Replace
Clean
Entry of exhaust gas into oil due to internal wear
PC600-8
SEN00453-02
40 Troubleshooting
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
Fuel leakage inside head cover

Fuel leakage from fuel filter, piping, etc.
Defective feed pump oil seal
Defective supply pump plunger
Defective common rail pressure
Defective spray by injector
Defective operation of injector
Causes
Leakage of fuel
Defective condition of fuel injection (fuel pressure, injection timing)

Degree of use of
EE
E
machine
More than for other machines of same model
Q
Q Q Q
Condition of fuel
Gradually increased
Q
Q
consumption
Suddenly increased
Q Q
There is external leakage of fuel from engine
w
Combustion is irregular
w
Engine oil level rises and oil smells of diesel fuel
w
w
When exhaust manifold is touched immediately after starting engine, temperaw
ture of some cylinders is low
Low idle speed is high
Q
Torque converter stall speed or pump relief speed is high
Q
Q Q
Q Q
Exhaust smoke Black
color
White
Q
Remove and inspect head cover directly
q
Inspect feed pump oil seal directly
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
If spill hose from injector is disconnected, much fuel spills
Carry out troubleshooting according to Abnormality in coolant temperature
sensor (*2)
Confirm with monitoring function on machine monitor
Remedy
q
q
q
q
q
q
Correct
Correct
Replace
Replace
Correct
Replace
Replace
Correct
Correct
Troubleshooting
Check items
Questions
Excessive injection of fuel

PC600-8
19
SEN00453-02
40 Troubleshooting
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)

Suddenly increased
Oil level
Gradually increased
Hard water is being used as coolant
Oil level has risen and oil is milky
Internal cracks in cylinder block
E
Q
Q
Q Q
Q
Q Q
There are excessive air bubbles in radiator, coolant spurts back
Pressure-tightness test of cylinder head shows there is leakage
Q
w
w
q q
Inspect cylinder block, liner directly
Inspect cylinder liner directly
20
Replace
Replace
Replace
Remedy
Replace
Replace
Troubleshooting
Check
items
Questions
Broken cylinder head, head gasket
Internal leakage in cooling systeml
Broken oil cooler core, O-ring
Internal leakage in lubrication system
Insufficient protrusion of cylinder liner
Causes
Damaged cylinder liner O-ring, holes caused by pitting
General causes why oil is in coolant
PC600-8
SEN00453-02
40 Troubleshooting
S-12 Oil pressure drops

General causes why oil pressure drops
Leakage, clogging, wear in lubrication system
Defective oil pressure control
Selection of oil by the temperature etc. specified in the "Operation and
Maintenance Manual" is not observed.

Degree of use of
E
E
E
machine
Oil pressure monitor indicates low oil pressure
Q w
Non-specified oil is being used
Q
Q
Replacement of filters has not been carried out according to Operation and
w
Maintenance Manual
Indicates pressure drop at low idle
w
Q
Q
Indicates pressure drop at low, high idle
Q
w w w Q
Q Q
Oil pressure
monitor
Indicates pressure drop on slopes
w
Sometimes indicates pressure drop
w
Q Q
Oil level monitor indicates oil level drop
w
w
Oil level in oil pan is low
w
External hydraulic piping is leaking, crushed
w
w
Oil is milky or smells of diesel oil
w
Metal particles are found when oil pan is drained
w
w
Metal particles are found in oil filter

q
Inspect oil pan strainer, pipe directly
Oil pump rotation is heavy, there is play in oil pump
Valve and spring of oil pump relief valve are fatigued, damaged
Inspect oil filter directly
Relief valve of EGR oil pump is damaged, oil leaks from it
Inspect EGR hydraulic piping directly
Carry out troubleshooting according to Abnormality in oil pressure sensor
(*1)
If oil level sensor is replaced, oil pressure monitor indicates normally
Remedy
q q
q
See S-13
Metal particles are found when oil filter is drained
q
q
q
q
q
q
Replace
Add
Clean
Clean
Replace
Adjust
Replace
Correct
Replace
Replace
Replace
Replace
Troubleshooting
Check items
Questions
Deterioration of oil due to overheatingl
Worn journal of bearing

Lack of oil in oil pan
Coolant, fuel in oil
Clogged strainer in oil pan
Clogged, broken pipe in oil pan
Defective oil pump
Defective oil pump relief valve
Clogged oil filter
Leaking, crushed, clogged hydraulic piping
Defective EGR oil pump
Leaking EGR hydraulic piping
Defective oil pressure sensor, wiring harness
Defective oil level sensor, wiring harness
Causes
PC600-8
21
SEN00453-02
40 Troubleshooting
S-13 Oil level rises (Entry of coolant or fuel)

General causes why oil level rises
Cracked EGR cooler (Entry of coolant)

Fuel leakage inside head cover
Cracks inside cylinder block
Damaged cylinder liner O-ring, holes caused by pitting
Worn, damaged rear oil seal
Broken oil cooler core, O-ring
Clogged water pump drain hole (breather hole), defective seal
Defective thermostat seat
Defects in supply pump
Causes
Coolant in oil (milky)

Fuel in oil (smells diluted diesel fuel)

Degree of use of
EE
E
machine
Fuel must be added more frequently
w
w
Coolant must be added more frequently
Q Q
w
There is oil in coolant
Q
Q Q
w
Oil smells of diesel fuel
w
w
Oil is milky
Q Q
w
When engine is started, drops of water come from muffler
Q Q
When radiator cap is removed and engine is run at low idle, an abnormal numw
Q
ber of bubbles appear, or coolant spurts back
Exhaust smoke is white
Q
Q
Water pump drain hole (breather hole) is clogged
w
When water pump drain hole (breather hole) is cleaned, coolant comes out
w
Oil level in damper chamber of machine is low
w
Oil level in hydraulic tank of machine is low
When EGR cooler outlet gas piping is removed, coolant containing antifreeze
q
flows out (*1)
q
Remove and inspect head cover directly
q
Inspect cylinder block, liner directly
q q
Inspect rear oil seal directly
q
q
Remove and inspect water pump directly
q
Remove and inspect thermostat cover directly
q
Remove and inspect supply pump directly
q
Remedy
22
Replace
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Correct
Replace
Troubleshooting
Check items
Questions
a If oil is in coolant, carry out troubleshooting for S-11 Oil is in coolant
PC600-8
40 Troubleshooting
SEN00453-02

PC600-8
23
SEN00453-02
40 Troubleshooting
S-14 Coolant temperature becomes too high (overheating)

General causes why coolant temperature becomes too high
Defective fan drive pump or motor
Defective coolant temperature gauge
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged, crushed radiator fins
Defective operation of thermostat
Broken water pump
Lack of coolant
Problem in coolant circulation system
Clogged, broken oil cooler
External leakage of coolant from EGR cooler
Drop in heat dissipation efficiency
Lack of cooling air (deformation, damage of fan)
Damaged cylinder liner O-ring, hole caused by pitting
Causes
Questions

Degree of use of
machine
Condition of
overheating
E E E
Sudden overheated
E E
Q w
Q w w
Always tends to overheat

Q
Coolant temperature Rises quickly

gauge
Does not go down from red range
w
w
Radiator coolant level monitor indicates drop of coolant level
w
w Q
Engine oil level has risen, oil is milky

Fan belt tension is low
When fan pulley is turned, it has play

w
Check items
Milky oil is floating on coolant

w
There are excessive air bubbles in radiator, coolant spurts back
When light bulb is held behind radiator core, no light passes through
Radiator shroud, inside of underguard are clogged with dirt or mud

w
Coolant is leaking because of cracks in hose or loose clamps
Coolant flows out from radiator overflow hose

Fan belt whines under sudden acceleration
q
Inspect EGR cooler for coolant leakage
Inspect cylinder liner directly
q
q
Temperature difference between upper and lower tanks of radiator is large

When operation of thermostat is carried out, it does not open at cracking temperature
q
q
Temperature difference between upper and lower tanks of radiator is slight
Inspect radiator core directly
When operation of radiator cap is carried out, its cracking pressure is low
When coolant temperature is measured, it is fount to be normal
24
Check, replace
Replace
Correct
Correct
Replace
Replace
Add
Replace
Remedy
Replace
Replace
Inspect fan pump oil pressure
Replace
Inspect fan rotation
Replace
Troubleshooting
Inspect oil cooler directly
PC600-8
SEN00453-02
40 Troubleshooting
S-15 Abnormal noise is made

General causes why abnormal noise is made

(abnormality in coolant temperature sensor)
Dirt caught in injector
Clogged, seized injector
Deformed cooling fan, loose fan belt, interference of fan belt
Removed, seized gear train bushing
Improper gear train backlash
a When the engine is accelerated, it is operated in the acceleration

mode and its sound becomes a little larger for up to about 3
seconds. This does not indicate abnormality, however.
Excessive wear of piston ring, cylinder liner
a The engine is operated in the low-temperature mode while it is not

warmed up sufficiently. Accordingly, the engine sound becomes
a little larger. This does not indicate abnormality, however.
a Judge if the noise is an internal noise or an external noise before

starting troubleshooting.
Defective inside of muffler (dividing board out of position)
Air sucked in from intake system
Broken dynamic valve system (valve, rocker lever)
Abnormal combustion
Cracked, leaking EGR gas piping
Leakage of air between turbocharger and cylinder head
Abnormality due to defective parts
Interference of turbocharger, seized turbocharger
Causes
Degree of use of
machine
Condition of
abnormal noise
Gradually occurred
Q
Q
w
w

Air leaks between turbocharger and cylinder head
When engine is cranked, abnormal sound is generated around EGR gas piping

Check items
Q Q Q
Sudden occurred
w
w
When engine is cranked, beat noise is generated around muffler

When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Color of exhaust
gas
w Q
w
Q w
Black
Q
w
Q Q
Abnormal noise is loud when engine is accelerated
When turbocharger is rotated by hand, it is fount to be heavy
Inspect EGR gas piping directly

Troubleshooting
Q
w
When muffler is removed, abnormal noise disappears
q q
Inspect fan and fan belt directly

When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
q q
q
Abnormal noise is heard only when engine is started
PC600-8
Correct
Replace
Correct
Replace
Replace
Replace
Replace
Replace
Correct
Replace
Replace
Remedy
Replace
Correct
Questions
25
SEN00453-02
40 Troubleshooting
S-16 Vibration is excessive

General causes why vibration is excessive
Stuck dynamic valve system (valve, rocker lever)

Worn main bearing, connecting rod bearing
Improper gear train backlash
Worn camshaft bushing
Improper injection timing
Loose engine mounting bolts, broken cushions
Broken output shaft, parts in damper on PTO
Causes
Defective parts (abnormal wear, breakage)

Misalignment between engine and chassis
Abnormal combustion

Degree of use of
machine
Suddenly increased
Condition of
vibration
Gradually increased
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
w
w
Q
Q
Q
Q
w
w
Q
Q Q
Q Q
Exhaust smoke is black

Inspect main bearing and connecting rod bearing directly
Inspect camshaft bushing directly
Inspect engine mounting bolts and cushions directly
Inspect output shaft or inside of damper directly
q
q
q
q
q
q
q
Remedy
26
Replace
Replace
Replace
Replace
Adjust
Replace
Troubleshooting
Check items
Questions
a If abnormal noise is made and vibration is excessive, carry out

troubleshooting for S-15 Abnormal noise is made, too..
PC600-8
40 Troubleshooting
PC600-8
SEN00453-02
27
SEN00453-02
40 Troubleshooting

2009 KOMATSU
All Rights Reserved
28
SEN01062-04
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up
50 Disassembly and assembly1

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

1.
(Rev. 2009.1)
1
Removal and installation of assemblies

Special tools
q
Special tools which are necessary for
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
q : Special tools that will be useful if available and are substitutable with tools
available on the market
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
:
79 Tmeans that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
* *** ****
Removal
q
In Removal section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not
described.
q
Various symbols used in Removal section are
explained and listed below.
k : Precautions related to work safety
a : Guidance or precautions for the work
[*1] : This mark shows that instructions or precautions for parts installation work are given in
Installation section.
6 : Amount of oil or coolant to be drained
4:
Weight of part or component
Installation
q
Unless otherwise instructed, installation of
parts is to be done in the reverse order to
removal.
q
Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which
corresponds to the mark in Removal section.
q
Common tools that are necessary for installation are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
Marks shown in the Installation section stand
for the following.
k
: Precautions related to work safety

: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
: Amount of oil or coolant to be replenished
Sketches of special tools

q
Various special tools are illustrated for the local
manufacture.
PC600-8
2.
SEN01062-04
Disassembly and assembly of assemblies

Special tools
q
Special tools which are necessary for disassembly and assembly of parts are
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used.
q : Special tools that will be useful if available and are substitutable with tools
available on the market.
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
:
79 Tmeans that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
* *** ****
Disassembly
q
In Disassembly section, the work procedures,
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for disassembly are described as [1], [2] etc. and
their part numbers, part names and quantities
are not described.
q
The meanings of the symbols used in Disassembly section are as follows.
k

6 : Amount of oil or coolant drained
Assembly
q
In Assembly section, the work procedures,
the amount of oil and coolant to be replenished
are described.
q
Common tools that are necessary for assembly are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
The meanings of the symbols used in Assembly section are as follows.
k

2 : Type of coating material
3 : Tightening torque
: Amount of oil or coolant to be replenished

Various special tools are illustrated for the local
manufacture.
PC600-8
SEN01062-04
Coating materials list
(Rev. 2009.02)
1
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Category
Komatsu
code
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 chloPolyethylene
ride), 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
LT-4
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
ThreeBond
1735
Gasket sealant
790-129-9140
Can
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.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.
Aron-alpha
201
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
Features: Resistance to heat and chemicals.

Polyethylene
Used for fitted portions used at high temperacontainer
tures.
1 kg
Used to seal various threaded portions, pipe

Polyethylene
joints, and flanges.
container Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-5
790-129-9080
LG-6
790-129-9160
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
790-129-9170
1 kg
Tube
Features: Silicon-based quick-setting sealant.

Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.

Used to seal transfer case, etc.
Tube
Used for rough surfaces such as the circle

gear top seal which does not need to be
clamped, water resistance of the clearance at
the welded area, etc.
Can be coated with paint.
LG-8
ThreeBond
1207B
LG-9
ThreeBond
1206D
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
419-15-18131
790-129-9310
100 g
200 g
PC600-8
Gasket sealant
CateKomatsu code
gory
Part number
Q'ty
Container
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
Used as lubricant/sealant when the radiator

hoses are inserted.
Can be coated with paint.
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
Feature: Can be used together with gaskets.

Used for covers of the transmission case and
steering case etc.
ThreeBond
1211
790-129-9090
100 g
Tube
Gasket sealant used to repair engine.
Tube
Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.
Can
Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuffing each other.
Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
Can
Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc.
Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
Feature: Lithium grease with extreme pressure

lubrication performance.
General purpose type.
Seizure
prevention
compound
Molybdenum
disulfide
lubricant
LM-P
LC-G
NEVER-SEEZ
09940-00040
09995-00250
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
SYGA-16CNM
LM-G (G2-M)
Grease
SEN01062-04
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
G2-S
ThreeBond
1855
G2-U-S
ENS grease
PC600-8
427-12-11871
200 g
190 g
Used for parts under heavy load.

Caution:
400 g x 10 Bellows-type Do not apply grease to rolling bearings like
400 g x 20 container
swing circle bearings, etc. and spline.
The grease should be applied to work equipment
16 kg
Can
pins at their assembly only, not applied for
greasing afterwards.
400 g
16 kg
400 g
16 kg
200 g
2 kg
Bellows-type
container
Can
Seizure resistance, heat resistance and water

resistance higher than molybdenum disulfide
grease.
Not conspicuous on machine since color is
white.
Bellows-type Since this grease is decomposed by natural baccontainer

teria in short period, it has less effects on microorganisms, animals, and plants.
Can
Tube
Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.
Can
Feature: Urea (organic system) grease with heat

resistance and long life. Enclosed type.
Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SEN01062-04
Part number
SUNSTAR
PAINT PRIMER
580 SUPER
SUNSTAR
PAINT PRIMER
435-95
Container
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.

20 ml
Glass
container
417-926-3910
22M-54-27230
Used as primer for painted surface on cab

side.
Used as primer for black ceramic-coated
surface on glass side and for hard polycarbonate-coated surface.
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
Used as primer for sash (Almite).

SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
417-926-3910
320 ml
Polyethylene
container
S is used for high-temperature season

and W for low-temperature season as
adhesive for glass.
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
Used as adhesive for glass.

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.

Cartridge
Used to seal joint of glasses.

Translucent white seal.
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Caulking material
Adhesive
Primer
SUNSTAR
GLASS
PRIMER 580
SUPER
Q'ty
Adhesive for cab glass
CateKomatsu code
gory
Used as adhesive for glass.

Used to seal joints of glass parts.
PC600-8
SEN01062-04
Special tools list
Component
Symbol
Part Name
795-630-5500
Standard puller
01010-81090
Bolt
01643-31032
Washer
Part No.
Sketch
Qty
* *** ****
New/remodel
Tools with part number 79 Tmeans that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
Necessity:
t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any modification.
Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
Sketches of special tools).
Necessity
Nature of work, remarks
Removal and installation of fuel supply

pump assembly
Removal and installation of cylinder

head assembly,
engine rear seal
790-331-1110
Wrench
Tightening of cylinder head bolt,

flywheel bolt
795-931-1100
Seal puller
Pulling out of oil seal
795T-521-1111
Push tool
01050-31655
Bolt
01050-31635
Bolt
795T-521-1150
Push tool
4
A
5
Removal and installation of engine front
seal, rear seal
Disassembly,
assembly of final
drive assembly
PC600-8
N Q
Press fitting of engine front seal

(Standard type, sleeve type)
01050-31635
Bolt
N Q Press fitting of engine front seal

(Sleeve type)
795T-421-1270
Push tool
N Q
01050-31645
Bolt
01643-31645
Washer
795T-421-1240
Push tool
N Q
01050-31645
Bolt
01643-31645
Washer
795T-421-1250
Push tool
Press fitting of engine rear seal

N Q (Sleeve type)
Press fitting of engine rear seal

(Standard type)
01050-31645
Bolt
01643-31645
Washer
796T-626-1110
Push tool
790-331-1110
Wrench
Tightening of ring gear bolt
8
Disassembly,
assembly of swing
machinery assembly
Pulling out of drive gear
Q Press fitting of bearing
790-501-5000
Unit repair stand
AC100V
790-501-5200
Unit repair stand
AC110V, 220V
790-901-4110
Bracket
796T-627-1510
Plate
796T-627-1520
Plate
Disassembly, assembly of final

drive
Disassembly,
assembly of final
drive assembly
Block
791-730-1130
Bolt
790-101-2360
Plate
01643-32060
Washer
01580-12016
Nut
796-627-1420
Adapter
790-201-2790
Spacer
790-201-2690
Plate
790-101-2102
Puller
(294 kN {30 ton})
790-101-1102
Pump
796-627-1020
Installer
Part Name
790-101-2510
Block
791-830-1320
Rod
790-101-2570
Washer
01643-31645
Washer
01580-11613
Nut
796-627-1410
Adapter
796T-627-1330
Push tool
790-101-2102
Puller
Sketch
790-431-1031
Part No.
New/remodel
Symbol
Qty
Component
Necessity
SEN01062-04
Removal of travel motor
Press fitting of floating seal
Press fitting of bearing

Q
790-101-1102
Pump
790-331-1110
Wrench
Tightening angle of cover bolt
Disassembly,
assembly of idler
assembly
791-575-1520
Installer
Installation of floating seal
791-601-1000
Oil pump assembly q
Filling with oil, check sealing
Disassembly,
assembly of track
roller assembly
4
5
Disassembly,
assembly of
carrier roller
Disassembly,
assembly of recoil
spring assembly
2
M
790-701-3600
Adapter
AC110 220 V, AC220 240 V
791-560-1520
Installer
791-601-1000
Oil pump assembly q
790-701-3600
Adapter
AC110 220 V, AC220 240 V
791-651-1510
Installer
791-601-1000
Oil pump assembly q

AC110 220 V, AC220 240 V
790-701-3600
Adapter
791-685-8502
Compressor
791-635-3160
Extension
790-101-1600
Cylinder
(686 kN {70 ton})
790-101-1102
Pump
790-201-1500
Push tool
796-632-1200
Remover, installer
Cylinder
790-101-4300
Removal and
installation of track
shoe assembly
(1,471 kN {150 ton})
790-101-4200
Puller
(294 kN {30 ton})
790-101-1102
Pump
790-331-1100
Wrench
Disassembly, assembly of recoil

spring
Installation of push tool
PC600-8
4
Disassembly,
assembly of 1 link at
field
7
8
PC600-8
791-680-9580
Adapter
791-680-9590
Guide
01010-52760
Bolt
01010-51440
Bolt
790-101-1102
Pump
790-101-4300
Cylinder
791-685-9510
Frame
791-685-9520
Frame
791-685-9530
Rod
791-685-9550
Nut
791-685-9560
Bolt
791-680-9570
Adapter
01010-51030
Bolt
04530-12030
Eyebolt
790-101-1102
Pump
790-101-4300
Cylinder
Part No.
Part Name
791-685-9540
Rod
791-685-9550
Nut
791-685-9510
Frame
791-685-9520
Frame
791-685-9530
Rod
791-685-9550
Nut
791-685-9560
Bolt
791-126-0150
Adapter
791-680-5520
Guide
791-126-0140
Pusher
791-680-9570
Adapter
01010-51030
Bolt
04530-12030
Eyebolt
791-685-9620
Extension
790-101-1102
Pump
790-101-4300
Cylinder
790-101-1102
Pump
790-101-4200
Puller
791-680-5542
Adapter
791-632-1110
Adapter
791-680-5580
Guide
Sketch
Qty
Symbol
New/remodel
Component
SEN01062-04
Necessity
1,471 kN
{150 ton}
1,471 kN
{150 ton}
Removal, press fitting of

master pin and regular pin
1,471 kN
{150 ton}
294 kN
{30 ton}
Disassembly,
field
Frame
791-685-9520
Frame
791-685-9530
Rod
791-685-9540
Rod
791-685-9550
Nut
791-685-9560
Bolt
791-126-0150
Adapter
01010-51030
Bolt
791-685-9620
Extension
791-680-5542
Adapter
791-680-5560
Guide
790-101-1102
Pump
790-101-4300
Cylinder
791-685-9510
Frame
791-685-9520
Frame
791-685-9530
Rod
791-685-9540
Rod
791-685-9550
Nut
791-685-9560
Bolt
Adapter
Bolt
791-685-9620
Extension
791-680-5560
Guide
791-632-1110
Adapter
791-680-9630
Adapter
790-101-1102
Pump
790-101-4300
Cylinder
Guide
791-126-0150
10 01010-51030
11 791-680-1520
12
10
Part Name
791-685-9510
Frame
791-685-9520
Frame
791-685-9530
Rod
791-685-9540
Rod
791-685-9550
Nut
791-685-9560
Bolt
791-126-0150
Adapter
791-680-5560
Guide
791-680-9570
Adapter
01010-51030
Bolt
791-680-1520
Guide
790-101-1102
Pump
790-101-4300
Cylinder
Sketch
791-685-9510
Part No.
New/remodel
Symbol
Qty
Component
Necessity
SEN01062-04
1,471 kN
{150 ton}

1,471 kN
{150 ton}
1,471 kN
{150 ton}
PC600-8
Qty
790-101-1102
Pump
790-101-4200
Puller
791-680-9501
Remover, installer
790-101-1102
Pump
14 790-101-4200
Puller
294 kN
{30 ton}
790-101-4300
Cylinder
1,471 kN
{150 ton}
796-660-2010
Oil stopper
Stopping hydraulic oil
790-101-2501
Push-puller
790-101-2510
Block
790-101-2520
Screw
791-112-1180
Nut
790-101-2540
Washer
790-101-2630
Leg
790-101-2570
Plate
790-101-2560
Nut
790-101-2660
Adapter
796T-416-1040
Push tool
Symbol
13
Disassembly,
field
Removal, installation of engine, PTO,

hydraulic pumps, etc
Disassembly,
assembly of center
swivel joint assembly
1
T
Disassembly and
assembly of travel
PPC valve assembly
294 kN
{30 ton}
Disconnection of rotor and shaft
796T-416-1050
Push tool
Q Press fitting of bushing
796T-416-1020
Push tool
790-502-1003
Cylinder repair
stand
Disassembly, assembly of
hydraulic cylinder
Expansion of piston ring
4
U
PC600-8
Part Name
Disassembly,
assembly of
hydraulic cylinder
assembly
Part No.
Sketch
Necessity
Component
SEN01062-04
New/remodel
790-720-1000
Expander
796-720-1670
Ring
07281-01279
Clamp
790-201-1702
Push tool kit
790-101-5021
Grip
01010-50816
Bolt
Installation of piston ring

Press fitting of
cylinder head bushing
790-201-1871
Push tool
Boom
790-445-4210
Push tool
Bucket
790-201-1881
Push tool
Arm
790-201-1500
Push tool kit
790-101-5021
Grip
01010-50816
Bolt
790-201-1680
Plate
790-201-1970
Plate
Bucket
790-201-1690
Plate
Arm
790-102-4300
Wrench
790-102-4310
Pin
Press fitting of dust seal
Removal, installation of piston
11
Operators cab
glass
12
796T-670-1210
Sleeve
Q Boom foot pin
796T-670-1220
Sleeve
Q Boom top pin
791-775-1130
Plate
796-670-1130
Screw
796-870-1110
Adapter
01643-33080
Washer
01803-13034
Nut
790-101-4000
Puller
(490 kN {50 ton})
790-101-1102
Pump
793-498-1210
Lifter (Suction cup) t
20Y-54-13180
Adapter
Symbol
Part No.
Part Name
Sketch
Qty
Removal of boom,
arm assembly
Necessity
Component
New/remodel
SEN01062-04
Removal of pin
Installation of operators cab

glass
PC600-8

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

2009 KOMATSU
All Rights Reserved
20
SEN01063-02
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of cylinder head assembly ...................................................................................... 8
Removal and installation of fuel injector assembly ....................................................................................... 24
Removal and installation of engine front seal ............................................................................................... 27
Removal and installation of engine rear seal ................................................................................................ 31
PC600-8
SEN01063-02
Remove frame (5).
6.
Disconnect connector M34 (6) from air conditioner compressor (7).

Loosen locknut (8) and disconnect air conditioner compressor (7).
[*1]
a Do not disconnect air conditioner hoses.
7.
Remove air conditioner compressor belt (9).
8.
Disconnect clamp (10).
9.
Remove bracket (11).
Part number
795-630-5500
A 1 01010-81090
01643-31032
Part name
Standard puller
t 1
Bolt
t 2
Washer
t 2
N/R
5.
Sketch
Special tools
Qty
Disconnect hose clamps (4).

a Disconnect the clamp of hose (H), too.
Necessity
4.
Symbol
Removal and installation of fuel

supply pump assembly
1
Removal
k
k
Lower the work equipment to the ground

and stop the engine.
Disconnect the cable from the negative ()
terminal of the battery.
1.
Remove the counterweight assembly. For

details, see Removal and installation of counterweight assembly.
2.
Remove the fan, fan motor and shroud assembly (1). For details, see Removal and installation of fan motor assembly.
10. Remove blow-by hose (12).
3.
Remove covers (2) and (3).
PC600-8
SEN01063-02
11. Remove the undercover of part (A).
18. Disconnect wiring harness clamp (19).

19. Disconnect connectors PCV1 (21), PCV2 (20),
and G (22).
12. Disconnect fuel hose (13).
[*2]
13. Disconnect filter (14).

14. Remove fuel tube (15).
20. Disconnect lubrication tube (23).
[*6]
[*7]
[*3]
15. Remove oil gauge (16).

[*4]
22. Remove lubrication tube and fuel tube assembly (25).

a (25-1): Lubrication tube, (25-2): Fuel tube
[*8]
23. Remove fuel tube assembly (26).
[*9]
24. Remove bracket (27).

25. Remove clamps (28).
26. Disconnect clamp (29).
17. Remove lubrication tube (18).
PC600-8
[*5]
28. Remove 4 covers (31).

a Remove 2 covers each from the fuel supply pump side and common rail side.
SEN01063-02
29. Remove high-pressure pipe assembly (32).
32. Check that bolt hole (H) is set to the tap hole of
the fuel supply pump drive gear.
a If the bolt hole is not set accurately, bar
the engine one more turn (The bolt hole is
set when the key is on the upper side).
33. Remove nut (34).
[*10]
a The washer and nut are set as one unit.
Take care not to drop the nut.
34. Install tool A1.
35. Tighten bolt (B) to pull out the gear.
a Keep tool A1 installed until the gear is
installed again.
30. Remove cover (33).

31. By barring the engine with bolt (BB), set stamp
(A) of the damper to pointer (P).
a At this time, the stamp of 25 TOP is
almost at the top.
PC600-8
36. Disconnect bracket (35).

37. Remove fuel supply pump (36).
SEN01063-02
Installation
k
k
k
1.
PC600-8
The clamp used for fixing a high-pressure

pipe must be a genuine Komatsu part and it
must be tightened to the specified torque.
Never bend a high-pressure pipe for the
convenience sake.
Before installing a high-pressure pipe, confirm the following points.
If any abnormality was found, replace it
with another healthy one. Otherwise, leakage of fuel can result.
q
Check that the taper seal portion of the
connection ((a) portion: areas 2 mm inside
the tip) is free from visually recognizable
striations (b) or patchy dents (c).
q
Check that nails are not caught by steps in
portion (d) (2 mm inside the tip) (this portion is free from deformation).
While setting key (K) of fuel supply pump (36)

to key way (G) of the gear, install fuel supply
pump (36).
2 Mounting bolt: Adhesive (LT-2)
SEN01063-02
2.
Tighten all of supply pump (36), bracket (35),

and high-pressure pipes (32) temporarily with
the fingers.
3.
Tighten high-pressure pipes (32) permanently.

3 Sleeve nut:
39.2 58.8 Nm {4 6 kgm}
(Common rail side)
39.2 49 Nm {4 5 kgm}
(Supply pump side)
4.
Tighten supply pump (36) permanently.
5.
Tighten bracket (35) permanently.
Carry out the following installation in the

reverse order to removal.
[*1]
Adjust the air conditioner compressor belt tension.
For details, see Testing and adjusting, Testing and
adjusting air conditioner compressor belt tension.
[*2]
Sleeve nut of fuel hose (13):

43 47 Nm {4.4 4.8 kgm}
[*3]
Joint bolt of fuel tube (15):

14.8 19.6 Nm {1.5 2.0 kgm}
(Supply pump side)
24.5 34.3 Nm {2.5 3.5 kgm}
(Filter side)
[*4]
6.
Install cover (31).

a Direct the slit on the fuel supply pump side
toward the cylinder block and direct that
on the common rail side down.
7.
Install bracket (27).
8.
Tighten the brackets and upper and lower

clamps of high-pressure pipe clamps (28),
(29), and (30) temporarily with the fingers and
then tighten them permanently in order.
3 Clamping bolt:
9.8 1 Nm {1.0 0.1 kgm}
Sleeve nut of fuel tube (17):

43 47 Nm {4.4 4.8 kgm}
[*5]
Joint bolt of lubrication tube (18):

9.8 12.7 Nm {1.0 1.3 kgm}
[*6]
Lubrication tube (23):

43 47 Nm {4.4 4.8 kgm}
[*7]
Joint bolt of fuel hose (24):

14.8 19.6 Nm {1.5 2.0 kgm}
PC600-8
SEN01063-02
[*8]
3
3
3
Clamp of fuel tube and lubrication tube

assembly (25): 9.8 1 Nm {1.0 0.1 kgm}
Joint bolt of lubrication tube (25-1):
7.9 12.7 Nm {0.8 1.3 kgm}
Joint bolt of fuel tube (25-2):
14.8 19.6 Nm {1.5 2.0 kgm}
(Supply pump side)
17.7 22.6 Nm {1.8 2.3 kgm}
(Common rail side)
[*9]
Joint bolt of fuel tube (26):

14.8 19.6 Nm {1.5 2.0 kgm}
(Supply pump side)
43 47 Nm {4.4 4.8 kgm}
(Sleeve nut side)
[*10]
Mounting nut of fuel supply pump drive gear:

176 196 Nm {18 20 kgm}
Check that the fuel injector wiring harness

is at least 10 mm apart from the high-pressure pipe.
Bleed air from the fuel system. For details, see
Testing and adjusting, Bleeding air from fuel
system.
PC600-8
SEN01063-02
Removal and installation of

cylinder head assembly
5.
Remove radiator undercover (4).
6.
Drain the coolant.
Wrench (Angle)
N/R
790-331-1110
Sketch
A2
Part name
Qty
Part number
Necessity
Symbol
Special tools
q 1
Removal
k
k
1.

2.
Sling engine hood (1) temporarily.
3.
Remove pin (2).
4.
Fix bolt (B) to hole (A) of bar (3) and erect

engine hood (1) upright.
Coolant: 58 l
7.
Remove undercover (A).
8.
Remove 3 covers (5).
PC600-8
9.
Disconnect filter bracket (6).

a Disconnect the fuel hose clamp (HC).
10. Disconnect reservoir tank hoses (7).
SEN01063-02
12. Remove covers (9) and (10).
13. Disconnect clamps (11) and (12).

14. Remove stay (13).
11. Lift off frame (8).

PC600-8
SEN01063-02
16. Remove air hose, tube and bracket assembly

(15).
[*1]
a Make a mark on the tube at the end of
each hose to indicate the insertion position of the hose. (See the figure below.)
[*3]
21. Remove filter assembly (20).

[*4]
23. Remove oil level gauge (22).

17. Loosen air hose clamps (16).
[*2]
24. Remove fuel tube assembly (23).
[*5]
25. Disconnect wiring harness (24).

19. Lift off muffler (18).

a Remove the hose clamp from the bottom.
10
PC600-8

a
Disconnect the following parts from around

cover (25).
SEN01063-02
32. Disconnect oil tubes (26).

33. Remove oil filter (27).
27. Disconnect connector SBP (71).

28. Disconnect connectors BP (72), EGR (73), and
SEGR (74).
30. Disconnect wiring harnesses (76).
31. Disconnect connector PEVA (77).
a Connector PEVA is abolished after engine
serial number 530885.
34. Disconnect oil filler clamp (28).

Exhaust side
37. Remove covers (78) (80).
PC600-8
11
SEN01063-02
44. Remove brackets (34).

[*8]
a Disconnect lubrication tube (35) from the
clamp and cylinder block side and take it
out after removing the exhaust manifold.

41. Remove brackets (85) (87).
42. Disconnect bypass tube (88).
[*7]
46. Remove the tube (36-1) between EGR cooler

from part (B).
[*9]

48. Remove lubrication tube (37).
49. Disconnect the turbocharger from plate (38).
12
PC600-8
SEN01063-02
50. Sling the turbocharger, exhaust manifold and

connector assembly (39) temporarily and
remove the exhaust manifold mounting bolts.
[*10]
59. Lift off pump and diffuser assembly (46).

a Take care of exposed bleeding tube (C).
51. Disconnect hose (H).

52. Lift off the turbocharger, exhaust manifold and
connector assembly (39).
4
Turbocharger, exhaust manifold and

connector assembly: 70 kg

61. Remove fuel return tube (48).
[*13]
62. Remove fuel return tube (49).
[*13]
63. Disconnect connector TIM (50), TFUEL (51).
53. Disconnect heater terminal (40).

54. Loosen clamps (41).
[*11]
64. Disconnect connector PIM (52) by the following method.

[*14]
1) Rotate housing (H1) in the direction of the
arrow.
2) Pull housing (H1) in the direction of the
arrow.
55. Disconnect air intake connector (42).

65. Disconnect high-pressure pipe clamps (53).
56. Remove corrosion resistor assembly (43). [*12]
57. Remove blow-by tube and hose assembly
(44).
58. Remove bracket assembly (45).
a White portion (W) is sealing tape applied
to cover the hole.
PC600-8
13
SEN01063-02
69. Lubrication tubes (59) and (60).
[*16]
70. Remove bypass valve (61).
[*16]
71. Disconnect lubrication tubes (62) and (63).

[*17]
72. Remove EGR valve (64).
[*18]
73. Remove tube (89) first and then remove air

housing assembly (58).
a Tube (89) is abolished after serial number
530885.

[*15]
14
PC600-8
SEN01063-02
75. Disconnect high-pressure pipe clamps (67)

and (68).
a There are clamps on the right side, too.
80. Remove clamp (95).
76. Sling air intake manifold assembly (69) and

remove the mounting bolts.

77. Lift off air intake manifold assembly (69).
4
Air intake manifold assembly: 40 kg
84. Remove clamps (99) and (100).

85. Remove 6 high-pressure pipes (101).
86. Disconnect connector (102).
a Disconnect connector (102) according to
the following procedure; Insert flat-head
screwdriver [3] in shoulder (a). While
pressing stopper (b), move the screwdriver in direction (X), and connector (c) is
disconnected.
(d): Fuel injector wiring side
78. Disconnect air bent tube (93).

79. Remove air bent tube (94).
PC600-8
[*19]
15
SEN01063-02
93. Remove push rod (109).
88. Remove spill tube (104).

89. Remove cylinder head cover (105).
94. Remove capture nut (111) from fuel injector

(110) and disconnect the wiring harness.
90. By barring the engine with bolt (BB), set stamp

of 16 TOP of the damper to pointer (P).
96. Remove holder mounting bolt (113).

97. Insert small L-bar [2] under connector (CN) of
fuel injector (110) and pry off fuel injector (110)
slowly.
a Never hold and pull out the solenoid valve
on the top of fuel injector (110) with pliers,
etc.
91. Loosen locknut (106) and then loosen adjustment screw (107) fully.
92. Remove rocker arm shaft assembly (108).
16
PC600-8
98. Loosen locknut (114) and adjustment screw

(115).
SEN01063-02
Installation
a
99. Remove crosshead assembly (116).

100.Remove mounting bolts (117) and auxiliary
bolt.
Before installing the cylinder head, check the

following items.
1) Measure stem length (e) of every bolt.
2) Make sure that stem length (e) of every
bolt is as follows.
q
Short bolt: Less than 170.8 mm
q
Long bolt: Less than 205.8 mm
3) If a mounting bolt is longer than the above
using limit or it has been tightened 5 times
(there are 5 punch marks on it), do not
reuse it but replace it.
101.Remove cylinder head assembly (118).

4
Cylinder head assembly: 25 kg
102.Remove cylinder head gasket (119).

4)
5)
PC600-8
Check that the cylinder head mounting

face and inside of the cylinder are free
from foreign matter.
When fitting the gasket, check that the
grommets are fitted correctly.
1.
Set cylinder head gasket (119).
2.
Install cylinder head (118).
17
SEN01063-02
Tighten cylinder head mounting bolts (1)

(6) and auxiliary bolt (7) in the following
order.
a A special socket is required to tighten the
head bolts.
2 Mounting bolt:
Molybdenum disulfide lubricant
(LM-P)
3 Mounting bolts ((1) (6) in the following
figure):
a Tighten in the order of (1) (6).
1st time: 137 157 Nm {14 16 kgm}
2nd time: 284 294 Nm {29.0 30.0 kgm}
3rd time:
1] When using tool A2
Retighten each bolt by 90 +30
in the
+0
order of (1) (6).
2]
3.
18
When not using tool A2

Make marks (a) and (b) on the bolts
and cylinder head, then retighten
each bolt by 90 +30
in the order of (1)
+0
(6).
a After tightening bolts (1) (6),
tighten auxiliary bolt (7).
3 Auxiliary bolt (7)
66.6 7.4 Nm {6.8 0.8 kgm}
Crosshead
Install crosshead (116).
a Adjust the crosshead according to the following procedure.
1] Loosen locknut (114) and return
adjustment screw (115).
2] Holding the top of the crosshead
lightly, tighten adjustment screw
(115).
3] After adjustment screw (115) touches
the valve stem, tighten it further by
20.
4] Tighten locknut (114) at this position.
3 Locknut:
58.7 5.9 Nm {6.0 0.6 kgm}
PC600-8
4.
Fuel injector
a Check that the inside of the injector sleeve
is free from dirt.
1] Install gasket (120) and O-rings (121)
to fuel injector (110).
2 O-ring: Engine oil (EO30-DH)
2] Install holder (122) in fuel injector
(110), then insert the injector connector in the high-pressure pipe insertion
hole.
3] Fit ball washer (123) to bolt (113) and
tighten holder (122) temporarily.
2 Ball washer:
Engine oil (EO30-DH)
a Tighten holder (122) permanently
after installing the wiring harness
and connector and tightening the
high-pressure pipe temporarily.
4]
5]
PC600-8
Install wiring harness terminal right

and left (111) to fuel injector (110) with
the nuts.
3 Terminal nut:
1.8 2.2 Nm {0.18 0.22 kgm}
Install spring clamp (124) and wiring
harness holder clamp (112).
a Slack off the wiring harness and
press it against the injector.
SEN01063-02
5.
Push rod
Install push rods (109).
a Check that the point of push rod is in the
cam follower socket area.
6.
Install connector (102).

a Install the connector before installing the
high-pressure pipe.
7.
High-pressure pipe
The clamp used for fixing a high-pressure
pipe must be a genuine Komatsu part and it
must be tightened to the specified torque.
Never bend a high-pressure pipe for the
convenience sake.
Before installing a high-pressure pipe, confirm the following points.
If any abnormality was found, replace it
with another healthy one. Otherwise, leakage of fuel can result.
q
Check that the taper seal portion of the
connection ((a) portion: areas 2 mm inside
the tip) is free from visually recognizable
striations (b) or patchy dents (c).
q
Check that nails are not caught by steps in
portion (d) (2 mm inside the tip) (this portion is free from deformation).
k
k
19
SEN01063-02
1)
2)
3)
4)
20
Put sleeve nut (126) of high-pressure pipe

(101) in the fuel high-pressure pipe insertion part and tighten it temporarily.
a Check that the O-rings are fitted to
both of the injector and sleeve nut.
Rotate sleeve nut (127) by 2 turns with the
fingers on the threads of the injector, and
then tighten sleeve nut (127) with a spanner (do not tighten it permanently at this
time).
a If sleeve nut (127) does not catch the
threads of the injector, press its end
with another small spanner etc. and
rotate its hexagonal part with the
spanner.
a After tightening sleeve nut (127),
check that the O-ring is not projected
from the end of the sleeve nut (127).
Tighten mounting bolts (113) of holder
(122) permanently.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
Tighten sleeve nut (127) of high-pressure
pipes (101).
a Tighten the common rail side, too.
a Control the tightening torque with
torque wrench [1] of spanner type.
3 Sleeve nut:
39.2 49 Nm {4 5 kgm}
8.
Install rocker arm and shaft assembly (108).

a Before tightening the mounting bolt, check
that the ball of adjustment screw (107) is
fitted to the socket of the push rod (109)
securely.
3 Mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a Adjust the valve clearance.
For details, see Adjusting valve clearance in Testing and adjusting.
3 Locknut (106):
53 64.7 Nm {5.4 6.6 kgm}
a After tightening the locknut, check the
valve clearance again.
PC600-8
9.
Install cylinder head cover (105).

29.4 34.3 Nm {3.0 3.5 kgm}
10. Install covers (98) to the sleeve nut of highpressure pipes (101).
a Direct the slit as follows.
Cylinder head side: Direct the slit down.
Common rail side: Direct the slit toward
the cylinder block.
SEN01063-02
15. Install the air intake manifold.

a Before installing the air intake manifold,
insert 3 bolts (B).
a Tighten the mounting bolts of air intake
manifold assembly in the order of [1] [24]
shown below.
3 Air intake manifold assembly mounting
bolt: 59 74 Nm {6 7.5 kgm}
11. Install fuel spill tube (104).

3 Fuel spill tube joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
12. Install wiring harness (103).
13. Install upper and lower clamps (126) and (99)
of the high-pressure pipe temporarily. At this
time, tighten the stay and upper and lower
clamps with the fingers.
a Tighten the clamps permanently after
installing the air intake manifold.
14. Insert lubrication tube (129) of turbocharger

(TC).
a The lubrication tube cannot be inserted
after the air intake manifold is installed.
PC600-8
21
SEN01063-02
16. High-pressure pipe clamp

1) Tighten high-pressure pipe clamps (126)
above the air intake manifold (described
above) and stay (127) permanently.
a Bend the rubber in advance.
3 Clamping bolt:
9.8 1 Nm {1 0.1 kgm}
2) Tighten stays (128) of clamps (99) under
the air intake manifold (described above)
temporarily.
3) Install high-pressure pipe clamp (100) and
bracket (96) temporarily with the fingers.
4) Install high-pressure pipe clamp (95) and
bracket (97) temporarily.
and (95) permanently first.
3 Clamping bolt:
9.8 1 Nm {1 0.1 kgm}
6) Tighten brackets (96) and (97) permanently.
permanently.
3 Clamping bolt:
9.8 1 Nm {1 0.1 kgm}
8) Tighten stays (128) permanently.

[*1]
Air hose clamp (Right and left):

8.8 0.5 Nm {0.9 0.05 kgm}
[*2]
MIKALOR clamp
a Use a new MIKALOR clamp.
1) Set the hose to the original position. (Insertion
depth of air hose: 80 mm)
2) Set bridge (BR) under the clamp bolt and
adjust its overlap (b) with bridge (BR) and band
to at least 5 mm.
3) Tightening of the clamp.
2 Threads of clamp bolt (BC):
Lubricating oil (THREEBOND PANDO 18B)
a Do not use an impact wrench.
q
When reusing the hose.
Install the clamp to the clamp mark made
on the hose.
3 Clamp bolt: Min. 6 Nm {0.6 kgm}
q
When using a new hose.
Tighten until dimension (a) is 5 8 mm.
[*3]
Tightening torque for fuel hose (19):

43 47 Nm {4.4 4.8 kgm}
[*4]
Tightening torque for fuel tube (21):

43 47 Nm {4.4 4.8 kgm} (Upper side)
14.8 19.6 Nm {1.5 2.0 kgm} (Lower side)
[*5]
Tightening torque for fuel tube assembly

(23):
24.5 34.3 Nm {2.5 3.5 kgm} (Filter side)
14.8 19.6 Nm {1.5 2.0 kgm} (Lower side)
[*7]
22
Mounting bolt of bypass tube (88):

44.1 53.9 Nm {4.5 5.5 kgm}
PC600-8
[*8]
Joint bolt of turbocharger lubrication tube

(35):
24.5 34.3 Nm {2.5 3.5 kgm}
[*9]
SEN01063-02
[*14]
1) Set the connector groove in position and insert
to the end.
2) Rotate housing (H1) in the direction of the
arrow until it clicks.
Mounting bolt of EGR cooler tube:

44.1 53.9 Nm {4.5 5.5 kgm}
[*10]
Exhaust manifold, turbocharger and connector
assembly
1) Apply heat-resistant sealant to the fitting parts
of the exhaust manifold (between ports No. 2
and No. 3 and between ports No. 4 and No. 5).
2 Fitting parts:
Heat-resistant sealant (HOLTS MH705)
2) Fit the gasket and sling and install exhaust
manifold (1).
3) Tighten the mounting bolts in the following
order.
a Tighten the 3 bolts of (1) (3) shown
below temporarily in the numeric order
and then tighten other bolts (4) (24) temporarily in the numeric order. Then, tighten
all bolts (1) (24) to the specified torque
in the numeric order.
2 Mounting bolt:
Seizure prevention compound (LC-G)
(NEVER-SEEZ (Bostik, Inc.) or equivalent)
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
[*15]
Joint bolt of lubrication tube (56):

34.3 44.1 Nm {3.5 4.5 kgm}
[*16] [*18]
3 Joint bolts of lubrication tubes (60) and (63):
24.5 34.3 Nm {2.5 3.5 kgm}
3 Mounting bolts of EGR valve (64) and
bypass valve (61): 59 74 Nm {6 7.5 kgm}
[*19]
Joint bolt of air vent tube (94):

9.8 12.7 Nm {1.0 1.3 kgm}
Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5
[*11]
See MIKALOR clamp [*2].
[*12]
Coolant: 58 l
Bleed air from the fuel system. For details, see

Testing and adjusting, Bleeding air from fuel
system.
Before starting the engine, check that the
wiring harnesses are at least 10 mm apart
from the high-pressure pipe.
Corrosion resistor joint bolt:

24.5 34.3 Nm {2.5 3.5 kgm}
[*13]
Fuel return tube joint bolts (48) and (49):

9.8 12.7 Nm {1.0 1.3 kgm}
PC600-8
23
SEN01063-02

injector assembly
1
5.
Remove covers (4).

a Remove the common rail side, too.
Removal
6.
Remove the clamp and high-pressure pipes

(5).
7.
Disconnect connector (6) of the injector wiring.

a Insert flat-head screwdriver [3] in shoulder
(a). While pressing stopper (b), move the
screwdriver in direction (X), and connector
(c) is disconnected.
(d): Fuel injector wiring side
8.
Remove cylinder head covers (7).
9.
By barring the engine with bolt (BB), set stamp

16TOP of the damper to pointer (P).
1.
2.

(The counterweight must be removed to bar
the engine.)
Remove the air intake manifold assembly (1).
For details, see Removal and installation of
cylinder head assembly.
3.
Remove clamp (2).
4.
Remove brackets (3).
24
PC600-8
10. Remove the mounting bolts and rocker arm

assembly (8).
a Loosen locknut (9), and then loosen
adjustment screw (10) by 2 3 turns so
that an excessive force will not be applied
to the push rod when the rocker arm
assembly is installed.
SEN01063-02
12. Remove holder mounting bolt (19) of fuel injector assembly (11) and then remove fuel injector
assembly (11).
a Insert small L-shaped bar [2] under the
connection of the fuel injector and pry off
the injector slowly.
a Do not grip the solenoid valve on the fuel
injector with pliers etc. to remove.
11. Disconnect the injector wiring harness according to the following procedure.
1) Remove 2 nuts (12) of the upper solenoid
valve of fuel injector (11).
2) Pull out spring clamp (13).
3) Disconnect clamp (14).
a Remove the injector wiring harness
1] Remove 1 mounting bolt (hexagon
socket head bolt) (17) of holder (16)
of connector (having an O-ring) (15).
2] Remove holder (16) and push in connector (15) to remove.
[*1]
PC600-8
25
SEN01063-02
Installation
1.
Referring to installation step 4 and after in

Removal and installation of cylinder head
assembly, install the removed parts up to the
air intake manifold.

When installing the parts, observe the precautions described in Removal and installation of
cylinder head assembly.
[*1]
Procedure for installing fuel injector wiring
harness assembly
a It is difficult to install the connector having
the O-ring from inside.
1) Remove O-ring (23) and take wiring harness connector (22) out of the connector
insertion opening.
2) Fit O-ring (23) and apply engine oil
(SAE30) to its outside.
3) Install connector holder (24) and push it
in.
4) Fix connector holder (24) with mounting
bolt (17).
26
PC600-8
SEN01063-02
3)

engine front seal
3 795-931-1100
Seal puller
795T-521-1111 Push tool

A
Sketch
t 1
Bolt
t 3
01050-31635
Bolt
t 3
795T-521-1150 Push tool
t 1 N Q
01050-31635
t 3
Bolt
a
a
a
t 1 N Q
4 01050-31655
N/R
Part name
Qty
Part number
Necessity
Symbol
Special tools
Insert the top end of tool A3 into the

drilled hole, and remove the front seal
by the impact of slide hammer (SH).
(Apply the slide hammer evenly not to
tilt the front seal.)
Remove the metal powders completely.
When the sleeve is attached, cut sleeve
(6) using a gad and hammer to remove it.
Take care not to damage crankshaft (5).
Removal
1.
Remove the fan and fan shroud assembly. For

details, see "Removal and installation of fan
motor assembly".
2.
Remove inside 6 mounting bolts (1) and pulley

and damper assembly (2).
a Since there are stamps on damper (2),
make a match mark (M) on it and the front
cover.
3.
Remove front seal (3) from housing (4) according to the following procedure.
a Take care in the removal not to damage
front seal (3) installation position on housing (4) and the seal contact face on crankshaft (5).
a Before removing, slightly drive the front
seal in once to free it from fixation.
a When front seal (3) is fixed too hard to the
housing (4), carry out the following procedure.
1) Drill through a hole of approx. 3 mm
dia. on front seal (3).
2) Replace the tip of tool A3 with the drill
type one.
PC600-8
27
SEN01063-02
Installation
a
a
a
a
a
Check the seal by checking the wear of the

shaft and replace it with the "standard seal" or
"sleeved seal".
If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
than 10 mm) and does not have any flaw, install
"standard seal A". In other cases, install
"sleeved seal B".
(7): Plastic inside cylinder which is also used
as installation guide.
(6): Sleeve.
Do not remove installation guide (7) from front
seal (3) before installing the front seal.
Handle front seal (3) and sleeve (6) as an
assembly and never separate them from each
other.
Standard spare seal
Sleeved seal
2)
1.
28
Procedure for installing standard seal

a Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and
rust of the housing.
a When installing the seal, do not apply oil
or grease to the shaft and seal lip. Wipe
off the oil from the shaft.
a Never remove inside plastic cylinder (7) of
the replacement seal before installing the
seal.
1) Set large inside diameter side (b) of plastic inside cylinder (7) to the end of crankshaft (5).
a Take care not to mistake the direction
of the plastic inside cylinder.
3)
Push the metal ring of front seal (3)

evenly as if you are passing over the
large inside diameter side of plastic inside
cylinder (7).
a Hit the metal ring of front seal with
plastic hammer evenly.
a Do not hit it strongly.
After pushing in the seal, remove plastic
inside cylinder (7).
a When removing the inside cylinder,
take care not to damage the seal lip.
PC600-8
4)
Using tool A4, tighten the 3 bolts evenly to

press fit seal (3) until the end of tool A4
reaches the end of crankshaft (5).
a Tighten tool A4 first until the 55-mm
bolts stop and then replace the 55mm bolts with the 35-mm bolts and
tighten them.
a Seal driving distance (a) from crankshaft: 9.1 10.1 mm
a When press fitting the seal, take care
not to damage the lip of the seal with
the tool set etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
SEN01063-02
2)
Set the sleeve of the front seal to the end

of crankshaft (5) and tighten the 3 bolts
evenly to press fit sleeve and front seal
assembly (9) until the end of tool A5
a Tighten tool A5 (for press fitting the
sleeved seal) until the 35-mm bolt
stops.
3)
Remove tool A5 (for press fitting the

sleeved seal) and install tool A4 (for press
fitting the seal).
Tighten the 35-mm bolts of tool A4 evenly
to press fit seal and sleeve assembly (9)
until the end of tool A4 reaches the end of
crankshaft (5).
a Seal driving distance (a) from crankshaft: 9.1 10.1 mm
not to damage the lip of the seal with
the tool set etc.
4)
2.
Procedure for installing sleeved seal

a When installing the front seal, do not apply
oil or grease to the shaft, inside cylinder
surface of sleeve (6) and seal lip.
1) Set sleeve (6) and front seal (3) assembly
to tool A5 (for fitting the sleeved seal).
2 Sleeve (6) inside cylinder surface:
Gasket sealant (LG-7)
PC600-8
29
SEN01063-02
3.
30
While setting match mark (M), install pulley

and damper assembly (2) and tighten the
mounting bolt (1).
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
PC600-8
SEN01063-02
5.

engine rear seal
3 795-931-1100
Seal puller
795T-421-1270 Push tool

6 01050-31645
01643-31645
A
7 01050-31645
01643-31645
01643-31645
t 1
t 4
Washer
t 8
t 1
Bolt
t 4
Washer
t 4
795T-421-1250 Push tool

8 01050-31645
Sketch
t 1
Bolt
795T-421-1240 Push tool
N/R
Part name
Qty
Part number
Necessity
Symbol
Special tools
Remove rear seal (2) according to the following procedure.

a Measure the distance from the end of the
housing.
1) Before pulling out rear seal (2), drive in it a
little to separate it from the flywheel housing (FWH).
t 1
Bolt
t 4
Washer
t 8
2)
Removal
1.
Remove the PTO assembly and hub assembly.

For details, see "Removal and installation of
PTO assembly".
2.
Remove 1 mounting bolt of flywheel (1) and

install guide bolt.
3.
Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (1) temporarily and remove the 8 mounting bolts.
4.
3)
If the seal is sleeved, cut and remove

sleeve (5) with a chisel and a hammer.
a When cutting, take care extremely not
to damage crankshaft (4).
Hitch the end of tool A3 to the metal ring
of rear seal (2) and pull out the seal with
impacts of slide hammer (SH).
a Do not use a drill etc. since chips may
enter the engine.
a If chips were made, remove all of
them.
Tool A3
Move flywheel (1) toward this side and lift it off.

k Since the socket part of the flywheel is
shallow, it may fall suddenly. Take care
not to catch your fingers in the flywheel.
4
PC600-8
Flywheel: 65 kg
31
SEN01063-02
a
Left: Standard seal, Right: Sleeved seal
Installation
a
Check the Teflon seal (Laydown lip seal) by

checking the wear of the crankshaft and
replace it with the "standard seal" or "sleeved
seal".
If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
than 10 mm) and does not have any flaw, install
standard seal (A). In other cases, install
sleeved seal (B).
a (3): Plastic inside cylinder which is also
used as installation guide.
a (5): Sleeve.
a Do not remove installation guide (3) from
rear seal (2) before installing the rear seal.
a Handle rear seal (2) and sleeve (5) as an
assembly and never separate them from
each other.
q Standard
a
a
a
32
spare seal
q Sleeved
seal
Clean, degrease, and dry the seal surface

on the flywheel housing side.
Clean, degrease, and dry the seal lip surface (periphery of the crankshaft).
Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and
rust of the housing.
PC600-8
1.
SEN01063-02
4)
Procedure for installing standard seal

a When installing rear seal (2), do not apply
oil or grease to the shaft and seal lip.
1) Set large inside diameter side (b) of plastic inside cylinder (3) of rear seal (2) to the
end of crankshaft (4).
a Take care not to mistake the direction
of the plastic inside cylinder.
2)
3)
PC600-8
Hold the metal ring of rear oil seal (2) with

both hands and push it in evenly.
After pushing in the seal, remove plastic
inside cylinder (3).
a When removing the inside cylinder,
take care not to damage the seal lip.
2.
Tighten the 3 bolts evenly to press fit rear

seal (2) until the end of tool A6 (for press
fitting the seal) reaches the end of crankshaft (4).
seal) first until it reaches the bolt (45
mm) and then tighten the bolt (25
mm).
not to damage the lip on the PTO side
with the tool set etc.
Procedure for installing sleeved seal

a When installing the rear seal, do not apply
oil or grease to the shaft and sleeve inside
cylinder surface (C).
1) Set sleeve and rear seal assembly (6) to
tool A7 (for press fitting the sleeved seal).
2 Sleeve inside cylinder surface (C):
33
SEN01063-02
2)
Set sleeve of the rear seal to the end of

crankshaft (4) and tighten the 4 bolts of
tool A7 evenly to press fit sleeve and rear
seal assembly (6).
sleeved seal) with 1 washer inserted
in each bolt until the bolts reach the
end.
3.
Flywheel
Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (1), install it to the crankshaft, and
tighten the bolts.
a If there are 5 punch marks on a bolt, do
not use that bolt but replace it.
2 Threads and seat of bolt:
Engine oil (EO30-DH)
4
3)
4)
34
Remove tool A7 (for press fitting the

sleeved seal) and install tool A8 (for press
fitting the seal).
Tighten the 4 bolts evenly to press fit
sleeve and rear seal assembly (6) until the
end of tool A8 (for press fitting the seal)
a Tighten the bolt of tool A8 (for press
fitting the seal) without washer until it
reaches, and then tighten the bolt
using 2 washers (for each bolt).
a Seal driving depth (b) from the end of
crankshaft: 13.2 0.2 mm
Flywheel: 65 kg
Tighten the mounting bolts according to the following procedure.

3 Flywheel mounting bolts
1st time: 118 4.9 Nm {12 0.5 kgm}
2nd time: 1) When using tool A2 (See the
tools list)
Retighten each bolt by 90 +30
in
+0
the order of [1] [8].
2) When not using tool A2
Make marks (f) on each bolt and
flywheel with paint, then retighten
each bolt by 90 +30
in the order
+0
of [1] [8].
PC600-8

a
After tightening, make 1 punch mark (g) on

each bolt head to indicate the number of tightening time.
After installing the flywheel, measure the facial

runout and radial runout with tool [1].
a Radial runout: Max. 0.30 mm
a Facial runout: Max. 0.30 mm

PC600-8
SEN01063-02
35
SEN01063-02

2009 KOMATSU
All Rights Reserved
36
SEN01064-02
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

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

engine, PTO and hydraulic pump
assembly
1
3.
Set engine hood (1) vertically as shown below.

1) Sling engine hood (1) temporarily.
2) Remove pin (2) and stay (3).
3) Fix hole (A) of stay (3) with bolt (B).
a Take care of the direction of stay (3).
4.
Remove undercover (4).
5.
Drain the coolant.
Oil stopper
N/R
796-660-2010
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
q 1
Removal
k
k
a
a
1.

Loosen the cap of the hydraulic tank gradually to release the internal pressure of the
hydraulic tank.
Install oil stopper plugs to the disconnected
tubes and hoses.
Before disconnecting each hose, mark it with a
tag etc. to indicate its position.
Remove the hydraulic tank strainer and stop
the oil with tool S.
a When not using tool S, remove the drain
plug and drain the oil.
6
2.
Hydraulic tank: 360 l

Coolant: 58 l
PC600-8
SEN01064-02
6.
9.
Lift off frame (8).
7.
Remove filter bracket (6).

a Disconnect the fuel hose clamp (HC).
8.
Disconnect reservoir tank hoses (7).

PC600-8
SEN01064-02
13. Remove handrail (14).

14. Disconnect hoses (15) from reservoir tank
(RT).
15. Disconnect connector P24 from under reservoir tank (RT).

20. Disconnect air hose (21).
[*1]
a Make a mark on the tube to show the position of the hose end.
21. Remove air tube and bracket assembly (22).
[*2]
22. Disconnect bracket (23).
23. Remove air tube (24).
[*3]
24. Disconnect radiator hose (25).
[*4]
25. Disconnect heater hoses (26) and (27).
17. Remove cover assembly (17).

a Lift off the cover and frame together.
PC600-8
SEN01064-02
33. Disconnect heater terminal (36).

26. Disconnect dust indicator hose (28).
34. Disconnect hose (37).
27. Remove air cleaner bands (29) and air cleaner
(30).
[*5]
28. Lift off frame, stay and bracket assembly (31).
[*7]
35. Disconnect connector M34 (38).

36. Loosen locknut (39) and disconnect air conditioner compressor (40).
[*8]
a Do not disconnect the air conditioner
hose.
37. Remove the air conditioner compressor belt.
38. Disconnect cover (41).
[*9]

30. Disconnect reservoir tank hoses (33).
31. Remove radiator hose (34).
[*6]
32. Disconnect hose clamp (35).
41. Remove undercovers (44) and (45).
PC600-8
SEN01064-02
48. Disconnect 2 hoses (57) from pump No. 1.

49. Disconnect hoses (58) (61).
51. Disconnect hoses (63) and (64) from the PTO
oil cooler.
52. Disconnect suction connector (65) from pump
No. 1.
a Do not disconnect suction hose (SH1)
from suction connector (65).
42. Disconnect lubrication hose (46) from above
the PTO.
53. Disconnect hose (66) from under the PTO.

44. Disconnect connector (49).
45. Remove 2 hoses (50) from pump No. 2.

47. Disconnect hoses (52) (56) from gear pump
(G.P.).
54. Disconnect clamps (67).

55. Disconnect hose (68) from the gear pump.
56. Disconnect suction connector (70) from the
gear pump.
a Do not disconnect suction hose (SH1)
from suction connector (70).
PC600-8
SEN01064-02
57. Disconnect suction connector (71) from pump

No. 2.
63. Disconnect starting motor terminal (84).

65. Disconnect ground wire (86).
66. Remove mounting bolts (87).
58. Disconnect fuel return hose (72).
[*11]
[*10]
59. Remove controller cover (73).

60. Disconnect connector P44 (74), ground wire
T09 (75), and connector E22 (76).
67. Lift off engine, PTO and pump assembly (88).

4
Engine, PTO and pump assembly:

2,700 kg
61. Disconnect connectors CE03 (77) and CE02

(78).
62. Disconnect clamps (79).
PC600-8
Use 2 M30 eyebolts (EB).
SEN01064-02
Installation
[*8]
Adjust the air conditioner compressor belt tension.
For details, see Testing and adjusting, Testing and
adjusting air conditioner compressor belt tension.
Carry out installation in the reverse order to

removal.
[*1], [*2]
3 Air hose clamps (right and left):
8.3 9.3 Nm {0.85 0.95 kgm}
[*3], [*7]
MIKALOR clamp
a Use a new MIKALOR clamp.
1) Set the hose to the original position.
(Insertion depth of air hose: 80 mm)
to at least 5 mm.
q
on the hose.
q
[*9]
Tightening torque for fuel hose (41):

43 47 Nm {4.4 4.8 kgm}
[*10]
Joint bolt of fuel return hose (72):

19.6 29.4 Nm {2.0 3.0 kgm}
[*11]
2
3
Engine mounting bolt: Adhesive (LT-2)

Engine mounting bolt:
824 1,030 Nm {84 105 kgm}

5
Coolant: 58 l
Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5
Hydraulic oil: 360 l
[*4]
Radiator hose clamp:

8.3 9.3 Nm {0.85 0.95 kgm}
[*5]
Air cleaner band:

17.6 21.6 Nm {1.8 2.2 kgm}
[*6]

8.3 9.3 Nm {0.85 0.95 kgm}
PC600-8

radiator assembly
SEN01064-02
4.
5.
Drain the coolant.
Removal
k
k
a
a

hydraulic tank.
tubes and hoses.
1.
2.
Remove pin (2).
3.
Fix bolt (B) to hole (A) of bar (3) and set engine
hood (1) vertically.
a Take care of the direction of bar (3).
PC600-8
Coolant: 58 l
6.
7.
Disconnect radiator hose (6).
8.
9.
Disconnect radiator hose (8).
[*1]
[*2]
SEN01064-02
11. Disconnect 2 fan hoses (11).

(These hoses must be disconnected to remove
radiator hose (13).)
a Prepare an oil receiver.
a Fit a plug.
q
Adapter size: #06 --- 2 pieces
17. Lift off radiator assembly (18) and (19).

4
Radiator assembly: 25 kg (One side)
Installation
q
[*3]
13. Remove radiator hose (13).
[*4]
14. Remove covers (14) (16).

removal.
[*1] [*4]
3 Radiator hose clamp:
8.3 9.3 Nm {0.85 0.95 kgm}
q

again.

5
Coolant: 58 l

16. Remove covers (C) (E).
10
PC600-8

hydraulic oil cooler assembly
SEN01064-02
8.
Remove lower mounting bolts (6).
9.
Disconnect tube (7) from the top of the hydraulic oil cooler.
Removal
k
k

hydraulic tank.
1.
Sling engine hood (1) temporarily and lift it off.

[*1]
2.
Open right and left covers (2).
3.
Remove plate (3).
10. Remove net (8).

11. Sling hydraulic oil cooler assembly (10) temporarily with (A).
13. Lift off hydraulic oil cooler assembly (10).
4
a
4.
5.
Drain the hydraulic oil tank.

6
AC: Air conditioner condenser,

FC: Fuel cooler
Hydraulic oil tank: 360 l
6.
Loosen drain plug (DP) and drain the hydraulic

oil cooler.
a Loosen the upper tube of the hydraulic oil
tank to let the air in.
7.
Disconnect tube (5) from the bottom of the

hydraulic oil cooler.
PC600-8
Hydraulic oil cooler assembly: 40 kg
11
SEN01064-02
Installation
q

removal.
[*1]
Precautions for installing engine hood
1. Secure clearance (FC) of at least 10 mm
between the engine hood and oil cooler frame.
2. The engine hood must not interfere with stopper (S).
3. Adjust the positions of hinge (H), bracket (B),
catcher (C), and U-bolt (UB).

again.
5
12
Hydraulic oil tank: 360 l (Refill capacity)
PC600-8

aftercooler assembly
SEN01064-02

1.
Remove engine hood (1).
2.
Remove right cover (2).
3.
Remove plate (3).
Disconnect aftercooler hose (4).

[*2]
5.
Disconnect oil cooler hoses (5) and (6).
6.
Disconnect aftercooler hose (7).

[*2]
7.
Sling aftercooler assembly (8) temporarily and

remove 6 mounting bolts (9) from the back
side.
8.
Lift off aftercooler assembly (8).
Removal
k
4.
[*1]
PC600-8
Aftercooler assembly (8): 40 kg
13
SEN01064-02
Installation
[*2]
MIKALOR clamp
a Use new MIKALOR clamps.
1) Set each hose to the original position.
(Insertion depth of air hose: 80 mm)
to at least 5 mm.
q
on the hose.
q

removal.
[*1]
Precautions for installing engine hood
1. Secure clearance (FC) of at least 10 mm
between the engine hood and oil cooler frame.
2. The engine hood must not interfere with stopper (S).
3. Adjust the positions of hinge (H), bracket (B),
catcher (C), and U-bolt (UB).
14
PC600-8
Removal and installation of fan

motor assembly
1
SEN01064-02
4.
5.
Drain the coolant.
Removal
k
k
a
a

hydraulic tank.
tubes and hoses.
1.
2.
Remove pin (2).
3.
Fix bolt (B) to hole (A) of bar (3) and set engine
hood (1) vertically.
PC600-8
Coolant: 58 l
6.
Remove the counterweight. For details, see

Removal of counterweight assembly.
7.
8.
Disconnect filter bracket (6).

a Disconnect the hose clamp (HC).
15
SEN01064-02
9.
15. Disconnect plates (13) and (14).
16. Disconnect 3 fan motor hoses (15) from the

bottom of the fan motor.
a Before disconnecting each hose, mark it
with a tag etc. to indicate its position.
a Fit a plug.
q
Adapter size: #06 --- 2 pieces
#04 --- 2 pieces
a Remove the clip, too.
10. Lift off frame assembly (8).

12. Disconnect 2 reservoir tank hoses (10).
[*1]
17. Disconnect connector A16 (16).

16
[*1]
PC600-8

21. Remove front and rear covers (20).
22. Remove cover (19-1) from the bottom of cover
(19).
SEN01064-02
25. Lift off fan and fan motor shroud assembly

(21).
4
Fan and fan motor shroud assembly:

100 kg
23. Sling fan and fan motor shroud assembly (21)

temporarily with (H).
24. Remove 5 mounting bolts (22) from the right
and left of fan and fan motor shroud assembly
(21) respectively.
26. Remove lock plate (23).
[*2]
27. Remove nut (24).

[*3]
a When removing the nut, insert a bar etc. in
part (C) to fix the fan assembly.
28. Using puller [1], remove fan assembly (25). [*4]
a When removing the fan assembly, do not
hit the motor shaft with a hammer etc.
PC600-8
17
SEN01064-02
a
Puller fixing tap (T) (4 M10 1.5 20)

made on boss (BS) can be used.
Installation
q

removal.
[*1]

8.3 9.3 Nm {0.85 0.95 kgm}
[*2]
When setting the bolt holes of the lock plate, do not
rotate the lock plate in the loosening direction. (If
bolt hole does not match, turn the lock plate clockwise to match the hole.)
[*3]
29. Disconnect connector V16 (26).

Fan mounting nut:

833 882 Nm {85 90 kgm}
After installing the nut, measure dimension (d).

(d): 1.2 3.0 mm
31. Disconnect tubes (28), (29), and (30).

a Disconnect the clamps, too.
32. Remove fan motor assembly (31).
[*4]
q
Degrease both hole and shaft.

5
18
Coolant: 58 l

again.
PC600-8

tank assembly
1
SEN01064-02
4.
Disconnect fuel supply hose (3) and return

hoses (4).
5.
Remove fuel tank mounting bolt.
6.
Lift off fuel tank assembly (5).
Removal
k
k
1.

Open the drain valve to drain the fuel.
6
2.
Remove handrail (1) and cover assembly (2).

4
3.
Fuel tank: 880 l (When full)
Cover assembly: 80 kg
Disconnect wiring connector P06 (6) from the

fuel tank.
[*1]
Fuel tank assembly: 500 kg
Installation
q
[*1]
PC600-8

removal.
3
Fuel tank mounting bolt:

319 608 Nm {32.5 62 kgm}
19
SEN01064-02

2009 KOMATSU
All Rights Reserved
20
SEN01065-03
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

Power train
Removal and installation of PTO assembly .................................................................................................... 2
Disassembly and assembly of PTO assembly ................................................................................................ 4
Removal and installation of swing motor and swing machinery assembly ..................................................... 7
Disassembly and assembly of swing machinery assembly ............................................................................ 8
Removal and installation of swing circle assembly ....................................................................................... 15
Disassembly and assembly of final drive assembly...................................................................................... 16
PC600-8
SEN01065-03
Removal and installation of PTO

assembly
1
3.
Remove partition cover (1) between the engine

and pump.

details, see "Removal and installation of counterweight assembly".
4.
Drain the PTO lubricating oil.
Lift off each hydraulic pump assembly. For

details, see "Removal and installation of
hydraulic pump assembly".
5.
6.
Disconnect lubrication hose (3).

a Disconnect lower lubrication hose, too.
7.
Using 2 M30 eyebolts, lift off PTO assembly

(6).
[*1]
Removal
k
k
a
a
1.
2.

hydraulic tank.
tubes and hoses.
Pump No. 1 assembly (No. 1): 170 kg
Cooling fan pump (Control, PTO lubrication and fan pump) assembly (G.P.):
90 kg
Lubricating oil: 6 l
PTO assembly: 210 kg
PC600-8
8. Remove shaft (7).

[*2]
Note: Do not remove coupling unit (8) from hub
assembly (9). When coupling (8) needs to
be replaced, replace it together with hub
assembly (9).
SEN01065-03
Installation
q

removal.
[*1]
PTO mounting bolt:

98 123 Nm {10 12.5 kgm}
[*2]
Hub assembly mounting bolt:

98 123 Nm {10 12.5 kgm}
Refilling with oil (PTO case)

Tighten the drain plug and add oil through the
oil filler to the specified level.
5
PTO case: 7.2 l (EO30-DH)
FWH: Flywheel housing
PC600-8
SEN01065-03
Disassembly and assembly of

PTO assembly
4.
Bearing
1) Using puller [1], remove bearings (7) from
gears (2) and (3).
Disassembly
1.
Remove all lubrication tubes (20).
2.
Case
Remove the mounting bolts and then remove
case (1) with a forcing screw.
a Check the quantity and thickness of the
inserted shims.
3.
Gear assemblies
Remove gear assemblies (2), (3), and (4).
a Using a puller, remove each gear assembly.
a When removing gears (2) and (3), remove
nipples (5) and (6) first and then use the
puller.
2)
3)
Remove snap ring (8).

Using puller [1], remove bearings (9) and
(10) from gear (4).
4)
5)
Remove snap ring (11) from case (1).

Remove outer race (12).
PC600-8
5.
Oil seal
Remove oil seal (13) from case (14).
SEN01065-03
2.
Bearing
1) Press fit outer race (12) to case (1).
2) Install snap ring (11).
2 Pin: Grease (G2-LI)
Assembly
a
Clean all the parts and check them for dirt or

damage. Coat their sliding surfaces with
engine oil before installing.
1.
Oil seal
Press fit oil seal (13) to case (14).
2 Press fitting surface of oil seal:
Adhesive (LG-6)
a Do not stick adhesive to the oil seal lip and
shaft.
a Add grease (G2-LI) to about 40 60%.
PC600-8
3)
4)
Press fit bearings (9) and (10) to gear (4).

Install snap ring (8).
5)
Press fit bearings (7) to gears (2) and (3).
SEN01065-03
3.
Gears
1) Install nipples (5) and (6) to case (14).
3 Nipple:
2.9 5.9 Nm {0.3 0.6 kgm}
2) Install gears (4), (3), and (2).
a Check that the gears rotate smoothly
and then apply red lead and check
the tooth contact.
2 Rolling surface of bearing:
Grease (G2-LI)
4.
Case
Install case (1).
2 Mating face of case:
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
PC600-8
SEN01065-03
Removal and installation of swing

motor and swing machinery
assembly
1
Removal
k
k

hydraulic tank.
1.
Remove step (1).
2.
Disconnect 4 hoses (2) between the control

valve and swing motor.
a Install tags and oil stopper plugs to all the
disconnected hoses.
3.
Installation
q

removal.
Disconnect 2 suction hoses (3).

[*1]
4.
Disconnect 2 swing holding brake hoses (4).
5.
Disconnect 3 drain hoses (5).
6.
Remove hose bracket (6).
7.
Disconnect drain plug assembly (8) from the

chassis at the rear of swing motor and swing
machinery assembly (7).
8.
Remove mounting bolts (9) and lift off swing

motor and swing machinery assembly (7). [*1]
4
PC600-8
Swing motor and swing machinery

assembly: 440 kg (1 piece)
Swing motor and swing machinery assembly

mounting bolt:
824 1,030 Nm {84 105 kg}

again.
Bleeding air
Bleed air from the swing motor. For details,
see Testing and adjusting, "Bleeding air from
each part".
SEN01065-03

swing machinery assembly
3)
Remove No. 1 carrier assembly (4).
1 796T-626-1110 Push tool
t 1
2 790-331-1110
t 1
Wrench
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
Disassembly
1.
Draining oil
Loosen drain plug and drain oil from swing
machinery.
6
2.
4.
Swing machinery case: 12.8 13.1 l
Cover
Remove mounting bolts, then lift off cover (1).
Disassembly of No. 1 carrier assembly

1) Push pin (5) in shaft (6), and knock out
shaft (6) from carrier (7).
a After removing the shaft, remove pin
(5).
2) Remove thrust washer (8), gear (9), bearing (10), and thrust washer (11).
10
11
CEP00208
3.
No. 1 carrier assembly.

1) Remove thrust washer (2).
2) Remove No. 1 sun gear (3).
5.
Ring gear
Lift off ring gear (12).
PC600-8
6.
No. 1 sun gear

1) Remove thrust washer (13).
2) Remove button (36) and spacer (14).
3) Remove No. 1 sun gear (15).
SEN01065-03
8.
Disassembly of No. 2 carrier assembly

1) Push in pin (18), and knock out shaft (19)
from carrier (17).
a After removing the shaft, remove pin
(18).
2) Remove thrust washer (20), gear (21),
bearing (22), and thrust washer (23).
19
22
17
20
21
23
4)
Remove thrust washer (16).
18
9.
CEP00213
Pinion shaft assembly

1) Remove bolt (24), then remove holder
(25).
2) Remove gear (26).
24
26
25
7.
No. 2 carrier assembly

Lift off No. 2 carrier assembly (17).
CEP00214
3)
Turn over case and pinion assembly, then

remove mounting bolts (28) of cover
assembly (27).
27
28
CEP00215
PC600-8
SEN01065-03
4)
Turn over case and pinion assembly (29),

and set on press stand, then using push
tool [1], remove pinion shaft assembly (30)
with press.
a Set a wooden block under the press,
and be careful not to damage the pinion shaft assembly when removing it.
10. Disassembly of pinion shaft assembly

1) Using push tool [2], remove cover assembly (27) and bearing (31) from shaft (32).
2) Remove oil seal (33) from cover (27).
Assembly
a
Clean all parts, and check for dirt or damage.

Coat the sliding surfaces of all parts with
1.
Bearing
Using push tool [3], press fit bearing (31) to
case (35).
2.
Cover assembly
1) Using push tool [4], press fit oil seal (33) to
cover (27).
2 Outside circumference of oil seal:
a Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when
press fitting.
11. Bearing
Using push tool, remove bearing (34) from
case (35).
35
34
CEP00220
10
PC600-8
2)
3.
Fit cover assembly (27) to case (35), and

tighten mounting bolts (28).
a Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when
press fitting.
a Take care that gasket sealant will not
be projected into the oil pass.
2 Cover mounting surface:
3 Mounting bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
2 Oil seal lip: Supply grease (G2-LI)
by about 40 60%.
Case assembly
1) Set case assembly (35) to shaft (32), then
using push tool [5], press fit bearing inner
race portion.
a When setting the case assembly to
the shaft, be extremely careful not to
damage the oil seal.
SEN01065-03
2)
Bearing
Using tool F1, press fit bearing (34).
a Press the bearing inner race and
outer race at the same time when
press fitting. Do not press only the
inner race when press fitting.
a After press fitting the bearing, check
that the case rotates smoothly.
3)
Gear, holder
Assemble gear (26), then fit holder (25)
and tighten bolt (24).
2 Mounting bolt:
Thread tightener (LT-2)
3 Mounting bolt:
179 196 Nm {16 20 kgm}
24
26
25
CEP00214
PC600-8
11
SEN01065-03
4.
Assembly of No. 2 carrier assembly

a There are the remains of caulking after fitting the pin at the end of side hole (h) of
the carrier. Remove the swelled part
inside the hole in advance.
1) Install bearing (22), upper and lower thrust
washers (23) and (20) to gear (21), then
install gear assembly to carrier (17).
22
5.

1) Assemble thrust washer (16).
17
20
21
2)
23
h
2)
CEP00226
Align with position of pin holes of shaft and

carrier, then tap with a plastic hammer to
install shaft (19).
a When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
Insert pin (18).
a After inserting the pin, caulk the pin
portion of the carrier.
a After assembling the carrier assembly, check that gear (21) rotates
smoothly.
3)
6.
21
18
12
Raise No. 2 carrier assembly (17) and

install.
a Align the position so that the tip of the
gear shaft enters at 4 places, then
install.
19
No. 2 sun gear

1) Install No. 2 sun gear (15) to No. 2 carrier.
2) Install spacer (14) and button (36).
3) Install thrust washer (13).
CEP00227
PC600-8
7.
SEN01065-03
Ring gear
Raise ring gear (12) and install.
2)
3)
a
Align position of pin holes of shaft and carrier, then tap with a plastic hammer to
install shaft (6).
a When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
Insert pin (5).
a After inserting the pin, caulk the pin
portion of the carrier.
After assembling the carrier assembly,
check that gear (9) rotates smoothly.
5
a
Apply the gasket sealant around the hole

(a) for checking oil, but do not apply
around the other holes.
2 Fitting faces of ring gear and case:
6
CEP00229
9.
8.

Install No. 1 carrier assembly (4).
Assembly of No. 1 carrier assembly

a There are the remains of the caulking when
the pin is inserted at the end face of hole
(h) at the side of the carrier, so remove the
caulked metal from the inside diameter of
the hole before starting to assemble.
1) Install bearing (10), upper and lower thrust
washers (8) and (11) to gear (9), then
install gear assembly to carrier (7).
10
11
CEP00228
PC600-8
13
SEN01065-03
10. No. 1 sun gear

1) Assemble No. 1 sun gear (3) to carrier
assembly.
2) Install thrust washer (2).
11. Cover
Using tool F2, install cover (1).
a When coating gasket sealant, follow the
precautions in item 7.
2 Cover mounting surface:
3 Mounting bolt:
First time:
98 Nm {10 kgm}
Second time: Tighten by 80 90.
(Make marks on each
bolt and the cover with
paint, then tighten the
bolt by 80 90.)
12. Refilling with oil

Tighten drain plug and add engine oil through
oil filler.
5
14
Swing machinery case:

12.8 l (low level)
13.1 l (high level)
PC600-8
SEN01065-03

circle assembly
1
Installation
q

removal.
Removal
1.
Remove the revolving frame assembly.

For details, see "Removal of revolving frame
assembly".
2.
Remove grease tube from swing circle.
3.
Remove mounting bolts (1).
[*1]
2
3
Mounting bolt: Thread tightener (LT-2)

Mounting bolt:
1,180 1,470 Nm {120 150 kgm}
[*2]
[*1]
a
a
a
4.
Using eyebolts and nut [1], lift off swing circle

assembly (2).
[*2]
4
5.
Swing circle mounting surface

Amount of grease (G2-LI) in oil bath:
Approx. 31 l
Coat inside teeth with grease (G2-LI).
Install the inner ring soft zone position (Smark), directing it to the right side of the
machine.
Swing circle assembly: 1,150 kg
Remove seal assembly (3).
PC600-8
15
SEN01065-03

final drive assembly
Disassembly
1.
790-501-5000
Unit repair stand
q 1
1 790-501-5200
Unit repair stand
q 1
Bracket
q 1
790-901-4110
q 1
Block
t 1
791-730-1130
Bolt
t 2
790-101-2360
Plate
t 2
01643-32060
Washer
t 2
Nut
t 2
Adapter
t 2
790-201-2790
Spacer
t 1
790-201-2690
Plate
t 1
790-101-2102
Puller
(294 N {30 ton})
t 1
Pump
t 1
Installer
t 1
790-101-2510
Block
t 1
791-830-1320
Rod
t 2
790-101-2570
Washer
t 2
01643-31645
Washer
t 2
Nut
t 2
Adapter
t 2
790-101-1102
5 796-627-1020
6 01580-11613
796-627-1410
796T-627-1330 Push tool
q 1
790-101-2102
Puller
t 1
790-101-1102
Pump
t 1
Wrench
t 1
7 790-331-1110
16
N/R
q 1
3 796T-627-1520 Plate
970-431-1031
Sketch
2 796T-627-1510 Plate
01580-12016
4 796-627-1420
Part name
Qty
Part number
Necessity
Symbol
Special tools
Draining oil
Set drain plug (1) at bottom and remove it to
drain oil from final drive case.
2.
Final drive case: 10.5 l (Each side)
Cover
1) Using tools J1 and J2, support final drive
assembly.
a Install by using the sprocket mounting bolt
holes on the hub.
2)
Using eyebolts [1], lift off cover (2).
PC600-8
3.
Spacer
Remove spacer (3).
4.
No. 1 sun gear shaft

Remove No. 1 sun gear shaft (4).
5.
SEN01065-03
3]
Remove 2 thrust washers (9), planetary gear (10), and bearing (11).
6.
No. 1 ring gear

Using eyebolts [2], lift off No. 1 ring gear (12).
7.
No. 2 ring gear

Using eyebolt [3], lift off No. 2 ring gear (13).

1) Lift off No. 1 carrier assembly (5).
2)
PC600-8
Disassemble No. 1 carrier assembly as

follows.
1] Push pin (6) in shaft (7).
2] Remove shaft (7) from carrier (8).
17
SEN01065-03
8.
Thrust washer
9.
No. 2 sun gear

Remove No. 2 sun gear (15).
2)
Disassemble No. 2 carrier assembly as

follows.
1] Push pin (18) in shaft.
2] Remove shaft (19) from carrier (20).
3]
10. Thrust washer
11. No. 2 carrier assembly

1) Lift off No. 2 carrier assembly (17).
18
Remove 2 thrust washers (21), planetary gear (22), and bearing (23).
12. Retainer
1) Sling the final drive assembly and remove
it temporarily.
2) Remove tool J2 and install tool J3, then
install final drive assembly to tool J3.
a Install tool J3 to the surface of the
travel motor case.
PC600-8
3)
Remove 22 mounting bolts (24) and 14

mounting bolts (25), then remove retainer
(26).
4)
Remove spacer (27).
13. Hub assembly

1) Using tool J4, remove hub assembly (28)
from travel motor assembly (29).
2) Using eyebolts [4], lift off hub assembly
(28).
PC600-8
SEN01065-03
3)
Disassemble hub assembly as follows.

1] Remove floating seal cover assembly (30) from hub (31).
2]
Remove bearings (32) and (33) from

hub.
14. Floating seal

1) Remove floating seal (34) from cover (35).
19
SEN01065-03
2)
Remove floating seal (36) from travel

motor (37).
3.
Assembly
a

Coat the sliding surfaces of all parts with
1.
Travel motor assembly

Install travel motor assembly to tools J1 and
J3.
2.
Floating seal
1) Using tool J5, install floating seal (36) to
travel motor (37).
a Remove all oil and grease from the
O-ring and O-ring contact surface,
and dry the parts before installing the
floating seal.
a After installing the floating seal, check
that the angle of the floating seal is
within 1 mm.
2)
20
Hub assembly
1) Assemble the hub assembly as follows.
1] Using push tool [5], press fit bearing
(32) to hub (31).
a Similarly, press fit bearing (33).
a Press fit the bearing until it fits to
the hub.
2]
Install floating seal cover assembly

(30) to hub (31).
2 Cover fitting face:
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
Using tool J5, install floating seal (34) to

cover (35).
a Observe the precautions for installation in 1) above.
PC600-8
2)
3)
4)
SEN01065-03
Using eyebolts, sling and install hub

assembly (28) to travel motor assembly.
Using tool J6, press fit the inner race of
bearing (32).
a Before press fitting, rotate the hub
assembly by two three turns on the
travel motor.
Under the condition of 3) above, measure
distance (a) between the inner race of the
bearing and retainer fitting face with depth
gauge or caliper [6].
a Press fitting force:
22 25 kN {2.2 2.6 ton}
a Calculate the thickness of spacer (27)
by the following formula.
Thickness of spacer =
Distance (a) (0.10 to 0.15)
a Distance (a) (Standard): 3.5 mm
a Thickness of spacer (Standard):
(t) = 3.4 mm
a Thicknesses of spacers:
t = 3.25, t = 3.3, t = 3.35, t = 3.4,
t = 3.45, t = 3.5, t = 3.55
2)
5.
4.
Install retainer (26) and tighten 22 mounting bolts (24) and 14 mounting bolts (25).
2 Mounting bolts (24), (25):
3 Mounting bolts (24), (25):
853 931 Nm {87 95 kgm}
Measurement of tangential force

Using push-pull scale [7], measure tangential
force of hub in its rotating direction on motor
case.
a Measure the tangential force at the
sprocket mounting hole on the hub.
a Tangential force: 620 N {63 kg} max.
a Measure the maximum tangential force
when the hub starts rotating.
Retainer
1) Install spacer (27) selected by step 2) 4)
above.
PC600-8
21
SEN01065-03
6.

1) Sling the final drive assembly and move it
temporarily.
2) Remove tool J3 from tool J1 and install it
to tool J2, then install final drive assembly
to tool J2.
a Install by using the sprocket mounting
bolt holes on the hub.
3)
22
Assemble No. 2 carrier assembly as follows.

a There is caulking left at the pin fitting
pa r t o f t h e c a r r i e r. R e m o v e t h e
swelled part inside the hole in
advance.
1] Install bearing (23) and 2 thrust washers (21) to planetary gear (22), then
install them to carrier (20).
2] Tap shaft (19) to install it to carrier
(20).
a When installing shaft (19), rotate
planetary gear (22), and take
care not to damage the thrust
washers.
3] Insert pin (18).
When inserting the pin, assemble

so that the 3 notched parts (portion a) on the circumference on
the pin do not overlap the thin
metal part (portion b) of the carrier. (Basically, the inside of the
chassis (direction A) is the thin
metal side).
However, with the actual part, the
thin metal may be on the opposite side, so check the part and
make sure when assembling that
the protruding parts of the pin is
not at the same place as the thin
metal.
a After inserting the pin, caulk the
pin portion of the carrier.
After assembling the carrier assembly, check that planetary gear (22)
rotates smoothly.
PC600-8
4)
7.
Sling and install No. 2 carrier assembly

(17).
SEN01065-03
10. No. 2 ring gear

1) Install O-ring to hub.
2) Using eyebolts [3], sling and install No. 2
ring gear (13).
a Do not apply gasket sealant to the fitting faces of the hub and No. 2 ring
gear.
a Degrease the fitting faces of the hub
and No. 2 ring gear.
Thrust washer
Install thrust washer (16).
8.
No. 2 sun gear

Install No. 2 sun gear (15).
9.
Thrust washer
Install thrust washer (14).
Install the ring gear with the identification cut (b) up.
11. No. 1 ring gear

Using eyebolts [2], sling and install No. 1 ring
gear (12).
2 Fitting faces of No. 1 ring gear and No. 2
ring gear: Gasket sealant (LG-6)
PC600-8
23
SEN01065-03

a
12. No. 1 carrier assembly

1) Assemble No. 1 carrier assembly as follows.
a Caulking remains at the pin fitting part
of the carrier. Remove the swelled
part inside the hole in advance.
1] Install bearing (11) and 2 thrust washers (9) to planetary gear (10), then
install them to carrier (8).
2] Tap shaft (7) to install it to carrier (8).
a When installing shaft (7), rotate
planetary gear (10), and take
care not to damage the thrust
washers.
3]
24
Insert pin (6).

a When inserting the pin, assemble
so that the 3 notched parts (portion c) on the circumference on
the pin do not overlap the thin
metal part (portion d) of the carrier. (Basically, the inside of the
chassis (direction B) is the thin
metal side).
However, with the actual part, the
thin metal may be on the opposite side, so check the part and
make sure when assembling that
the protruding parts of the pin is
not at the same place as the thin
metal.
a After inserting the pin, caulk the
pin portion of the carrier.
2)
After assembling the carrier assembly, check that planetary gear (10)
rotates smoothly.
Sling and install No. 1 carrier assembly

(5).
PC600-8
13. No. 1 sun gear shaft

Install No. 1 sun gear shaft (4).
14. Spacer
Install spacer (3).
SEN01065-03
Refilling with oil

1) Tighten drain plug (1) and remove oil filler
plug (38).
3 Drain plug:
59 78 Nm {6 8 kgm}
2) Set cover with "TOP" position up, and supply oil up to bottom of oil filler.
5
3)
Final drive case (Each side):

10.5 l (EO30-DH)
Tighten oil filler plug (38).
3 Oil filler plug:
59 78 Nm {6 8 kgm}
a After installing the final drive assembly to the machine, check the oil level
again by the above method.
15. Cover
1) Using eyebolts [1], sling and install cover
(2).
2 Fitting face of cover:
2)
PC600-8
Tighten the cover mounting bolts in the following order.

3 Cover mounting bolt:
1st time:
98 Nm {10 kgm}
2nd time:
Tighten by 150.
(Make marks on each bolt and the
cover with paint, then tighten the
bolt by 144 155 with tool J7.)
25
SEN01065-03

2010 KOMATSU
All Rights Reserved
26
SEN01066-03
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

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

shoe assembly
1
3.
Using tool M, pull out master pin.
4.
Fit block or hydraulic jack [1] (10 ton) under

shoe at idler end, then remove guide pin [2].
[*2]
5.
Raise tip of track shoe with crane, and move

machine slowly to rear to open track shoe
assembly (3).
796-632-1200
Remover, installer t 1
790-101-4300
Cylinder (1,471
kN {150 ton})
t 1
790-101-4200
Puller
(294 kN {30 ton})
t 1
790-101-1102
Pump
t 1
Wrench
t 1
4 790-331-1100
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
Removal
1.
Positioning master pin

a Move the master pin so that it is midway
between the idler and the carrier roller.
The track shoe is opened to the rear, so
be sure that there is enough space.
2.
[*1]
Loosen track shoe tension.
k Never loosen lubricator (1) more than
one turn.
a If the track tension is not relieved even
when the lubricator is loosened, move the
machine backwards and forwards.
PC600-8
SEN01066-03
Installation
q

removal.
[*1]
a Adjust the track shoe tension.
For details, see Testing and adjusting, Adjusting track shoe tension.
3 Lubricator:
73.5 14.7 Nm {7.5 1.5 kgm}
[*2]
a Assemble spacer (4) and washer (5) to the
link, connect to bottom link, then install guide
pin.
PC600-8
N/R
Sketch
791-685-9560
Bolt
t 4
791-126-0150
Adapter
t 1
01010-51030
Bolt
t 1
791-685-9620
Extension
t 1
791-680-5542
Adapter
t 1
791-680-9580
Adapter
t 1
791-680-9590
Guide
t 1
791-680-5560
Guide
t 1
01010-52760
Bolt
t 2
790-101-1102
Pump
t 1
01010-51440
Bolt
t 2
790-101-4300
Cylinder (*1)
t 1
790-101-1102
Pump
t 1
791-685-9510
Frame
t 1
790-101-4300
Cylinder (*1)
t 1
791-685-9520
Frame
t 1
791-685-9510
Frame
t 1
791-685-9530
Rod
t 1
791-685-9520
Frame
t 1
791-685-9540
Rod
t 1
791-685-9530
Rod
t 1
791-685-9550
Nut
t 3
791-685-9550
Nut
t 3
791-685-9560
Bolt
t 4
791-685-9560
Bolt
t 4
791-126-0150
Adapter
t 1
791-680-9570
Adapter
t 1
01010-51030
Bolt
t 1
01010-51030
Bolt
t 1
791-685-9620
Extension
t 1
04530-12030
Eyebolt
t 1
791-680-5560
Guide
t 1
790-101-1102
Pump
t 1
791-632-1110
Adapter
t 1
790-101-4300
Cylinder (*1)
t 1
791-680-9630
Adapter
t 1
791-685-9540
Rod
t 1
790-101-1102
Pump
t 1
791-685-9550
Nut
t 3
790-101-4300
Cylinder (*1)
t 1
791-685-9510
Frame
t 1
11 790-680-1520
Guide
t 1
791-685-9520
Frame
t 1
791-685-9510
Frame
t 1
791-685-9530
Rod
t 1
791-685-9520
Frame
t 1
791-685-9550
Nut
t 3
791-685-9530
Rod
t 1
791-685-9560
Bolt
t 4
791-685-9540
Rod
t 1
791-126-0150
Adapter
t 1
791-685-9550
Nut
t 3
791-680-5520
Guide
t 1
791-685-9560
Bolt
t 4
791-126-0140
Pusher
t 1
12 791-126-0150
Adapter
t 1
791-680-9570
Adapter
t 1
791-680-5560
Guide
t 1
01010-51030
Bolt
t 1
791-680-9570
Adapter
t 1
04530-12030
Eyebolt
t 1
01010-51030
Bolt
t 1
791-685-9620
Extension
t 1
791-680-1520
Guide
t 1
791-101-1102
Pump
t 1
790-101-1102
Pump
t 1
790-101-4300
Cylinder (*1)
t 1
790-101-4300
Cylinder (*1)
t 1
790-101-1102
Pump
t 1
790-101-1102
Pump
t 1
790-101-4200
Puller (*2)
t 1
790-101-4200
Puller (*2)
t 1
791-680-5542
Adapter
t 1
791-680-9501
Remover, installer t 1
791-632-1110
Adapter
t 1
790-101-1102
Pump
t 1
8 791-680-5580
Guide
t 1
790-101-4200
Puller (*2)
t 1
791-685-9510
Frame
t 1
790-101-4300
Cylinder (*1)
t 1
791-685-9520
Frame
t 1
9 791-685-9530
Rod
t 1
791-685-9540
Rod
t 1
791-685-9550
Nut
t 3
6
7
Part name
Qty
Part number
Necessity
Symbol
Special tools
10
13
14
N/R
Part name
Sketch
Part number
Qty
Disassembly and assembly of 1

link in field
1
Necessity
Symbol
SEN01066-03
(*1) : 1,471 kN{150 ton}

(*2) :
294 kN{30 ton}
PC600-8
Disassembly
1.
Using two bolts (2), install tool N1 (adapter,

guide, bolt) to link (1).
a It is also possible to use 2 track bolts for
bolt (2).
2.
Assemble tool N2 (pump, cylinder 1471 kN

{150 t}) and tool N3 (frame, rod, adapter, bolt x
1, eyebolt), then raise chassis and set on track.
3.
SEN01066-03
4.
Set tool N5 (adapter, guide, pusher) in position, then apply hydraulic pressure and remove
pin (3).
When the cylinder reaches the end of its
stroke, insert extension N5 between the
adapter and guide, and repeat the operation.
5.
Set tool N6 (294 kN {30 ton} puller) and spacer

[1] to center of roller tread of link to be disassembled, then apply hydraulic pressure to
puller and open link 5 6 mm.
Insert rod of tool N4 from cylinder end, and

install with 2 nuts.
a Pass the rod through the hole in link (1) to
install.
PC600-8
SEN01066-03
Assembly
1.
Assemble the link sub-assembly.

1) Set tool N7 to end face of link, then press
fit bushing (1).
2) Set tool N7 to end face of link (pin end),
and press fit pin (2).
2.
Set link sub-assembly (3) on link to be connected.
3.
Set link (4) on opposite side, and support with

tool N8 (guide).
4.
Set tools N9 and N10 in same way as for operation to remove pin, then use tool N9 (adapter,
extension, guide, adapter, bolt) for press fitting
pin, and tool N10 (extension, guide, adapter,
bolt) for press fitting bushing, and press fit in
turn.
5.
Use tool N13 (294 kN {30 t} puller) in same

way as when disassembling, and push open
link (5) at bushing end.
6.
Set link (6) at pin end to link (5) at bushing end,

connect with tool N11 (guide), then remove
tool N13 (puller).
PC600-8
7.
SEN01066-03
Set tool N9 at pin (7) end, then use tool N12

(adapter, bolt, and guide) to press fit pin (7).
2 Pin press-fitting hole in link:
PC600-8
SEN01066-03
Removal and installation of idler,

recoil spring assembly
1
3.
Disconnect recoil spring assembly (4) from

idler assembly (3).
[*1]
Removal
1.
Remove track shoe assembly.

track shoe assembly.
a Remove lubricator (1).
Idler assembly: 350 kg
Recoil spring assembly: 460 kg
Installation
q
2.
Sling idler and recoil spring assembly (2), and

pull out to the front to remove.
4
Idler and recoil spring assembly:

Approx. 800 kg

removal.
[*1]
Mounting bolt between idler and recoil

spring:
824 1,030 Nm {84 105 kgm}
PC600-8
SEN01066-03

idler assembly
t 1
791-601-1000
Oil pump assembly
q 1
790-701-3600
Adapter
q 1
Remove shaft (8) from idler.
6.
Remove 2 floating seals (4) from idler (7).
7.
Remove bushings (9) and (10) from idler.
Idler assembly: 350 kg
Disassembly
1.
5.
Sketch
N/R
Qty
Symbol
2
Necessity
Installer
1 791-575-1520
L
Part name
Turn over idler assembly, remove pin (6), then

remove support (7).
Special tools
Part number
4.
Remove plug (1) and drain oil.

6
Idler: 400 500 cc
2.
Set idler assembly (2) on block [1], remove pin

(3), then remove support (5).
3.
Remove floating seal (4).
PC600-8
SEN01066-03
8.
Remove floating seals (4) from supports (5)

and (7).
Assembly
a
1.
Using tool L1, assemble floating seals (4) to

supports (6) and (3).
2.
10
When installing the floating seal, clean,

degrease and completely dry the contact
faces of the O-ring and floating seal
(hatched parts in the figure below). Take
care that dirt does not stick to the contact
face of the floating seal.
After installing the floating seal, check that
its angle is within 1 mm and its projection
(a) is 9 11 mm.
Using tool [1], press fit bushings (10) and (9) to

idler.
PC600-8
3.
4.
Using tool L1, assemble floating seal (4) to

idler.
a For precautions for installing the floating
seal, see 1.
Turn over idler and using tool L1, assemble

floating seal (4).
seal, see 1.
SEN01066-03
8.
Turn over idler, and assemble support (5) to

shaft.
a When installing the support to the shaft,
align their pin hole with each other.
9.
Install pin (3) to secure support (5).
10. Using tool L2, supply oil by specified quantity,

then tighten plug (1).
5
3
5.
Install shaft (8) to idler.
6.
Assemble support (7) to shaft.

a When installing the support to the shaft,
align their pin hole with each other.
7.
Install pin (6) to secure support (7).
PC600-8
Idler: 400 500 cc (EO30-DH)

Plug: 16.66 37.86 Nm {1.7 3.8 kgm}
11
SEN01066-03

recoil spring assembly
791-685-8502
Compressor
t 1
791-635-3160
Extension
t 1
790-101-1600
Cylinder
(686 N {70 ton})
t 1
790-101-1102
Pump
t 1
Push tool
t 1
2 790-201-1500
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
Disassembly
2
8
7
10
5
3
14
12 13
1
11
CEP00054
1.
Remove piston assembly (2) from recoil spring

assembly.
2.
Disassembly of recoil spring assembly

1) Set tool M1 to recoil spring assembly (1).
k The recoil spring is under large
installed load, so be sure to set the
tool properly. Failure to do this is
dangerous.
a Installed load of spring:
291.8 kN {29,770 kg}
M1
2)
3)
3.
Apply hydraulic pressure slowly to compress spring, then remove lock plate (3),
and remove nut (4).
a Compress the spring to a point where
the nut becomes loose.
a Free length of spring:
Approx. 859 mm
Remove yoke (6), cylinder (7) and dust
seal (8) from spring (5).
Disassembly of piston assembly

1) Remove lock plate (10) from piston (9),
then remove valve (11).
2) Remove snap ring (12), then remove Upacking (13) and ring (14).
CEP00055
12
PC600-8
SEN01066-03
Assembly
3.
1.
Assembly of piston assembly

1) Assemble ring (14) and U-packing (13) to
piston (9), and secure with snap ring (12).
2) Tighten valve (11) temporarily, and secure
with lock plate (10).
2.
Assembly of recoil spring assembly

1) Using tool M2, assemble dust seal (8) to
cylinder (7).
Assemble piston assembly (2) to recoil spring

assembly (1).
2 Piston sliding portion and wear ring:
Grease (G2-LI)
a Assemble the cylinder assembly so that
the mounting position of the valve is 90 to
the side.
a Fill the inside of the cylinder with approx.
200 cc of grease (G2-LI), then bleed the
air and check that grease comes out of the
grease hole.
M2
8
CEP00062
2)
3)
4)
PC600-8
Assemble cylinder (7) and yoke (6) to

spring (5), then set to tool M1.
2 Sliding portion of cylinder:
Grease (G2-LI)
Apply hydraulic pressure slowly to compress spring, and tighten nut (4) so that
installed length of spring is dimension (a),
then secure with lock plate (3).
a Installed length (a) of spring:
715 mm
Remove recoil spring assembly (1) from

tool M1.
13
SEN01066-03
Removal and installation of track

roller assembly
1
3.
Removal
1.
Lower work equipment to ground, then loosen

lubricator (1), and relieve track tension.
[*1]
k The adjustment cylinder is under
extremely high pressure, so never
loosen the lubricator more than one
turn. If the grease does not come out
easily, move the machine backwards
and forwards.
Lower chassis completely, remove mounting

bolts of track roller assembly (3), then jack up
machine with work equipment, and remove
track roller assembly (3) to outside of machine.
[*3]
4
Track roller assembly: Approx. 110 kg
Installation
q
2.
Remove mounting bolts of track roller guard

(2), then swing work equipment 90, jack up
machine with work equipment, and remove
track roller guard (2) towards outside of
machine.
[*2]
4
Track roller guard: 50 kg

removal.
[*1]
a Adjust the track tension.
For details, see Testing and adjusting, Testing
and adjusting track shoe tension.
[*2]
2
3
Roller guard mounting bolt:

Roller guard mounting bolt:
1,180 1,470 Nm {120 150 kgm}
[*3]
2
3
14
Track roller assembly mounting bolt:

Track roller assembly mounting bolt:
980 1,176 Nm {100 126 kgm}
PC600-8
SEN01066-03

track roller assembly
Installer
t 1
791-601-1000
Oil pump
assembly
q 1
790-701-3600
Adapter
q 1
3 791-560-1520
L
Sketch
N/R
Part name
Qty
Part number
Necessity
Symbol
Special tools
Track roller assembly: 110 kg
Disassembly
8
5
6
10
4
9
3
1
2
11
1.
Remove pin (1), then remove collar (2).
2.
Remove floating seals (3) from collar (2) and

roller (4).
PC600-8
CEP00084
3.
Pull out roller (4) from shaft (5).

a It is filled with 540 660 cc. of oil, so drain
the oil at this point or lay a cloth to prevent
the area from becoming dirty.
4.
Remove floating seals (6) on opposite side

from roller (4) and collar (8).
15
SEN01066-03
5.
6.
16
Remove pin (7), then remove collar (8) from

shaft (5).
Assembly
1.
Using push tool [1], press fit bushings (9) and

(10) to roller (4).
2.
Assemble collar (8) to shaft (5), and install pin

(7).
3.
Using tool L3, install floating seals (6) to shaft

(5).
a When installing the floating seal, clean,
faces of O-ring (6c) and floating seal (6a)
a After installing the floating seal, check that
(a) is 5 7 mm.
4.
Using tool L3, install floating seals (6) and (3)

to roller (4).
seals (6b), (6d), (3b), and (3d), see 3
above.
Remove bushings (9) and (10) from roller (4).
PC600-8
5.
SEN01066-03
Assemble shaft (5) to roller (4).
9.
Using tool L4, apply standard pressure to roller

oil filler port, and check for leakage of air from
seal.
a Standard pressure: 0.1 MPa {1 kg/cm2}
a Method of checking
The standard pressure shall be maintained for 10 seconds and the indicator of
the gauge shall not go down.
L4
6.
Turn over roller (4) and shaft (5) assembly.
7.
Using tool L3, install floating seals (3) to collar

(2).
seals (3a) and (3c), see 3 above.
CEP00100
10. Using tool L4, fill track roller assembly with oil,
then tighten plug (11).
5
3
Track roller oil:

540 660 cc (EO30-DH)
Plug: 16.66 37.86 Nm {1.7 3.8 kgm}
L4
8.
Assemble collar (2) to shaft (5), and install pin

(1).
To oil pump
2
To vacuum tank
CEP00201
11
5
CEP00099
CEP00202
PC600-8
17
SEN01066-03

carrier roller assembly
Installation

removal.
Removal
1.
2.
Lower work equipment to ground, then loosen

lubricator (1), and relieve track tension.
[*1]
k The adjustment cylinder is under
extremely high pressure, so never
loosen the lubricator more than one
turn. If the grease does not come out,
move the machine backwards and forwards.
[*2]
Carrier roller assembly mounting bolt:

490 607 Nm {50 62 kgm}
Using hydraulic jacks, push up track to a position where carrier roller assembly can be
removed, then remove carrier roller assembly
(2).
[*2]
4
18
[*1]
a Adjust the track tension.
For details, see Testing and adjusting, Testing
and adjusting track shoe tension.
Carrier roller assembly: 50 kg
PC600-8
SEN01066-03

carrier roller assembly
Installer
t 1
791-601-1000
Oil pump assembly
q 1
790-701-3600
Adapter
q 1
5 791-651-1510
L
Remove floating seal (6) from support (7).
6.
Secure support (7) with block [3].
7.
Using push tool [4], push shaft (8) out of support (7) with press.
8.
Remove floating seal (9) from roller (5).
9.
Remove bushings (10) and (11).
Sketch
N/R
Part name
Qty
Part number
Necessity
Symbol
Special tools
5.
Carrier roller assembly: 50 kg
Disassembly
1.
Remove plug (1) to drain oil.

6
Carrier roller assembly: 135 165 cc
2.
Remove cover (2).
3.
Remove cover (3).
4.
Remove shaft (4) from roller (5).

a If roller (5) is erected, shaft assembly (4)
falls. Take care.
PC600-8
19
SEN01066-03
Assembly
1.
2.
Using tool [5], press fit bushing (10) to roller

(5).
a Press fit bushing (11) similarly.
3.
Using push tool [4], press fit shaft (8) to support (7).
4.
Using tool L5, press fit floating seal (6) to support (7).
a For fitting procedure of the floating seal,
see 2 above.
5.
Install shaft assembly (4) to roller (5).
6.
Install cover (3).

3 Mounting bolt:
44.12 53.93 Nm {4.5 5.5 kgm}
7.
Install cover (2).

3 Mounting bolt:
44.12 53.93 Nm {4.5 5.5 kgm}
Using tool L5, press fit floating seal (9) to roller

(5).
20
When installing the floating seal, clean,

faces of the O-ring and floating seal
After installing the floating seal, check that
(a) is 9 11 mm.
PC600-8
SEN01066-03
8.
Using tool L6, apply standard pressure to oil

filler to check seal for air leakage.
a Standard pressure: 0.1 MPa {1 kg/cm2}
a Check method: Keep the standard pressure for 10 seconds, and check that the
gauge reading does not drop.
9.
Using tool L6, fill carrier roller assembly with

oil, then tighten plug (1).
5
3
Carrier roller: 135 165 cc (EO30-DH)

Plug:
30.89 37.75 Nm {3.15 3.85 kgm}
PC600-8
21
SEN01066-03

revolving frame assembly
5.
Disconnect all upper pipes (2) of the center

swivel joint.
a Before disconnecting each hose, mark it
with a tag etc. to indicate its position.
a Install oil stopper plugs to the disconnected hoses.
6.
Pull out pin (3) and move link (4) toward the
frame.
7.
Revolving frame assembly

[*1], [*2]
1) Using M46 eyebolts (EB) (Length: Min.
450 mm), install wires to the counterweight mounting portion and boom cylinder pin, sling the revolving frame
assembly temporarily.
a Use 2 cranes.
a Use wires which are not damaged.
a When winding wires around the revolving
frame without using eyebolts (EB), apply
pads to the corners of the revolving frame.
2) Remove the remaining bolts and revolving
frame assembly (5).
Removal
1.
k
k
Remove the work equipment assembly. For

details, see Removal and installation of work
equipment assembly.
Stop the engine.
hydraulic tank.
2.

3.
Disconnect grease tube from the swing circle.
4.
Remove all revolving frame mounting bolts (1),

except 3 4 pieces at the front and rear. [*1]
a While running the engine and swinging the
upper structure, remove the mounting
bolts.
a If the engine is not started, remove the
swing motor and swing the upper structure
with a crane.
22
Revolving frame assembly: 11,000 kg
PC600-8
SEN01066-03
Installation
q

removal.
[*1]
Mounting bolt: Adhesive (LT-2)

Mounting bolt:
1,860 1,910 Nm {189 195 kgm}
[*2]
Top of swing circle: Gasket sealant (LG-6)

again.
PC600-8
23
SEN01066-03

counterweight assembly
Installation

removal.
Removal
k

1.
Sling counterweight assembly (1) temporarily.

a No eyebolts are necessary.
2.
Remove mounting bolts (2).

a Width across flats: 65 mm
3.
Lift off counterweight assembly (1).
[*1]
a Evenly adjust the clearance between the door
and counterweight and that between the
revolving frame and counterweight to 15 5
mm.
3 Counterweight mounting bolt:
3,430 4,212 Nm {350 430 kgm}
[*1]
Counterweight assembly:
10,750 kg (For countries other than USA)
13,500 kg (For USA)
24
PC600-8

counterweight remover
assembly
SEN01066-03
Removal
k
a
a
1.
2.
3.

tubes and hoses.
Remove the mounting bolts and lower counterweight (2).
[*1]
a Width across flats of mounting bolt: 65 mm
hydraulic tank.
4.
Disconnect hoses (7) (9).
5.
6.
Disconnect clamps (13) (17).
Remove pin (1) and disconnect counterweight

(2).
Disconnect hoses (3), (5) and (6).

PC600-8
25
SEN01066-03
7.
Sling counterweight remover assembly (11).
Installation
q

removal.
[*1]
8.

again.
Remove mounting bolts (12) and lift off counterweight remover assembly (11).
4
26
Counterweight mounting bolt:

3,430 4,212 Nm {350 430 kgm}
Counterweight remover assembly:

1,270 kg
PC600-8
PC600-8
SEN01066-03
27
SEN01066-03

2009 KOMATSU
All Rights Reserved
28
SEN01067-03
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

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

hydraulic tank assembly
5.
Disconnect hose (4) from filter (F).
6.
Disconnect hoses (5) (8) from under filter (F).
7.
Remove the undercover.
8.
Disconnect hoses (9) (12) from the inside

rear of hydraulic tank (27).
Removal
k
k
a
a
1.

hydraulic tank.
tubes and hoses.
Drain the hydraulic oil.
6
Hydraulic oil: 360 l (Refill capacity)
2.
Remove handrails (1).
3.
Remove plate (2).
4.
Remove cover (3).
PC600-8
9.
Disconnect hoses (13) (22) from the rear of

the hydraulic tank.
SEN01067-03
13. Remove 4 bolts (26) from the front of the

hydraulic tank.

a There is another clamp under clamp (23).
11. Disconnect connector P22 (24).
14. Remove the mounting bolts and lift off hydraulic tank (27).
4
12. Disconnect suction tube (25).

a Since suction hose (SH) is fixed with
MIKALOR clamp, do not disconnect it. If it
is disconnected, see Removal and installation of hydraulic pump assembly, Installation.
Installation
q

removal.

again.
5
PC600-8
Hydraulic tank assembly: 430 kg
SEN01067-03

hydraulic pump assembly
7.
Remove cover (3).
8.
Lift off cover assembly (5).
9.
Disconnect dust indicator hose (6).
Oil stopper
N/R
796-660-2010
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tool
q 1
Removal
k
k
a
a
1.

hydraulic tank.
tubes and hoses.
Remove the hydraulic tank strainer and stop
the oil with tool S.
a When not using tool S, remove the drain
plug and drain the oil.
6
2.
Hydraulic tank:
360 l (Refill capacity)
Remove cover (1).
10. Disconnect hose clamp (7).
[*1]
11. Remove air cleaner bands (8).
[*2]
12. Remove air cleaner (9).

13. Remove air cleaner bracket.
3.
Open the engine hood.
4.
Remove handrail (2).
5.
Disconnect hose (4) from reservoir tank (RT)

under cover (3).
6.
Disconnect connector P24 from the bottom of

reservoir tank (RT).
PC600-8
14. Upper side of pump No. 2

1) Remove bracket (11).
2) Disconnect 4 hoses (12).
Upper side of cooling fan pump (G.P.)
Disconnect hoses (14) (18).
SEN01067-03
16. Lower side of pump No. 2

1) Disconnect 3 hoses (28).
2) Disconnect suction connector (29).
a Since suction hose (SH2) is fixed with
MIKALOR clamp, do not disconnect
it.
17. Lower side of cooling fan pump (G.P.)
1) Disconnect suction hose (31).
a Since suction hose (SHG) is fixed
with MIKALOR clamp, do not disconnect it.
15. Pump No. 1

1) Disconnect hoses (19) (22).
2) Disconnect wiring harness (23).
3) Disconnect hoses (24) (26).
a Since suction hose (SH1) is fixed with
MIKALOR clamp, do not disconnect
it.
PC600-8
18. Lift off each pump

4
Cooling fan pump assembly (G.P.): 90 kg
SEN01067-03
Installation
q

removal.
[*1]
Air hose clamps (right and left):

8.3 9.3 Nm {0.85 0.95 kgm}
3)
4)
a
[*2]
Air cleaner band:

17.6 21.6 Nm {1.8 2.2 kgm}
Reference
When suction hoses (SH), (SH1), (SH2), and
(SHG) are disconnected
a Since these hoses are fixed with MIKALOR
clamps, observe the following precautions
when installing them.
1)
2)
Use new MIKALOR clamps.

Set each hose to the original position.
Insertion depth: 95 mm (SH)
85 mm (SH1, SH2)
80 mm (SHG)
Apply adhesive evenly over the tube side.
2 Apply evenly over the tube side:
Adhesive (THREEBOND 4314)
Set bridge (BR) under the clamp bolt and adjust

its overlap (b) with bridge (BR) to at least 5 mm.
Tightening of the clamp.
Do not use an impact wrench.
q
When reusing the hose
on the hose.
q
When using a new hose
Tighten until dimension (a) is as follows.
12 15 mm: SH
7 10 mm: SH1, SH2, SHG

again.
5
Bleeding air
Bleed air from the hydraulic circuit. For details,
see Testing and adjusting, Bleeding air from
each part.
PC600-8
SEN01067-03

control valve and solenoid valve
assembly
1
Removal
k
k
a
a
1.
2.

hydraulic tank.
Bleed air from the hydraulic circuit. For
details, see Testing and adjusting, Releasing remaining pressure in hydraulic circuit.
Before disconnecting each hose, make a
match mark on it or fit a tag to it to indicate its
position.
tubes and hoses.
Remove control valve assembly upper cover
(1) and step (2).
3.
Disconnect hoses (18) and (19) between the

control valve and swing motor and 2 swing
motor suction hoses (20).
4.

valve and arm and bucket cylinders.
Disconnect the following wiring connectors.

q
(3) : (P03) (Swing switch)
q
(4) : (P26) (R pump pressure sensor)
q
(5) : (P25) (F pump pressure sensor)
q
(6) : (P02) (Boom lower switch)
q
(7) : (P04) (Arm in switch)
q
(8) : (P06) (Boom raise switch)
q
(9) : (P05) (Bucket dump switch)
q
(10) : (P01) (Bucket curl switch)
q
(11) : (V03) (Bucket HI cancel solenoid)
q
(12) : (P08) (Arm out switch)
q
(13) : (V07) (CO cancel solenoid)
q
(14) : (V08) (Main 2-stage relief valve
solenoid)
q
(15) : (V06) (Boom head 2-stage safety valve
solenoid)
q
(16) : (V04) (Travel speed shifting solenoid)
q
(17) : (V05) (Swing holding brake solenoid)
PC600-8
SEN01067-03
5.
Remove hose (22) between the control valve

and return filter.
6.
Disconnect 2 hoses (23) between the line filter

and control valve.
7.
Disconnect 3 return hoses (24).
8.
Disconnect hose (25).
9.
Disconnect 3 hoses (26).
14. Sling control valve and solenoid valve assembly (32) temporarily and remove it together
with the bracket.
4
Control valve and solenoid valve assembly:

330 kg
10. Disconnect connectors P03 (27) and P26 (28).
Installation
q

removal.

again.
11. Disconnect each tube (29) from the control

valve side or opposite side.
a Disconnect the tubes from the chassis
completely, if necessary.
12. Disconnect all PPC hoses (30) from the front
and rear of the control valve.
13. Disconnect all hoses (31) from each solenoid
valve.
Bleeding air
Bleed air from the hydraulic circuit. For details,
see Testing and adjusting, Bleeding air from
each part.
PC600-8

control valve assembly
SEN01067-03
Precaution
a
Spools: Take care that the arm Hi (AH), arm Lo

(AL), bucket Lo (BKL), and boom Lo (BML)
spools must be installed in the correct directions.
PC600-8
Apply liquid seal (SEALEND 242 or equivalent)

to the mating faces.
2 Mating faces:
Liquid seal (SEALEND 242 or equivalent)
SEN01067-03
Disassembly and assembly of main control valve assembly
Disassembly
10
PC600-8

a
Since the set pressure of the safety valve cannot be adjusted without removing it from the
machine, do not disassemble it.
The left main control valve is explained below
as an example.
1.
Main relief valve, jet sensor relief valve

Remove main relief valve (1) and jet sensor
relief valve (2).
2.
Safety valves having suction ports

Remove safety valves (3) and (5) having suction ports.
3.
Check valve
Remove plug (6), then remove spring (7) and
check valve (8).
4.
Left travel valve

1) Remove case (9). Remove retainer (10),
shim (11), spring (12), retainer (13), spring
(14), and retainer (15), then remove spool
(16).
2) Remove case (17), then remove retainer
(18), shim (19), spring (20), retainer (21),
spring (22), and retainer (23).
q
Apply to the spools of the swing valve,
right travel valve, boom HI valve (right
control valve), and boom LO valve (left
control valve).
q
Swing valve spool (Right control valve)
1] Shim (11) and retainer (13) are
not installed.
not installed.
q
Boom HI valve (Right control valve)
1] Two shims (11) are installed.
2] Plates are installed instead of
items (17) (23) in 2) above.
q
Boom LO valve spool (Left control
valve)
1] Shim (11) is not installed.
2] Items (18) (21) in 2) above are
not installed.
5.
Arm throttle valve

1) Remove plug (24) and spring (25).
2) Remove plate (26) and pull out spool (27).
q
Items (24), (25), and (26) of the swing priority valve (right control valve) in 1) and 2)
above are installed reversely.
PC600-8
SEN01067-03
6.
Bucket valve
1) Remove case (28). Remove spring (29)
and retainer (30), then pull out spool (31).
2) Remove case (32), then remove spring
(33) and retainer (34).
q
Apply to the spools of the arm LO valve,
service valve (right control valve) and arm
HI valve (left control valve).
q
Arm LO valve (Right control valve)
A retainer is installed between case
(32) and spring (33).
q
Arm HI (Left control valve)
Shim (35) is installed.
7.
Straight travel valve

1) Remove plate (36), then remove spring (37).
2) Remove plug (38), then pull out spool (39).
11
SEN01067-03
Assembly
12
PC600-8
SEN01067-03
1.
Straight travel valve

1) Install spool (39) and fit the O-ring, then
install plug (38).
2) Install spring (37), then install plate (36).
5.
Check valve
Install check valve (8) and spring (7), then fit
the O-ring and install plug (6).
3 Plug: 177 216 Nm {18 22 kgm}
2.
Bucket valve
1) Install spool (31). Install retainer (34) and
spring (33), then fit the O-ring and install
case (32).
2) Install retainer (30) and spring (29), then fit
the O-ring and install case (28).
q
Apply to the spools of the arm LO valve,
service valve (right control valve), and arm
HI valve (left control valve).
q
Arm LO valve (Right control valve)
Install the retainer between case (32)
and spring (33).
q
Arm HI valve (Left control valve)
Install shim (35).
6.
Safety valves having suction ports

Fit the O-ring, then install safety valves (5) and
(3) having suction ports.
3 Safety valve having suction port:
216 235 Nm {22 24 kgm}
7.
Jet sensor relief valve and main relief valve

Install jet sensor relief valve (2) and main relief
valve (1).
3 Jet sensor relief valve:
49 58.8 Nm {5 6 kgm}
3 Main relief valve:
177 196 Nm {18 20 kgm}
3.
Arm throttle valve

1) Install spool (27) and fit the O-ring, then
install plate (26).
2) Install spring (25) and fit the O-ring, then
install plug (24).
q
Reversely reinstall items (24), (25), and
(26) of the swing priority valve (right control valve) in 1) and 2) above.
4.
Left control valve

1) Install spool (16), then install retainer (23),
spring (22), retainer (21), spring (20), shim
(19), and retainer (18). Fit the O-ring and
install case (17).
2) Install retainer (15), spring (14), retainer
(13), spring (12), shim (11), and retainer
(10), then fit the O-ring and install case
(9).
q
Apply to the spools of the swing valve,
right travel valve, boom HI valve (right
control valve), and boom LO (left control
valve).
q
Swing valve spool (Right control valve)
not installed.
not installed.
q
Boom HI valve (Right control valve)
1] Install 2 shims (11).
2] Install plates instead of items
(17) (23) in 2) above.
q
Boom LO valve spool (Left control valve)
1] Shim (11) is not installed.
2] Items (18) (21) in 2 above are
not installed.
PC600-8
13
SEN01067-03

motor assembly
1
Removal
k
k

hydraulic tank.
1.
Remove step (1).
2.

valve and swing motor.
a Install tags and oil stopper plugs to all the
disconnected hoses.
3.
Disconnect 2 suction hoses (3).
4.
Disconnect 2 swing holding brake hoses (4).
5.
Disconnect 3 drain hoses (5).
6.
Remove hose bracket (6).
7.
Lift off swing motor assembly (7).

4
14
Installation
q

removal.
[*1]
a When installing, apply gasket sealant to the
following parts. (Apply the gasket sealant
around the bolt hole only at oil check hole (a).)
a When applying the gasket sealant to the ring
gear, take care.
2 Mating face of swing motor assembly:
[*1]
Swing motor assembly: 60 kg (1 piece)

again.
Bleeding air
Bleed air from the swing motor. For details, see
Testing and adjusting, Bleeding air from each
part.
PC600-8
Removal and installation of center

swivel joint assembly
1
SEN01067-03
Installation
q

removal.
Lower the work equipment completely to

the ground and stop the engine. Then
loosen the oil filler cap of the hydraulic tank
slowly to release the pressure inside the
hydraulic tank.
Refilling with oil (hydraulic tank)

through the system. Then check the oil level
again.
1.
Disconnect all hoses (1) at bottom of center

swivel joint assembly.
a Before disconnecting, mark all the hoses
with tags to prevent mistakes in the
mounting position when installing.
Bleeding air
Bleed the air from the travel motor.
For details, see Testing and adjusting, Bleeding air from each part.
2.
Remove elbow (2).
3.
Disconnect all hoses (3) at top of swivel joint

assembly.
a Before disconnecting, mark all the hoses
with tags to prevent mistakes in the
mounting position when installing.
4.
Pull out pin (4) and move link (5) towards frame.
5.
Sling center swivel joint assembly (6), then

remove 4 mounting bolts from bottom.
Removal
k
PC600-8
Center swivel joint assembly: 45 kg
15
SEN01067-03

center swivel joint assembly
T1
790-101-2501
Push-puller
t 1
790-101-2510
Block
t 1
790-101-2520
Screw
t 1
791-112-1180
Nut
t 1
790-101-2540
Washer
t 1
790-101-2630
Leg
t 2
790-101-2570
Plate
t 2
790-101-2560
Nut
t 2
790-101-2660
Adapter
t 2
N/R
Sketch
Part name
2
Qty
Part number
Necessity
Symbol
Special tools
Disassembly
1.
Remove cover (1).
2.
Remove snap ring (2).
3.
Using tools T1, pull out swivel rotor (4) and ring
(3) from swivel shaft (5).
4.
Remove O-rings (6) and slipper seals (7) from

swivel rotor (4).
16
CEP00381
PC600-8
SEN01067-03
Assembly
1.
Assemble slipper seals (7) and O-rings (6) to

swivel rotor.
2.
Set swivel shaft (5) on block [2], then using

push tool [1], tap swivel rotor (4) with a plastic
hammer to install.
2 Contact surface of rotor, shaft:
Grease (G2-LI)
a When installing the rotor, be extremely
careful not to damage the slipper seal and
O-ring.
2
3
CEP00381
3.
Install ring (3) and secure with snap ring (2).
4.
Fit O-ring and install cover (1).

3 Mounting bolt:
66.15 7.35 Nm {6.75 0.75 kgm}
PC600-8
17
SEN01067-03

work equipment PPC valve
assembly
Disassembly
1.
2.
Remove nut (1), then remove disc (2) and boot

(3).
Remove bolts, then remove plate (5).

a Do not remove joint (4) unless it is to be
replaced.
3.
Remove seal (6) and collar (7).
4.
Pull out piston (8), and remove retainer (9),

springs (10) and (11), and shim (12).
a Spring (10) consists of two springs each of
two types with different installed loads, so
check the mounting position (hydraulic
port) and mark with tags to prevent mistakes when installing.
5.
Pull out valve (13) from body (14).
5
6
7
8
9
10
11
12
13
14
CEP00424
18
PC600-8
SEN01067-03
7.
Assembly
1.
Assemble valve (13) to body (14).
2.
Assemble shim (12) and spring (11) to valve

(13).
a When assembling spring (11), set the end
with the small coil diameter (inside diameter) at shim (12) end.
3.
Assemble spring (10), retainer (9), and piston

(8).
a The number of loops in the coil for spring
(10) is different for each of the hydraulic
ports below, so be careful when installing.
Position of port
Free length of spring (mm)
P1, P2
44.4
P3, P4
42.4
Assemble boot (3) and disc (2), and tighten

with nut (1).
3 Nut: 112.8 14.7 Nm {11.5 1.5 kgm}
a After assembling the disc, adjust the
height of the disc.
For details, see Testing and adjusting,
Adjusting PPC valve.
The position of each port is marked at the

bottom of the valve body.
2 Piston: Grease (G2-LI)
a When assembling piston (8), coat the outside of the piston and the inside of the
hole in the body with grease.
4.
Fit O-ring to collar (7) and assemble in body

(14), then install seal (6).
5.
Install plate (5).

3 Mounting bolt:
13.2 1.5 Nm {1.35 0.15 kgm}
6.
Install joint (4).

2 Sliding portion of joint: Grease (G2-LI)
2 Female thread of body:
a Coat two places on the female thread with
one drop of thread tightener each as
shown in the diagram below.
3 Joint: 44.1 4.9 Nm {4.5 0.5 kgm}
a Keep strictly to the tightening torque.
PC600-8
19
SEN01067-03

travel PPC valve assembly
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tool
2 796T-416-1040 Push tool
t 1
T 3 796T-416-1050 Push tool
t 1
4 796T-416-1020 Push tool
t 1
Disassembly
1.
Remove screw (27) to remove lever (26).
6.
Remove seal (8) and collar (10).
2.
Remove mounting bolt (15) to remove case

(11), shaft (16) and lever (13) assembly.
7.
3.
Remove pin (19).
Remove piston (7) to remove retainer (5),

springs (6) and (4) and shim (3).
a Store shim (3) after checking the thickness
and the number of shims at each mounting position.
4.
Remove shaft (13), bushings (20) (20a) and

lever (12) from the case.
8.
Remove valve (2) from body (1).
5.
20
Remove mounting bolt (17) to remove plate

(14).
a Check the thickness and the mounting
position of washer (18).
a Remove pin (31) from body (1).
PC600-8
SEN01067-03
Assembly
Only the precautions for assembling the travel PPC
valve assembly are described.
a
When assembling, clean and inspect the parts

closely and take care fully so that dirt, rust,
flaw, etc. will not cause a trouble.
When installing piston (7), apply grease (G2LI) to its outside and the inside of the body
hole.
Install spring (4) with its small diameter side on

the shim (3) side.
q
Diameter of spring (Inside diameter)
Small diameter side: 4.9, Large diameter
side: 5.55
3)
4)
5)
Assemble shaft (13) with the following procedure.

1) Using tool T2, install bushing (20) to case.
a Install bushing from 10 chamfered
side.
a Installing dimension (A) of the bushing should be as follows.
q
A: 24.8 0.3 mm
Do not apply shock load to the bushing
directly.
2)
PC600-8
Using tool T3, install bushing (20a) to

case.
a Install bushing from 10 chamfered
side.
a Installing dimension (B) of the bushing (14a) should be as follows. (End
surface of bushing will tightly fit to the
end surface of case.)
q
B: 5.3 0.3 mm
a Do not apply shock load to the bushing directly.
Install lever (12).

Install shaft (13).
Using tool T4, install pin (19).
a Installing dimension (C) of the pin
(17) should be as follows.
q
C: 0 0.5 mm
a Do not apply shock load to the pin
directly.
Apply grease (G2-LI) to the rocking part of

shaft (16) and the contact surfaces of lever
(13) and piston (7) and the contact surfaces of
damper (21) and pin (20).
2 Quantity of grease (G2-LI)
Rocking part of shaft:
4 8 cc/periphery
Contact surfaces of lever and piston:
0.3 0.8 cc/place
Contact surfaces of plate and pin:
0.3 0.8 cc/place
Install washer (18) 1.6 mm thick first. If the difference between both sides at the stroke end
of the lever exceeds 0.7, change the washer
thickness to reduce the difference to below
0.7. (If the washer thickness is reduced by
0.3 mm, the stroke end angle is increased by
0.39.)
q
Thickness of washer (t):
1.0, 1.3, 1.6, 1.9, 2.2 mm
21
SEN01067-03
a
22
Tighten each part to the following torque.

q
Plug (29): 6 11 Nm {0.6 1.1 kgm}
q
Plug (28): 4 9 Nm {0.4 0.9 kgm}
q
Screw (27): 7.8 9.8 Nm {0.8 1.0 kgm}
q
Bolt (15): 25 30 Nm {2.5 3.2 kgm}
q
Bolt (17): 27 30 Nm {2.8 3.5 kgm}
PC600-8
SEN01067-03
4)

hydraulic cylinder assembly
Part name
1 790-502-1003
Cylinder repair
stand
q 1
2 790-720-1000
Expander
q 1
796-720-1670
Ring
q 1
07281-01279
Clamp
q 1
790-201-1702
Push tool kit
t 1
790-101-5021
Grip
01010-50816
Bolt
790-201-1871
Push tool
790-445-4210
Push tool
790-201-1881
Push tool
790-201-1500
Push tool kit
t 1
790-101-5021
Grip
01010-50816
Bolt
790-201-1680
Plate
790-201-1970
Plate
790-201-1690
Plate
790-102-4300
Wrench
t 1
790-102-4310
Pin
t 2
4
U
Sketch
Part number
N/R
Qty
Necessity
Symbol
Special tools
Disassemble piston rod assembly as follows.

1] Set piston rod assembly (2) to tool
U1.
2]
Remove piston assembly stopper

screw (3).
Screw size:
M12 pitch 1.75: Boom, Arm, Bucket
Disassembly
1.
Piston rod assembly

1) Remove piping from cylinder assembly.
2) Remove mounting bolts, and disconnect
head assembly (1).
3) Pull out piston rod assembly (2).
a Place a container under the cylinder
to catch the oil.
PC600-8
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.
23
SEN01067-03
3]
Using tool U6, remove piston assembly (4).

q
When not using tool U6, use the
drill holes (10: 2 places) and
loosen the piston assembly.
4]
5]
6]
Remove plunger (5).

Remove collar (6).
Remove head assembly (7).
7]
24
2.
Disassembly of piston assembly

1) Remove ring (11).
2) Remove wear ring (12).
a 2 pieces are installed to each of the
bucket cylinder and boom cylinder, and
4 pieces to the arm cylinder.
3) Remove piston ring (13).
4) Remove O-ring and backup ring (14).
3.
Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (15).
2) Remove snap ring (16), then remove dust
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
Remove cap (8), and pull out 11 balls

(9), then remove cushion plunger
(10).
q
Arm cylinder only
PC600-8
Assembly
a
a
1.
Be careful not to damage the packings, dust

seals, and O-rings.
Do not try to force the backup ring into position. Warm it in warm water (50 60C) before
fitting it.
SEN01067-03
2.
Assembly of piston assembly

1) Using tool U2, expand piston ring (13).
a Set the piston ring on tool U2, and
tu rn the han dle 8 1 0 times to
expand the ring.
2) Set tool U3 in position, and compress piston ring (13).
Assembly of cylinder head assembly

1) Using tool U4, press fit bushing (20).
2) Assemble buffer ring (19).
3) Assemble rod packing (18).
4) Using tool U5, install dust seal (17), and
secure with snap ring (16).
5) Install O-ring and backup ring (15).
3)
4)
5)
PC600-8
Install O-ring and backup ring (14).

Assemble wear rings (12).
Assemble rings (11).
a Be careful not to open the end gap of
the ring too wide.
2 Ring groove: Grease (G2-LI)
25
SEN01067-03
3.
Piston rod assembly

1) Set piston rod assembly (2) to tool U1.
2)
3)
4)
6)
Assemble piston assembly (4) as follows.

When using rod and piston assembly (2) again
a Wash thoroughly and remove all
metal particles and dirt.
1] Screw in piston assembly (4),
then use tool U6 to tighten piston
assembly so that position of
screw thread hole matches.
a Remove all burrs and flashes
with a file.
Assemble head assembly (7).

Fit O-ring and backup ring to collar (6),
then assemble.
Assemble plunger (5).
a After tightening the piston, check that
the plunger has a little play.
2]
3]
5)
26
Tighten screw (3).

2 Threaded part:
Adhesive
(Locktite No. 262 or equivalent)
3 Screw (3):
58.9 73.6 Nm {6 7.5 kgm}
Caulk thread at 4 places with
punch.
Set cushion plunger (10) to piston rod,

then assemble 11 balls (9), and secure
with cap (8).
q
Arm cylinder only
a After installing, check that the cushion
plunger end has a little play.
PC600-8
SEN01067-03
When using a new part for either or

both of rod or piston assembly (2)
a For the rod with bottom cushion,
mark the cushion plug position
on the end face of the rod.
q
Arm cylinder only
1] Screw in until piston assembly
(4) contacts end face of rod, then
use tool U6 to tighten.
3 Piston assembly (4):
294 29.4 Nm {30 3.0 kgm}
a After tightening the piston,
check that there is play in
plunger (5).
3]
4]
5]
2]
Machine one hole used to install

screw (3).
a Apply the drill to the V-groove
between piston (4) and
threaded part of rod (2), and
make a hole horizontally.
a For the cylinder with bottom
cushion (arm cylinder), avoid
the cushion plug position
when machining.
q
Screw machining dimension
(mm)
Cylinder
Drill
diameter
Bottom
hole
depth
Tap used
Tap
depth
Bucket
Boom
10.3
36
12 x 1.75
29
Arm
10.3
43
12 x 1.75
36
PC600-8
After machining, wash thoroughly to remove all metal particles and dust.
Tighten screw (3).
2 Threaded part:
Adhesive
(Locktite No. 262 or equivalent)
Screw:
58.9 73.6 Nm {6 7.5 kgm}
Caulk thread at 4 places with
punch.
27
SEN01067-03
7)
Assemble piston rod assembly (2).

2 Seal portion: Grease (G2-LI)
a Set the end gap of the ring at the horizontal (side) position, align the axial
center of shaft and cylinder tube, then
insert.
a After inserting, check that the ring is
not broken and has not come out,
then push in fully.
8)
Tighten head assembly (1) with mounting

bolts.
3 Mounting bolt :
Cylinder
9)
28
Tightening torque
Bucket, Boom
892 137 Nm {91.0 14 kgm}
Arm
1,270 200 Nm {130 20 kgm}
Install piping.
PC600-8

grease gun assembly
SEN01067-03
Assembly
1.
Install joint (1) to the hose.

a Wind seal tape two to three times around
the threaded portion as to bite into it starting from a position one winding away from
the end of the threaded portion.
3 Joint screwing portion:
5.9 11.8 Nm {0.6 1.2 kgm}
2.
Install gun assembly (2) to joint (1).

the end of the threaded portion.
3 Joint screwing portion:
3.9 6.9 Nm {0.4 0.7 kgm}
3.
Install nozzle (3) to gun assembly (2).

the end of the threaded portion. Screw in
the joint manually. When manual screwing
becomes disabled, use the tool and further screw in using nozzle (3).
4.
Install cap (4) to nozzle (3).
Disassembly
1.
Remove joint (1) from the hose.
2.
Remove gun assembly (2) from joint (1).
3.
Remove nozzle (3) from gun assembly (2).
4.
Remove cap (4) from nozzle (3).
PC600-8
29
SEN01067-03

2009 KOMATSU
All Rights Reserved
30
SEN01068-02
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

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

bucket cylinder assembly
(Backhoe specification)
5.
Removal
k
Retract the bucket cylinder piston rod to

about 200 mm before the dump stroke end,
lower the work equipment to the ground,
and set the lock lever in the lock position.
1.
Set block [1] under the arm top, block [2]

between the link and arm, and block [3]
between the bucket cylinder and arm.
2.
Remove pin (1) on the head side.
3.
Run the engine and retract the piston rod and

bind it with wires etc. to prevent it from coming
out.
k Stop the engine and release the residual pressure from the hydraulic circuit. For details, see Testing and
adjusting, "Releasing remaining pressure in hydraulic circuit."
4.
Disconnect right and left hoses (2).
Sling bucket cylinder assembly (3) temporarily

and remove pin (4) on the bottom side and
then remove bucket cylinder assembly.
[*2]
a Check the quantity and positions of the
inserted shims.
4
Pin (4): 25 kg
Bucket cylinder assembly: 470 kg
[*1]
PC600-8
Installation
q
SEN01068-02
Bleeding air
Bleed air from the hydraulic cylinder. For
details, see Testing and adjusting, "Bleeding
air from each part."

again.

removal.
[*1]
Inside surface of bushing:

Molybdenum disulfide lubricant (LM-P)
2 Greasing after installing pin:
Molybdenum disulfide grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust clearance (a) between links (5) and (6)
to 1 2 mm with the shim.
q
Shim thickness: 0.8 mm
[*2]

a Adjust clearance (b) between the bottom end
of cylinder (3) and bracket (7) to below 1 mm
with the shim.
q
PC600-8
SEN01068-02

bucket cylinder assembly
(Loading shovel specification)
3.
Disconnect grease tube (2).
4.
5.
Sling piston rod end and bottom end, and

remove plate, then using forcing screws (Thread
dia. = 16 mm, Pitch = 2.0 mm), pull out pin (4).
[*2]
a Pull out the pin to a position where the cylinder bottom can be disconnected.
Removal
k
a
1.
Extend the arm cylinder fully, set the bottom of the bucket horizontal, lower the
work equipment completely to the ground
and stop the engine. Operate the control
levers several times to release the remaining pressure in the hydraulic piping.
Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
Fit plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering.
Sling bucket cylinder assembly, and remove
plate, then using forcing screws (Thread dia. =
16 mm, Pitch = 2.0 mm), remove pin (1). [*1]
4
Pin: 40 kg
2.
Start engine and retract piston rod fully.

k Tie the rod with wire to prevent it from
coming out.
k After stopping the engine, release the
pressure inside the piping.
Releasing pressure in PPC circuit.
6.
Pin: 100 kg
Raise bucket cylinder assembly (5) carefully

and remove.
4
PC600-8
SEN01068-02
Installation
q

removal.
[*1]
When aligning the mounting position of the

pin, do not insert your fingers in the pin
hole.
[*2]

hole.
a Adjust with shims so that the clearance at
the cylinder bottom end is less than 1 mm.
Bleed the air from the work equipment circuit.

For details, see Testing and adjusting, Bleeding air from hydraulic cylinder.
Refilling with oil

a Add oil to the specified level, and run the
engine to circulate the oil through the system. Then check the oil level again.
PC600-8
SEN01068-02
Removal and installation of arm

cylinder assembly
1
Removal
k
Extend the arm cylinder piston rod to about

200 mm before the in stroke end, lower the
work equipment to the ground, and set the
lock lever in the lock position.
1.
Set block [2] between the arm cylinder and

boom.
2.
Disconnect grease hose (1).
3.
Pull out head pin (2).

[*1]
a If the head pin cannot be pulled out, use
tool [1].
4
4.
5.
6.
7.
Sling arm cylinder assembly (6) temporarily,

remove plate (7), and pull out bottom pin (8).
[*2]
a If the bottom pin cannot be pulled out, use
tool [1].
a Check the quantity and positions of the
inserted shims.
4 Pin (8): 40 kg
8.
Remove arm cylinder assembly (6).
Pin (3): 35 kg
Run the engine and retract the piston rod and

bind it with wires etc. to prevent it from coming
out.
k Release the residual pressure from the
hydraulic circuit. For details, see Testing and adjusting, "Releasing remaining pressure in hydraulic circuit."
Arm cylinder assembly: 730 kg

a Fit an oil stopper plug to the disconnected
hose to prevent foreign matter from entering the hose.
PC600-8
SEN01068-02
Installation
q

removal.
[*1]

[*2]

a Adjust clearance (a) between the bottom end
of cylinder (6) and bracket (9) to below 1 mm
with the shim.
q
Bleeding air
Bleed air from the hydraulic cylinder. For
details, see Testing and adjusting, "Bleeding
air from each part."

again.
PC600-8
SEN01068-02

cylinder assembly
(Loading shovel specification) 1
3.
Disconnect hoses (3).
4.
Sling piston rod end and bottom end, and

remove plate, then pull out pin (4).
[*2]
a Pull out the pin to a position where the cylinder bottom can be disconnected.
Removal
k
a
1.
Retract boom cylinder fully, and extend arm

cylinder, then set the bottom of the bucket
horizontal, lower the work equipment completely to the ground and stop the engine.
Operate the control levers several times to
release the remaining pressure in the
hydraulic piping.
Fit blind plugs in the hoses after disconnecting
Pin: 30 kg
Sling arm cylinder assembly, and remove plate,

then pull out pin (2).
[*1]
a Pull out the pin to a position where the piston rod can be disconnected.
4
2.
Pin: 30 kg
5.
Lift off arm cylinder assembly (5) carefully.

4
Arm cylinder assembly: 600 kg

k Tie the rod with wire to prevent it from
coming out.
PC600-8
SEN01068-02
Installation
q

removal.
[*1]

hole.
[*2]

hole.

Refilling with oil

PC600-8
SEN01068-02
Removal and installation of boom

cylinder assembly
1
6.
Start engine, and retract piston rod, then tie

piston rod with wire to prevent it from coming
out.
k Stop the engine and release the
remaining pressure in the circuit. For
details, see Testing and adjusting,
"Releasing remaining pressure in
hydraulic circuit."
7.
Support boom cylinder assembly (2) with a

stand, etc., and disconnect hose (4).
8.
Sling boom cylinder assembly and remove

plate (6).
9.
Pull out bottom pin (7).

[*2]
a If the bottom pin cannot be pulled out easily, use the forcing taps (16 x 2).
Removal
k
Retract the arm and bucket cylinder piston

rods fully, lower the work equipment completely to the ground, then put the work
equipment lock lever in the LOCK position.
Fit blind plugs in the hoses to prevent dust or
dirt from entering.
1.
2.
Sling boom cylinder assembly (2) temporarily,

and remove lock bolt (8).
3.
Remove plate (9).

a Check the number, thickness, and positions of the shims.
4.
Sling boom cylinder assembly (2) temporarily.
5.
Pin (7): 30 kg
Using tool [1], pull out head pin (3), then disconnect piston rod from boom.
[*1]
4
Pin (3): 110kg (1 piece)
10. Remove boom cylinder assembly.

4
10
Boom cylinder assembly:

550 kg (1 piece)
PC600-8
Installation
q
SEN01068-02
Bleeding air
Bleed the air.
For details, see Testing and adjusting, "Bleeding air from each part."

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.

removal.
[*1]

2 Lubrication after fitting pin:
k When aligning the position of the pin hole,
never insert your fingers in the hole.
a Adjust the shim so that gap (a) between rod
end of cylinder (2) and plate (9) will be 1 mm
maximum.
q
Thickness of shim: 0.5 mm
[*2]

a Adjust with shims so that clearance (b)
between bracket (11) and the bottom end face
of boom cylinder (2) is less than 1 mm.
q
Shim thickness: 0.8, 1.5 mm
PC600-8
11
SEN01068-02

cylinder assembly
5.
Lower boom cylinder assembly onto stand,

then disconnect hoses (4).
6.
Sling boom cylinder assembly, and remove

16 mm, Pitch = 2.0 mm), pull out foot pin (5).
[*2]
7.
Remove boom cylinder assembly (6).
Removal
k
Extend the arm and bucket fully, lower the

work equipment completely to the ground
and stop the engine. Operate the control
levers several times to release the remaining pressure in the hydraulic piping.
Fit plugs in the hoses after disconnecting them,
to prevent dirt or dust from entering.
1.
2.
Remove plate (2).
3.
Sling boom cylinder assembly, pull out pin (3),

and disconnect piston rod from boom.
[*1]
4.
k
k
12

Tie the rod with wire to prevent it from coming out.
After stopping the engine, release the pressure inside the piping.
Boom cylinder assembly: 550 kg
PC600-8
SEN01068-02
Installation
q

removal.
[*1]

pin, do not insert your fingers in the pin hole.
[*2]


Refilling with oil

PC600-8
13
SEN01068-02

bottom dump cylinder assembly
5.
Remove 3 mounting bolts, then using forcing

screws (Thread dia. = 16 mm, Pitch = 2.0 mm),
pull out pin (4).
[*2]
4
Pin: 20 kg
Removal
k
Set the bottom of the bucket horizontal, and

retract the rod to a position where the rod
connecting pin of the bottom dump cylinder can be removed. Then fit a block under
the bucket, lower the work equipment completely to the ground and stop the engine.
1.
Remove cover (1).
2.
Sling bottom dump cylinder assembly, and

remove lock plate, then using forcing screws
(Thread dia. = 16 mm, Pitch = 2.0 mm), pull out
pin (2).
[*1]
6.
Lift off bottom dump cylinder assembly (5).

4
Bottom dump cylinder assembly: 120 kg
Installation
q

removal.
[*1]

[*2]
3.
4.
14

Remove hoses (3).


Refilling with oil

PC600-8

bucket assembly
SEN01068-02
Removal
k
1.
Set the back of the bucket facing down,

lower the work equipment completely to the
ground, then set the work equipment lock
lever to the LOCK position.
Remove plate (1), then remove connecting pin
(2) of the link and bucket.
[*1]
a Check the number and thickness of the
shims, and keep in a safe place.
4
Pin (2): 55 kg
2.

link to arm with wire to prevent piston rod from
coming out.
hydraulic circuit."
3.
Remove plate (3), then remove connecting pin

(4) of the arm and bucket.
[*2]
4
4.
Pin (4): 65 kg
Start engine and raise work equipment, swing

work equipment, then remove bucket assembly (5).
4
PC600-8
Bucket assembly: 2,500 kg
15
SEN01068-02
Installation
q

removal.
[*1]

Lubricant containing molybdenum
disulfide (LM-G)
[*2]

Lubricant containing molybdenum
disulfide (LM-G)
a Insert the O-ring at the end face of the bucket
boss securely.
a Adjusting of bucket clearance
1) Measure gap (a) between arm (8) and
bucket (5).
a It is easier to measure if the bucket is
moved to one side so that all the play
is in one place.
2) Adjust the shim so that gap (a) will be 0.5
1 mm.
q
Shim thickness: 0.5, 1.0 mm
16
PC600-8

bucket assembly
(Loading shovel specification)
SEN01068-02
4.
Removal
k
Set the bottom of the bucket horizontal,

lower the work equipment completely to the
ground and stop the engine. Operate the
control levers several times to release the
remaining pressure in the hydraulic piping.
1.
Sling bucket cylinder assembly, and remove

16 mm, Pitch = 2.0 mm), pull out pin (1). [*1]
a Remove the pin on the other side in the
same way.
2.
Start the engine and retract the piston rod fully.

k Bind the piston rod with wires, etc., to
prevent it from coming out.
4
3.
Sling bucket assembly, and remove 3 mounting bolts, then using forcing screws (Thread
dia. = 16 mm, Pitch = 2.0 mm), pull out pin (4).
[*2]
a Remove the pin on the other side in the
same way.
4
5.
Pin: 55 kg
Lift off bucket assembly (5).

4
Bucket assembly: 6,000 kg
Pin: 40 kg
After stopping the engine, release the residual pressure in the piping. For details, see
Testing and adjusting, Releasing residual
pressure in PPC valve hydraulic circuit.
Disconnect bottom dump cylinder hose (2).
Installation
q

removal.
[*1] [*2]
k When aligning the mounting position of the
a
PC600-8

After completion of the air bleeding operation,
add engine oil to the hydraulic tank to the
specified level.
17
SEN01068-02

assembly
796T-670-1220 Sleeve
t 1
791-775-1130
Plate
t 1
796-670-1130
Screw
t 1
Adapter
t 1
Washer
t 1
01803-13034
Nut
t 1
790-101-4000
Puller
(490 N {50 ton})
t 1
790-101-1102
Pump
t 1
796-870-1110
V 1 01643-33080
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
6.

piston rod with wire to prevent it from coming
out.
hydraulic circuit."
7.
Disconnect 2 bucket cylinder hoses (4).
8.
Remove plate (5), then using tool V1, pull out

boom top pin (6).
[*2]
a There are shims installed, so check the
number, thickness, and position, and keep
in a safe place.
Removal
1.
Remove bucket assembly.

For detail, see "Removal of bucket assembly."
2.
Secure link to arm with wire.

k Extend the arm cylinder piston rod to a
point approx. 200 mm before the end of
the arm IN stroke, then lower the arm
on to block [1] and stand [2], and set
the work equipment lock lever to the
LOCK position. Then, stop the engine.
3.
Set block between arm cylinder and boom.
4.
5.
Remove plate (2), and pull out head pin (3) of

arm cylinder.
[*1]
a If the pin does not come out, use tool [1]
and remove the pin from the head end.
4
Pin (6): 80 kg
Pin (3): 35 kg
CEP00525
18
PC600-8
9.
SEN01068-02
Start engine, then raise boom and remove arm

assembly (7).
4
Installation
q
Arm assembly: 3,200 kg

removal.
[*1]

[*2]
CEP00526
PC600-8

a Adjust with shims so that clearance (a)
between boom (8) and the bottom end face of
arm (7) is less than 1 mm.
q
Bleeding air
Bleed the air.

19
SEN01068-02

assembly
6.
Removal
1.
Remove bucket assembly.

bucket assembly.
2.
Lower the tip of the arm assembly to the ground.
3.
Sling arm cylinder assembly (1) temporarily

and disconnect the rod side from the arm.
arm cylinder assembly.
a Secure the arm cylinder assembly to the
boom with lever block [1].
residual pressure in the piping. For
Releasing residual pressure in PPC
valve hydraulic circuit.
Sling arm assembly, and pull out pin (5). [*1]

a Pull out the pin on the other side in the
same way to a position where the arm can
be disconnected from the boom.
7.
Pin: 110 kg
Lift off arm assembly (6).

4
Arm assembly: 2,800 kg
Installation
q

removal.
[*1]
4.
5.
20
Disconnect right and left bottom dump cylinder

hoses (2).
Disconnect right and left bucket cylinder hoses
(3) and (4), 2 pieces on each side.

Bleeding air
Bleed the air.

PC600-8
SEN01068-02

assembly
1
796T-670-1210 Sleeve
t 1
791-775-1130
Plate
t 1
796-670-1130
Screw
t 1
Adapter
t 1
Washer
t 1
01803-13034
Nut
t 1
790-101-4000
Puller
(490 N {50 ton})
t 1
790-101-1102
Pump
t 1
796-870-1110
V 1 01643-33080
Sketch
N/R
Part name
Qty
Part number
Necessity
Symbol
Special tools
5.
Sling boom assembly (10).
6.
Using tool V1, remove boom foot pin (3), then

remove boom assembly (10).
[*1]
in a safe place.
4
Boom foot pin: 150 kg
Boom assembly: 4,800 kg
Removal
1.
Remove arm assembly.

For details, see "Removal of arm assembly."
k Lower the boom assembly completely
to the ground, then set the work equipment lock lever to LOCK position.
2.
Disconnect boom cylinder assembly from

boom.
For details, see "Removal of boom cylinder
assembly."
3.
Disconnect front lamp wiring.
4.
Disconnect bucket cylinder hoses (1) and arm

cylinder hoses (2).
PC600-8
10
CEP00299
21
SEN01068-02
Installation
q

removal.
[*1]

between end face of foot of boom (10) and
revolving frame (11) is less than 1 mm.
q
Shim thickness: 1.0 mm and 1.5 mm
Bleeding air
Bleed the air.

22
PC600-8

assembly
SEN01068-02
5.
Disconnect bottom dump cylinder hoses (3),

bucket cylinder hoses (4), and arm cylinder
hoses (5).
a When the hoses are disconnected, oil may
spurt out, so loosen the hose flanges
slowly before disconnecting.
6.
Disconnect head lamp wiring.
7.
Using the tool V1, remove boom foot pins (6),

then lift off boom assembly (7).
[*2]
Removal
1.

arm assembly.
2.
Sling bucket cylinder assembly (1), remove

plate, then pull out pin (2), and remove bucket
cylinder assembly.
[*1]
4
Pin: 100 kg
Remove the bucket cylinder on the other

side in the same way.
3.
Sling boom, set stand [1] at tip of boom to support boom.
4.
Remove boom cylinder from boom.

boom cylinder assembly.
a Remove the boom cylinder on the other
side from the boom in the same way.
PC600-8
Boom assembly: 3,880 kg
23
SEN01068-02
Installation
q

removal.
[*1] [*2]
k When aligning the mounting position of the
q
Bleeding air
Bleed the air.

24
PC600-8
SEN01068-02
Removal and installation of work

equipment
1
796T-670-1210 Sleeve
t 1
791-775-1130
Plate
t 1
796-670-1130
Screw
t 1
Adapter
t 1
Washer
t 1
01803-13034
Nut
t 1
790-101-4000
Puller
(490 N {50 ton})
t 1
790-101-1102
Pump
t 1
796-870-1110
V 1 01643-33080
Sketch
N/R
Part name
Qty
Part number
Necessity
Symbol
Special tools
5.
Sling boom assembly (10).
6.
Using tool V1, remove boom foot pin (3), then

disconnect work equipment assembly.
[*1]
in a safe place.
4
Boom foot pin: 150 kg
Work equipment assembly: 13,800 kg
Removal
1.

For details, see "Removal of arm assembly."
k Lower the boom assembly completely
to the ground, then set the work equipment lock lever to LOCK position.
2.
Disconnect boom cylinder assembly from

boom.
For details, see "Removal of boom cylinder
assembly."
3.
Disconnect front lamp wiring.
4.
Disconnect bucket cylinder hoses (1) and arm

cylinder hoses (2).
k To prevent oil from spurting out when
the engine is started, fit blind plugs
securely in the piping at the chassis
end.
PC600-8
10
CEP00299
25
SEN01068-02
Installation
q

removal.
[*1]

between end face of foot of boom (10) and
revolving frame (11) is less than 1 mm.
q
Shim thickness: 1.0 mm and 1.5 mm
Bleeding air
Bleed the air.

26
PC600-8
Removal and installation of work

equipment
SEN01068-02
3.
Disconnect head lamp wiring.
4.
Set bottom of bucket horizontal, lower work

equipment completely to ground, then sling
boom assembly (4).
5.
Using the tool V1, remove boom foot pins (5),

then disconnect work equipment assembly. [*1]
6.
Start engine, drive machine slowly in reverse,

and operate crane to lower boom foot to ground.
k Before driving the machine in reverse,
check that the boom foot is completely
separated from the machine body.
Removal
k
1.
2.
Retract the boom cylinder fully, extend the arm

cylinder, set the bottom of the bucket horizontal, then lower the work equipment completely
to the ground and stop the engine.
Operate the control levers several times to
release the remaining pressure in the
hydraulic piping. Then loosen the oil filler
cap slowly to release the pressure inside
the hydraulic tank.
Release the remaining pressure in the circuit.
For details, see Testing and adjusting, Releasing pressure in hydraulic circuit.
Disconnect boom cylinder from boom.
boom cylinder assembly.
Disconnect bottom dump cylinder hose (1), bucket
cylinder hoses (2), and arm cylinder hoses (3).
a When the hoses are disconnected, oil may
spurt out, so loosen the hose flanges
slowly before disconnecting.
k To prevent oil from spurting out when
the engine is started, fit blind plugs
securely in the piping at the chassis end.
PC600-8
Work equipment assembly: 16,200 kg
27
SEN01068-02
Installation
q

removal.
[*1]

Adjust the lifting height of the boom assembly
so that the boom foot is at the height of the
mount on the chassis.
Bleeding air
Bleed the air.

28
PC600-8
PC600-8
SEN01068-02
29
SEN01068-02

2009 KOMATSU
All Rights Reserved
30
SEN01069-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

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

operators cab
6.
Remove air conditioner connector plate (15).
7.
Disconnect connectors L03 (16), H03 (17),

H04 (18), and H05 (19).
8.
Disconnect upper and lower duct joints (20)

and (21).
9.
Remove controller sub-plate (22) and incline it

against the air conditioner.
Removal
k
1.

Remove rear covers (1), (2), (3), and (4).
2.
Remove duct (5), cover (6), and plate (7).
3.
Remove plate (8), duct (9) and the element.

a Remove the duct lock clip.
4.
Disconnect connector S13 (10).
5.
Disconnect cab wiring connectors N02 (11),

M10 (12), H08 (13), and H09 (14).
a Remove the clip and separate the wiring
harness from the cab.
PC600-8
10. Remove cover (23) and floor mat (24).
SEN01069-01
15. Disconnect radio antenna (31).

16. Remove clip (32) and take wiring harness (33)
out of grommet (34).
11. Move right console (25) into the cab.

12. Remove monitor panel undercover (26).
17. Take grommet (35) out of the right front of the
cab.
18. Disconnect the windshield washer hose from
(36).
19. Remove 4 mounting bolts (37) and 5 mounting
bolts (38).
a Check the types of the bolts.
13. Disconnect cab wiring connector W04 (27)

(Wiper motor).
14. Remove ducts (28) and (29).
a Both (28) and (29) are 2 in number.
a Cut the tie-wrap on the monitor wiring harness.
a Sling the monitor assembly and cab
together.
a When removing the monitor assembly,
remove cover (30) in advance.
PC600-8
SEN01069-01
20. Using lever block [1], lift off operator's cab

assembly (39).
4
Installation
q
Operator's cab assembly: 300 kg

removal.
Reference
Connection of window washer hoses
When starting the engine while the operator's

cab is removed (for transportation, etc.), use
the following brackets.
1) Bracket (41) for controller (40)
Part No.: 208-53-13920
2)
1)
Hose length from clamp end of part A: Connect

to the hose on the floor side at 150 mm.
2)
Hose length from clamp end of part B: Connect

to the hose on the tank side at 200 mm.
a Cut the extra part of each hose perpendicularly to it. (See the lower right of the figure.)
3)
Insert each hose end (HE) in joint (J) securely

until it touches joint (J). (See the upper right of
the figure.)
Bracket (42) for monitor panel assembly

(30)
Part No.: 208-53-13910
PC600-8
SEN01069-01
Removal and installation of operators cab glass (stuck glass)
Among the panes of window glass on the 4

sides of the operator's cab, 4 panes (1) (4)
are stuck.
In this section, the procedure for replacing the
stuck glass is explained.
When replacing front window glass (4), remove
front window assembly (5). (It is impossible to
replace only the front window glass while the
front window assembly is installed to the operator's cab.)
For the procedure for replacing the front window assembly, see "Removal and installation
of front window assembly."
PC600-8
(1) :
(2) :
(3) :
(4) :
(5) :
Right side window glass

Left side rear window glass
Door lower window glass
Front window glass
Front window assembly
(Front window glass + Front frame)
(6) : Both-sided adhesive tape
(16): Center trim seal
SEN01069-01
1 793-498-1210
Lifter
(Suction cup)
t 2
2 20Y-54-13180
Adapter
t 2
N/R
1.
Using a knife and scraper [5], remove the

remaining adhesive and both-sided adhesive
tape from the metal sheets (glass sticking surfaces) of the operator's cab.
a Remove the adhesive and both-sided
adhesive tape to a degree that they will
not affect adhesion of the new adhesive.
Take care not to scratch the painted surf a c e s . ( I f t h e pa i n t e d s u r f a c e s a r e
scratched, adhesion will be lowered.)
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.
Sketch
Part name
Qty
Part number
Installation
Necessity
Symbol
Special tools
Removal
a
Remove the window glass to be replaced

1.
Using seal cutter [1], cut the adhesive between

broken window glass (7) and operator's cab
(metal sheet) (8).
If a seal cutter is not available, widening the

cut with a screwdriver, cut the adhesive and
both-sided adhesive tape with knife [4].
2.
Remove the window glass.
PC600-8
3.
Apply primer (10).

a The using limit of primer (10) is 4 months
after the date of manufacture. Do not use
primer (10) after this limit.
a Use the primer within 2 hours after
unpacking it.
a Even if the primer is packed again just
after it is unpacked, use it within 24 hours
after it is unpacked for the first time. (Disc a r d t h e p r i m e r 2 4 h o u r s a ft e r i t i s
unpacked.)
1) Stir the primers for paint and glass sufficiently before using them.
a If the primer has been stored in a
refrigerator, leave it at the room temperature for at least half a day before
stirring it. (If the primer is unpacked
just after taken out of the refrigerator,
water will be condensed. Accordingly, leave the primer at the room
temperature for a sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer glass primer.
SEN01069-01
3)
Evenly apply paint primer to the surfaces

to stick both-sided adhesive tapes and the
surfaces out of those surfaces on operator's cab (8) which will be coated with the
adhesive.
2 Paint primer:
SUNSTAR PAINT PRIMER
580 SUPER or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2
times, its performance will be lowered.)
a
q
PC600-8
Parts to be coated with primer: Apply

the primer all over dimension (a).
Dimension to apply primer (a): 25 mm
SEN01069-01
a
q
q
In addition to the above parts, apply

the primer to right side window glass
(1) and door lower window glass (3).
Range to apply primer additionally for
right side window glass (1): (b)
Range to apply primer additionally for
door lower window glass (3): (c)
After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
4)
Evenly apply glass primer to the sticking

surfaces of window glass (9).
2 Glass primer:
SUNSTAR GLASS PRIMER
580 SUPER or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2
times, its performance will be lowered.)
a
a
a
Never apply wrong primer. If the glass

primer is applied by mistake, wipe it
off with white gasoline.
Parts to be coated with primer: Apply

the primer to the sticking surfaces of
window glass (9) and all over dimension (d) which will be on both-sided
adhesive tape (6) and operator's cab
(8).
Do not apply the primer to the
boarder about 5 mm wide between
the black part and transparent part of
the glass.
After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
Never apply wrong primer. If the
paint primer is applied by mistake,
wipe it off with white gasoline.
PC600-8
4.
SEN01069-01
a
Stick both-sided adhesive tape (6) along the

inside edge of the glass sticking section.
a Do not remove the release tape of the
both-sided adhesive tape on the glass
sticking side before sticking the glass.
a When sticking the both-sided adhesive
tape, do not touch the cleaned surface as
much as possible.
a Take care that the both-sided adhesive
tape will not float at each corner of the
window frame.
1)
PC600-8
Stick both-sided adhesive tape (6a)

additionally for right side window
glass (1).
Positions to stick additional bothsided adhesive tape for right side window glass:
(f) : 50 mm
(g) : 90 mm
(h) : 250 mm
2)
Stick both-sided adhesive tape (6) for left

side rear window glass (2) as shown in the
figure.
3)
Stick both-sided adhesive tape (6) for door

lower window glass (3) as shown in the
figure.
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.
SEN01069-01
a
a

a
Stick both-sided adhesive tape (6b)

additionally for door lower window
glass (3).
Positions to stick additional bothsided adhesive tape for door lower
window glass:
(j) : 110 mm
(k) : 90 mm
(m) : 200 mm
5.
4)
10
Stick both-sided adhesive tape (6) for front

window glass (4) as shown in the figure.
Stick both-sided adhesive tape (6c) of

the lower side of the front window
glass along the outside edge of the
lower line, differently from other bothsided adhesive tapes (6). (If it is
stuck along the inside, it will be seen
through the transparent part of the
glass.)
Position the new window glass.

1) Check the clearance between the window
glass and the operator's cab on the right,
left, upper, and lower sides, and then
adjust it evenly.
2) Stick tapes [6] between window glass (9)
and operator's cab (8) and draw positioning line (n).
a Stick tapes [6] to the right, left, and
lower parts of the right side window
glass, left side rear window glass, and
door lower window glass for accurate
positioning.
3) Cut the tape between window glass (9)
and operator's cab (8) with a knife, and
then remove the window glass.
a Do not remove the tapes left on the
window glass and operator's cab
before installing the window glass.
PC600-8
6.
When positioning front window glass

(4), set its horizontal position to the
frame width and set its vertical position so that height difference (p)
between it and the frame top will be 3
mm.
Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (Summer):
SUNSTAR PENGUINE
SEAL 580 SUPER "S"
2 Adhesive (Winter):
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25C.
a Never heat the adhesive higher than
30C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
PC600-8
SEN01069-01
1)
Break aluminum seal (13) of the outlet of

adhesive cartridge (12) and install the
nozzle.
2)
Cut the tip of the adhesive nozzle (14) so

that dimensions (q) and (r) will be as follows.
q
Dimension (q): 10 mm
q
Dimension (r): 15 mm
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.
11
SEN01069-01
5)
Apply adhesive (15) to the outside of bothsided adhesive tape (6) of the operator's
cab.
7.
a
a
a
12
Apply adhesive (15) to dimensions (s)

and (t) of both-sided adhesive tape
(6) of operator's cab (8).
q
Dimension (s): 10 mm
q
Dimension (t): 15 mm
Apply adhesive (15) thicker than
both-sided adhesive tape (6).
Apply the adhesive evenly.
Apply adhesive (15) additionally for

additional both-sided adhesive tape
(6a) of the right side window glass
and additional both-sided adhesive
tape (6b) of door lower window glass.
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.
You can perform this work efficiently

by pulling window glass (9) from
inside of the operator's cab with suction cup (Y1).
PC600-8
SEN01069-01
8.
Fix the window glass.

1) After installing right window glass (1) to
the operator's cab, insert stopper rubbers
(Y2) to 2 places (v) at the bottom of the
glass to fix the glass.
After installing front window glass (4),

fill the clearances between it and center trim seal (16) with caulking material
in range (s) to dimensions (t) and (u).
After applying the primer to glass (4)
of section A A, apply adhesive as
caulking material.
q
Caulking dimension (t): 2 mm
q
Caulking dimension (u): 5 mm
a When caulking, mask the glass side
and form the adhesive with a rubber
spatula as shown in the figure.
a Wipe off projected adhesive.
2 Glass primer:
SUNSTAR GLASS
PRIMER 580 SUPER
2 Adhesive: SUNSTAR PENGUINE
SEAL 580 SUPER "S" or "W"
2)
PC600-8
Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and double-sided adhesive tape to fit them completely.
13
SEN01069-01
9.
After installing the window glass, remove the

primer and adhesive from the operator's cab
and window glass.
a Using white gasoline, wipe off the adhesive before it is dried up.
a When cleaning the glass, do not give an
impact to it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20C and humidity of 60%).
2) After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait
at least 14 hours, at least 24 hours in total,
before operating the machine actually.
14
PC600-8
Removal and installation of front

window assembly
1
k

To replace the front window glass, the front
window assembly must be removed from the
operator's cab. The procedure for removing
and installing the front window assembly (front
frame and front window glass) is explained
below.
SEN01069-01
3.
Release the rear locks of the cab.
4.
Lower the front window assembly carefully a

little. Put out rollers (8) and (9) under the right
and left sides of the front window through the
portion from which the corner block was
removed in step 2 (the portion where the rail is
open) and hold them.
5.
Remove rollers (8) and (9) under the right and

left sides of the front window.
Removal
1.
Raise front window assembly (13) to the ceiling and fix it with the rear locks (right and left).
2.
Remove left corner block (1).

[*1]
a There is not a right corner block.
a Left striker bolt (2) will be used to hang the
pull-up assist cable in step 6.
PC600-8
15
SEN01069-01
6.
Remove left lower pin (10).

[*2]
a If left lower pin (10) is removed, plate (12)
at the end of pull-up assist cable (11)
comes off.
a Hang plate (12) on the left striker bolt.
k The return load of 58.8 N {6 kg} is
applied to the rear of the operator's
cab. Accordingly, take care when
removing left lower pin (10) to disconnect pull-up assist cable (11).
8.
Lower front window assembly (13) completely.

a Do not let the front window assembly
touch the monitor.
9.
Twist front window assembly (13) to the right

and left to remove both upper rollers (14) and
(15) from the rails, and then remove front window assembly (13).
Installation
7.
Put out the bottom of front window assembly

(13) through the rail opening portion and lower
it gradually.

removal.
[*1]
16
Adjust opening and closing of the front window

assembly according to the following procedure.
1.
Open and close the front window to check that

it does not interfere with the rails and the rollers are not hitch.
2.
If there is any problem in opening or closing of

the front window, loosen the mounting bolts of
roller adjustment brackets (16) and (17) and
adjust the condition of the front window, and
then tighten the mounting bolts again.
3 Mounting bolt: 34.3 Nm {3.5 kgm}
PC600-8
3.
Raise the front window assembly and fix it with

the rear locks (on both sides).
a Check that the locks in the rear of the
operator's cab are applied securely.
4.
Install left corner block (1).

a Tighten striker bolt (2) permanently after
adjusting it in step 5 below.
a Install the left corner block so that there
will be no level difference at rolling surface
(R) of the roller.
a Install left corner block (1) so that level difference (a) between it and the rail will be 0
1.0 mm.
PC600-8
SEN01069-01
5.
Adjust the striker bolt (Adjust the "close" lock

side of the front window assembly) according
1) Tighten left striker bolt (2) and right striker
bolt (3) at roughly right positions so that
cab-side trim seal (18) will be fitted to front
window glass (19).
2) Open and close the front window assembly and check the working condition of
right and left locks (20).
1] If both locks do not work normally,
move the striker bolts toward the rear
of the cab and tighten them again.
2] After moving the striker bolts, check
the fitness of front window glass (19)
and cab-side trim seal (18) which was
checked in step 1).
3] Repeat the work in 1] and 2] until the
fitness of the front window glass and
the working condition of both locks
(20) are acceptable, and then tighten
the striker bolts.
6.
After adjusting the striker bolts, splash water

heavily over the front window glass and check
that the water does not leak into the cab.
17
SEN01069-01
7.
18
Adjust the "open" lock side of the front window

assembly.
1) After adjusting the "close" lock side of the
front window in step 5, raise the front window assembly to the ceiling.
2) Check the following on the "close" lock
side of the front window assemblies at the
rear right and left of the operator's cab.
q
Check the working condition of right
and left locks (20).
q
Check that right and left stopper rubbers (22) are in contact with the front
window assembly and they have
bending allowance of 1.5 3.0 mm.
q
Check that limit switch (23) is pushed
back 4 7 mm by the front window
assembly.
a Since the position of limit switch (23)
cannot be adjusted, the "open" position of the front window assembly is
decided within the functioning range
of this switch.
a Limit switch (23) is installed so that
the wiper will not move even if the
wiper switch is turned ON by mistake
while the front window assembly is
"open". If the wiper operates while
there is not the front glass, it will fall
into the cab and break down.
a To see if limit switch (23) is effective,
turn the key switch ON and then turn
the wiper switch ON while the front
window assembly is "open". If limit
switch (23) is effective, the wiper
does not operate at this time.
q
After the above check, if the front window
assembly needs to be adjusted, perform
the following.
3) Close front window assembly (13).
4) Loosen striker plate (24).
6)
Loosen locknuts (26) of right and left rubber stoppers (22) and move right and left
rubber stoppers (22) back so that the front
window assembly will not touch the right
and left rubber stoppers (22) when it is
"open".
7)
Set the rubber stoppers so that limit switch

(23) will be pushed back 4 7 mm by the
front window assembly (13) (while it is
"open").
Adjust the working condition of lock (20)
and tighten 2 striker plate mounting bolts
(27).
8)
PC600-8
9)
Adjusting right and left rubber stoppers

(22)
1] Bring right and left rubber stoppers
(22) in contact with front window
assembly (13) (while it is "open").
2] Close front window assembly (13).
3]
4]
8.
SEN01069-01
Rotate right and left rubber stoppers

(22) to the left by 1.5 turns.
a Rotating rubber stoppers (22) to
the left by 1 turn is equivalent to
compressing the rubber about
1.5 mm.
a While the front window assembly is "open", it must compress
right and left rubber stoppers
(22) by 1.5 3.0 mm.
Tighten locknuts (26) of right and left
rubber stoppers (22).
Adjust front window assembly stopper (28).

1) Adjust and fix right and left stoppers (28)
so that stoppers (D) of front window
assembly (13) will be in contact with faces
(c) of stoppers (28) when front window
assembly (13) is pulled up.
9.
[*2]
Check the latching effort of the front window

assembly.
1) After finishing steps 5 8, check that
latching efforts of right and left locks (20)
and (21) are even.
a Check the latching efforts on both
"close" side (at the front of the operator's cab) and "open" side (at the rear
of the operator's cab).
3
2
PC600-8
Left lower pin:

27 34 Nm {2.75 3.47 kgm}
Mounting bolt: Adhesive (LT-2)
19
SEN01069-01

2009 KOMATSU
All Rights Reserved
20
SEN01070-02
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

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

conditioner unit assembly
7.
Remove ducts (10) and (11).
8.
Disconnect connectors D01 (12), D02 (13),

S30 (14), R09 (15), R18 (16), R08 (16-1), R10
(16-2), and K01 (17).
9.
Remove and sling controller (18).
Removal
k
k
1.

If you drain the coolant or if you disconnect
the heater hose when the coolant temperature in the radiator is high, you may be
scalded. In this case, wait until the coolant
temperature lowers and then drain the coolant or disconnect the heater hose.
Collect the air conditioner refrigerant (R134a)
from air conditioner circuit in advance.
[*1]
a Ask professional traders for collecting and
filling operation of refrigerant.
a Never release the refrigerant to the atmosphere.
k If refrigerant gets in your eyes, you
may lose your sight. Accordingly, put
on protective goggles, gloves and
working suits with long sleeves while
you are collecting the refrigerant or filling the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified person.
q
Refrigerant quantity: 1,260 50 g
2.
Swing the upper structure by 90.
3.
Drain the coolant.

6
4.
10. Remove plate (19).

11. Disconnect air conditioner unit connectors M27
(20) and M33 (21).
Coolant: 58 l
Remove rear covers (1), (2), (3), and (4).
12. Remove the air conditioner unit undercover.

a Part (A)
5.
Remove duct (5), cover (6), and plate (7).
6.
Remove plate (8) and duct (9).

a Remove the duct lock clip.
PC600-8
13. Remove mounting bolt (24) and connector

(25).
[*1]
14. Disconnect heater hoses (22) and (23) and air
conditioner hose (26).
[*1]
a Put tags to the disconnected hoses and
tubes to prevent a mistake in re-connecting them.
SEN01070-02
Installation
q
[*1]

removal.
a
a
a
a
When installing the air conditioner circuit

hoses, take care that dirt, water, etc. will
not enter them.
When connecting each air conditioner
hose, check that the O-ring is fitted to the
joint.
Check that each O-ring is free from flaw
and deterioration.
Coat the O-ring with compressor oil for
R134a (DENSO: ND-OIL 8, ZEXEL: ZXL
100 PG (PAG 46 or equivalent)) and
tighten the nuts with 2 spanners.
15. Remove the 7 mounting bolts and air conditioner unit assembly (27).
a (18): Removed controller.
Hose clamp (M6 bolt):

7.84 11.8 Nm {0.8 1.2 kgm}
Hose screw of M16 x 1.5:
11.8 14.7 Nm {1.2 1.5 kgm}
19.6 24.5 Nm {2.0 2.5 kgm}
29.3 34.3 Nm {3.0 3.5 kgm}
Filling air conditioner circuit with refrigerant (R134a)

Fill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 1,260 50 g

5
PC600-8
Coolant: 58 l
SEN01070-02

engine controller assembly
6.
Remove engine controller assembly (9).
[*1]

1.
Remove cover (1).
2.
Remove controller cover (2).
3.
Disconnect connectors CE02 (3) and CE03

(4).
a Use a hexagonal wrench of 4 mm.
4.
Disconnect clamps (5).
Disconnect connector (8).

a Use a hexagonal wrench of 4 mm.
Removal
k
5.
PC600-8
SEN01070-02
Installation
q

removal.
[*1]
When connecting connectors (3), (4), and (8),
check that there is no dust, dirt, etc. in them.
Reference
Method of replacing O-ring seal of power connector (4)
O-ring seal: 1010-074-0406 (NIHON-DEUTSCH LIMITED)
1)
Using tweezers [1], hold the claw and

remove cover (6).
2)
Using tweezers [1], remove O-ring (7).
PC600-8
SEN01070-02
Removal and Installation of

KOMTRAX terminal assembly
Removal
k
Removal and installation of pump

controller assembly
1
Removal
Disconnect the negative () terminal of battery.

1.
Remove covers (1), (2), and (3).
1.
Remove covers (1), (2), and (3).
2.
Disconnect GPS connector (4) and antenna

wire (5).
2.
Disconnect pump controller wiring connectors

C01 (4), C02 (5), and C03 (6).
3.
Disconnect connector G01 (6).
3.
Remove the 4 mounting bolts and pump controller assembly (7).
4.
Remove 4 mounting bolts and

KOMTRAX terminal assembly (7).
remove
Installation
q
Installation
q

removal.

removal.
PC600-8

monitor assembly
SEN01070-02
Installation

removal.
Removal
k

1.
Remove cover (1) and disconnect wiring connector P15 of air conditioner sunlight sensor
(2).
a Raise and remove the cover.
2.
Remove the 3 mounting screws and monitor

assembly (3).
a Disconnect monitor panel wiring connectors P01, P02, and P70 before removing
the monitor assembly.
PC600-8
SEN01070-02

2009 KOMATSU
All Rights Reserved
SEN00144-03
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

Hydraulic circuit diagram (1/4) (Backhoe specification).................................................................................. 3
Hydraulic circuit diagram (2/4) (ATT specification) ......................................................................................... 5
Hydraulic circuit diagram (3/4) (Loading shovel specification) ....................................................................... 7
Hydraulic circuit diagram (4/4) (Loading shovel specification) ....................................................................... 9
PC600-8
SEN00144-03
PC600-8
Hydraulic circuit diagram (1/4) (Backhoe specification)
Hydraulic circuit diagram (1/4)

PC600, 600LC-8
SEN00144-03
PC600-8
Hydraulic circuit diagram (2/4) (ATT specification)

PC600, 600LC-8
SEN00144-03
PC600-8
Hydraulic circuit diagram (3/4) (Loading shovel specification)

PC600, 600LC-8
SEN00144-03
PC600-8
Hydraulic circuit diagram (4/4) (Loading shovel specification)

PC600, 600LC-8
SEN00144-03
PC600-8
PC600-8
SEN00144-03
11
SEN00144-03

2010 KOMATSU
All Right Reserved
12
SEN00145-04
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model
Serial number
PC600-8
PC600LC-8
30001 and up
30001 and up

Electrical circuit diagram (1/6) ........................................................................................................................ 3
Electrical circuit diagram (5/6) .......................................................................................................................11
Electrical circuit diagram (6/6) ...................................................................................................................... 13
Connector arrangement diagram.................................................................................................................. 15
Electrical circuit diagram for air conditioner .................................................................................................. 17
PC600-8
SEN00145-04
PC600-8
Electrical circuit diagram (1/6)

PC600, 600LC-8
SEN00145-04
PC600-8

PC600, 600LC-8
SEN00145-04
PC600-8

PC600, 600LC-8
SEN00145-04
PC600-8

PC600, 600LC-8
SEN00145-04
PC600-8

PC600, 600LC-8
SEN00145-04
PC600-8
11

PC600, 600LC-8
SEN00145-04
PC600-8
13
Connector arrangement diagram

PC600, 600LC-8
Connector arrangement diagram

Connector
No.
A01
A02
A03
A05
A06
A07
A09
A10
A11
A13
A15
A16
A26
B01
B02
B03
B11
B12
B13
B14
B15
B16
B17
B18
B19
B21
B22
B23
B24
B25
B26
B27
B28
B29
BP
CE02
CE03
CM01
CM02
CM03
CN1
CN2
CN3
CN4
CN5
CN6
CP01
CP02
CP03
D01
D02
D03
D04
E22
EGR
ENG
F01
G
G01
G02
G03
G04
G05
H01
H02
H03
H04
H05
H06
H07
H08
H09
J01
J02
J03
J04
J05
J06
J07
J08
J11
J12
J13
J14
J15
J16
J17
J18
J19
J20
J21
J22
J23
J24
J25
J26
J27
J28
J1939
JM01
JM02
JM03
JM04
JM05
JM06
JM07
JM08
K01
K01
K02
K03
L01
L02
L03
L04A
L04B
L05
L06
X
X
DT
DT
DT
SWP
SWP
DT
DT
DT
X
DT
X
HD30
DT
DT
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
DT-T
DRC
DRC
70
40
40
DT
DT
DT
DT
DT
DT
DRC
OTP
DRC
SWP
SWP
SWP
SWP
DT
DT-T
DRC
SUMITOMO
Number
of pins
4
4
12
12
12
16
8
6
6
2
2
2
2
21
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
50
4
12
20
16
2
2
2
2
2
2
24
40
40
8
8
8
8
6
2
60
20
2
X
X
X
X
M
S
S
S
S
S090
M
1
1
1
1
8
8
16
16
12
20
1
Inspection connector
Intermediate connector
J
J
J
J
J
J
J
J
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
DT
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
DRC
M
DT
DT
DT
DT
M
YAZAKI
YAZAKI
YAZAKI
YAZAKI
20
20
20
20
20
20
20
20
Joint connector (Black)

Joint connector (Black)
Joint connector (Green)
Joint connector (Green)
Joint connector (Pink)
Joint connector (Orange)
Joint connector (Orange)
Joint connector (Pink)
Centralized terminal (Horn signal)
Centralized terminal (Horn signal)
Centralized terminal
CAN connector
Centralized terminal (Engine)
KOMTRAX (If equipped)
Resistor (30z)
CAN terminal resistance
CAN terminal resistance
Working lamp (Boom)
Right headlamp
Room light
Headlamp
Headlamp
Rotary lamp (If equipped)
Step light
Model
3
6
6
10
4
3
3
4
6
40
2
3
3
2
2
2
2
2
2
2
Component name
Intermediate connector (To boom working lamp)
Intermediate connector (Flash light)
Intermediate connector (To fan reverse solenoid)
Intermediate connector (Travel pressure switch)
Intermediate connector (Circuit breaker)
Circuit breaker (1)
Circuit breaker (2)
Circuit breaker (3)
Circuit breaker (4)
Circuit breaker (5)
Circuit breaker (6)
Circuit breaker (7)
Circuit breaker (8)
Circuit breaker (9)
Circuit breaker (1)
Circuit breaker (2)
Circuit breaker (3)
Circuit breaker (4)
Circuit breaker (5)
Circuit breaker (6)
Circuit breaker (7)
Circuit breaker (8)
Circuit breaker (9)
Bypass valve
Engine controller
Engine controller
Machine monitor
Machine monitor
Machine monitor
Injector #1
Injector #2
Injector #3
Injector #4
Injector #5
Injector #6
Pump controller
Pump controller
Pump controller
EGR valve
Engine controller
Fuse
G sensor
Address of
stereogram
W-1
W-1
Q-2
W-1
Q-1
V-1
Q-2
R-1
F-1
D-9
D-1
G-9
Q-1
A-7
C-9
B-9
K-2
K-2
K-1
L-4
L-1
L-1
M-4
M-3
M-1
K-3
K-3
K-2
L-4
M-3
L-1
M-4
M-3
M-2
AI-7
I-8
J-8
Q-6
Q-5
Q-5
AI-6
AK-9
AI-6
AI-3
AI-3
AN-7
Y-9
X-9
X-9
AB-2
AB-2
U-1
T-1
J-6
AJ-8
AK-2
X-2
AI-4
Z-9
Y-9
Y-9
Z-9
Z-9
AE-9
W-9
V-9
V-9
Q-7
W-1
AA-6
AA-5
Y-2
Y-3
Y-3
Z-3
Z-3
Z-3
Z-3
AA-4
F-1
E-1
E-1
D-1
D-1
I-2
AL-8
AM-1
AL-1
AL-1
AN-3
AN-4
AM-8
AM-8
Y-9
Z-1
Q-4
A-5
AE-8
AD-7
AC-7
AD-8
Connector
Number
Model
No.
of pins
L07
DT
2
M01
PA
9
M02
KES0
2
M03
KES0
2
M04
YAZAKI
2
M05
M
6
M06
KES
2
M07A
Terminal
1
M07B
Terminal
1
M08A
Terminal
1
M08B
Terminal
1
M09
M
2
M10
M
2
M11
M
3
M12
M
2
M13
M
2
M14
D
2
M15
M
6
M16
X
2
M23
Terminal
1
M26
S
12
M27
18
M29
20
M30
16
M33
4
M34
X
1
N01
90
4
N02
DT
12
NE
FRAMATOME
2
P01
AMP
3
P02
X
2
P03
X
2
P04
AMP
3
P05
X
2
P06
X
2
P08
X
2
P09
X
2
P13
X
2
P17
2
P20
M
2
P21
DT
2
P22
DT
2
P23
DT
2
P24
DT
2
P25
DT
3
P26
DT
3
P29
DT
2
P31
Y050
2
P44
DT
2
PAMB
FRAMATOME
3
PCV1
SUMITOMO
2
PCV2
SUMITOMO
2
Component name
PEVA
FRAMATOME
PFUEL
PIM
POIL
R01
R02
R03
R04
R05
R06
R07
R08
R09
R10
R15
R16
R17
R18
R30
R31
RES
S01
S02
S04
S05
S06
S07
S08
S10
S11
S12
S13
S14
S21
S22
S25
S30
SBP
SEGR
ST
T01
T02
T04
T05
T06
T07
T08
T09
T10
TETR
TFUEL
TIM
TWTR
V01
V03
V04
V05
V06
V07
V08
V11
V13
V17
V20
V21
AMP
AMP
SUMITOMO
Terminal
Terminal
Terminal
Terminal
Relay
Relay
Relay
Relay
Relay
Relay
Terminal
Terminal
Terminal
Relay
Relay
DT
Terminal
M
M
M
M
M
M
Y090
Y090
Y090
M
M
Terminal
Terminal
90
S
DT
DT
DT
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
3
3
3
1
1
1
1
5
5
5
5
5
5
1
1
1
5
5
4
2
6
3
4
2
3
2
2
2
2
2
2
2
6
6
16
8
4
4
2
1
1
1
1
1
1
1
1
1
Flash light (If equipped)

Radio
Speaker (Left)
Speaker (Right)
Cigarette lighter
Wiper motor
Window washer motor
Horn (High tone)
Horn (High tone)
Horn (Low tone)
Horn (Low tone)
Optional power supply
Intermediate connector (Optional power supply)
DC/DC converter
12V socket
12V socket
Travel alarm
Lower wiper
Electric grease gun
Intake air heater
Intermediate connector (Air conditioner)
Auto air conditioner control unit
Auto air conditioner control unit
Air conditioner compressor electromagnetic clutch
Boot program
Network bus
NE sensor
Bucket curl pressure switch
Boom lower pressure switch
Swing pressure switch
Arm IN pressure switch
Bucket dump pressure switch
Boom raise pressure switch
Arm OUT pressure switch
Travel pressure switch
Bottom dump switch (For loading shovel)
Air conditioner high/low pressure switch
Fuel control dial
Fuel level sensor
Hydraulic oil temperature sensor
Air cleaner clogging sensor
Radiator coolant level sensor
Front pump pressure sensor
Rear pump pressure sensor
Ambient temperature sensor (Intake air temperature)
Daylight sensor
Engine oil level switch
Ambient pressure sensor
Supply pump 1
Supply pump 2
EG valve inlet pressure sensor
(PEVA is abolished after engine serial number 530885)
Common rail pressure
Boost pressure
Engine oil pressure sensor
Battery relay (E) terminal
Battery relay (BR) terminal
Battery relay (M) terminal
Battery relay (B) terminal
Light relay
Starting motor cutout relay (PPC lock)
Starting motor cutout relay (Personal code)
Horn relay
Step light relay
Flash light relay (If equipped)
Intake air heater relay (Inlet)
Intake air heater relay (Outlet)
Intake air heater relay (Drive coil inlet)
Intake air heater relay drive relay
Blower relay
Compressor relay
Resistor (620z)
Starting switch
Light switch
Swing lock switch
Machine pushup switch
Boom shockless switch
Rotary lamp switch
Lower wiper switch
Horn switch
Knob switch
Rear limit switch
Step light switch
PPC oil pressure lock switch
Emergency pump drive switch
Swing holding brake release switch
Intermediate connector (To right console emergency switch)
Model selector connector
Bypass valve
EGR valve position sensor
Starting motor S, R circuit
Floor frame ground
Cab ground
Revolving frame ground
Engine body ground
PACKARD
PACKARD
PACKARD
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Fuel temperature sensor

Boost temperature sensor
Coolant temperature sensor
PPC basic pressure lock solenoid
Bucket high cancel solenoid
Travel high/low selector solenoid
Swing holding brake solenoid
Boom head 2-stage safety valve solenoid (Machine pushup)
CO cancel solenoid
TVC solenoid
Fan pump EPC solenoid
Fan reverse solenoid
Bottom dump close (For loading shovel)
Bottom dump open (For loading shovel)
Address of
stereogram
X-2
AH-8
AG-8
Q-3
AC-4
H-1
C-1
C-1
B-2
B-2
AA-5
AA-6
AA-6
AA-7
AA-8
J-5
D-1
A-6
J-7
AA-4
AA-6
AA-5
J-7
AA-7
AM-2
H-1
I-9
H-9
I-8
J-2
I-2
G-9
S-1
H-1
U-1
R-8
A-6
J-4
H-9
J-6
H-9
H-9
G-9
Q-5
J-8
AK-1
AI-5
AI-5
AK-9
AJ-2
AN-5
AJ-2
M-8
K-8
L-9
M-9
R-8
S-8
T-9
Z-2
Z-2
Z-1
M-7
M-7
K-7
Z-2
AA-7
AA-4
AL-8
Q-7
S-8
S-9
T-9
X-2
X-2
Q-7
V-1
AF-9
F-1, AH-2
V-1
U-9
U-9
T-9
Z-2
AI-7
AI-8
Y-3
AH-3
B-2
A-2
A-3
A-3
A-4
J-7
C-1
AN-4
AN-6
AN-7
G-1
H-1
F-9
F-9
D-9
E-9
E-9
J-4
J-6
SEN00145-04
PC600-8
15
Electrical circuit diagram for air conditioner
Electrical circuit diagram for air conditioner

PC600, 600LC-8
SEN00145-04
PC600-8
17
PC600-8
SEN00145-04
19
SEN00145-04

2008 KOMATSU
All Right Reserved
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Shop Manual (PC600LC-8)

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SEN00128-15

00 Index and foreword

00 Index and foreword

Composition of shop manual

Shop Manual, contents binder, binder label and tabs

00 Index and foreword

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

00 Index and foreword

50 Disassembly and assembly

90 Diagrams and drawings

00 Index and foreword

00 Index and foreword

Hydraulic system, Part 2

00 Index and foreword

Reduced cylinder mode operation ................................................................................................ 18

00 Index and foreword

00 Index and foreword

Failure code [CA2271] EGR Valve Pos Sens High Error.............................................................. 58

00 Index and foreword

E-14 Fuel gauge does not display correctly ................................................................................. 27

00 Index and foreword

S-4 Engine stops during operations..............................................................................................

50 Disassembly and assembly

00 Index and foreword

Disassembly and assembly of main control valve assembly ........................................................ 10

00 Index and foreword

PC600, 600LC-8 Hydraulic excavator

00 Index and foreword

Foreword and general information

00 Index and foreword

Important safety notice

If welding repairs are needed, always

Prohibition of operation and handling by

6 Safety check before starting work

Wearing protective goggles

Wearing shielding goggles and protectors

9 Good physical condition and preparation

Precautions against work which you are

00 Index and foreword

Preparations for work

Precautions during work

When removing a cover which is under

Precautions for sling work and making

00 Index and foreword

When installing wire ropes to an angular

11) Do not use twisted or kinked wire ropes.

00 Index and foreword

If the load is unstable or the wire rope

Precautions for using mobile crane

Selecting wire ropes

The allowable load is one-sixth of the

00 Index and foreword

Example of O-ring (Fitted to every joint of

For tightening torque, see the precautions for

00 Index and foreword

How to read the shop manual

Composition of shop manual

Revision and distribution