The Komatsu PC2000-8 Mining Excavator is a big production machine for stripping, loading trucks, and hard digging in mining pits and quarries. The Komatsu PC2000-8 Mining Excavator Shop Manual (SEN01607-40) is what shop mechanics and field techs reach for when something’s broken, out of spec, or coming apart for overhaul. People usually want this manual when fault codes won’t quit, boom or bucket performance drops, or a major component needs to come out of the frame.
What this manual helps you do
- Trace hydraulic problems in the main and pilot circuits using the test ports, flow paths, and step-by-step diagnostic routines these manuals usually lay out.
- Diagnose engine and electronic control issues with the kind of troubleshooting trees and wiring diagrams you’d expect in a shop-level book.
- Follow disassembly and reassembly sequences for major components like swing, travel, cylinders, and front attachment so you don’t miss hidden fasteners or seals.
- Check adjustment procedures for things like travel, swing, and attachment functions so the machine behaves correctly after repairs.
- Handle machine-level rebuild work, from pulling components safely to verifying systems are ready to go back into production.
Who this is for
This is aimed at shop mechanics, field service techs, and rebuild shops that actually tear into a PC2000-8, not just grease and fuel it. If you’re an operator or fleet manager just wanting daily checks and basic service intervals, you’re better off with the Operation & Maintenance Manual instead of this shop manual.
FAQ
Q: Is this a PDF I can download and search?
A: Yes, it’s a PDF you can download, search by keyword, and print specific pages for use in the shop.
Q: Is it detailed enough for full component teardown?
A: Yes, a shop manual at this level is written for full diagnostic work and major component disassembly and reassembly on the PC2000-8.
Q: How do I know if it matches my exact PC2000-8 machine?
A: Check your machine’s identification plate and make sure it matches the PC2000-8 designation; if your tag shows a different series, you’ll need that matching shop manual instead.
Bottom line: If you’re the one actually fixing or rebuilding a PC2000-8, this shop manual is what you want; if you only do basic servicing or operate the machine, keep looking for the O&M book instead.
📘 Show Index
Table of Contents:
- 00 Index and foreword
- Index
- Composition of shop manual
- Table of contents
- Foreword and general information
- Safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling of electric equipment and hydraulic component
- Handling of connectors newly used for engines
- How to read electric wire code
- Precautions when carrying out operation
- Method of disassembling and connecting push-pull type coupler
- Standard tightening torque table
- Conversion table
- 01 Specification
- Specification and technical data
- Specification drawings
- Specifications
- Weight table
- Table of fuel, coolant and lubricants
- 10 Structure, function and maintenance standard
- Engine and cooling system
- Radiator and oil cooler
- PTO
- PTO lubrication system
- Power train
- Power train
- Swing machinery
- Swing circle
- Final drive
- Sprocket
- Undercarriage and frame
- Track frame
- Idler
- Carrier roller
- Track roller
- Track shoe
- HIC system
- Hydraulic system, Part 1
- Hydraulic piping drawing
- Hydraulic tank
- Oil cooler
- Line oil filter
- Pilot oil filter
- Return oil filter
- Motor drain oil filter
- Pump drain filter
- Accumulator
- Travel junction valve
- Solenoid valve
- Hydraulic cylinder
- Greasing system
- Center swivel joint
- Hydraulic ladder system
- Service center system
- Hydraulic system, Part 2
- Hydraulic system, Part 2
- Control valve
- Electronic OLSS system
- Swing motor
- Cooling fan motor (For radiator and oil cooler)
- Cooling fan pump
- Hydraulic system, Part 3
- Travel motor
- Hydraulic pump
- PPC valve
- Variable back pressure valve
- Suction selector valve
- PPC cut-off valve
- Work equipment
- Work equipment
- Dimensions of work equipment
- Cab and its attachments
- Air conditioner piping
- Cab
- Electrical system
- Engine control
- Electrical control system
- Monitor system
- Sensor
- ORBCOMM terminal
- 20 Standard value table
- Standard service value table
- Standard service value table for engine
- Standard service value table for chassis (Backhoe specification)
- Standard service value table for chassis (Loading shovel specification)
- 30 Testing and adjusting
- Testing and adjusting, Part 1
- Tools for testing, adjusting, and troubleshooting
- Measuring engine speed
- Testing air boost pressure
- Testing exhaust temperature
- Testing exhaust color
- Adjusting valve clearance
- Testing compression pressure
- Testing blow-by pressure
- Testing engine oil pressure
- Handling fuel system parts
- Releasing residual pressure in fuel system
- Testing fuel pressure
- Reduced cylinder mode operation
- No-injection cranking
- Testing leakage from pressure limiter and return rate from injector
- Bleeding air from fuel circuit
- Bleeding air from fuel circuit (lowgrade fuel specification)
- Testing fuel system for leakage
- Testing and adjusting alternator belt tension
- Testing and adjusting air conditioner compressor belt tension
- Handling controller high-voltage circuit
- Testing and adjusting, Part 2
- Testing swing circle bearing clearance
- Remaining pressure relief from HIC circuit
- Gas filling in HIC circuit accumulator
- Bleeding air from HIC circuit and supplying oil to it
- Testing and adjusting track shoe tension
- Testing and adjusting work equipment, swing and travel circuit oil pressures
- Testing and adjusting control circuit oil pressure (output pressure of self pressure reducing valve)
- Testing and adjusting main pump control signal
- Measuring fan speed
- Measuring fan pump EPC solenoid current
- Measuring fan pump EPC solenoid valve output pressure
- Oil pressure measuring points for pump discharge pressure or jet sensor differential pressure
- Measuring PPC valve output pressure
- Measuring solenoid valve outlet pressure
- Adjusting work equipment and swing PPC valve
- Testing and adjusting travel deviation
- Testing work equipment hydraulic drift cause portion
- Testing oil leakage
- Remaining pressure relief from hydraulic circuit
- Air bleeding from each component
- Testing and adjusting auto grease system
- Adjusting mirrors
- Testing and adjusting clearance of hydraulic ladder proximity switch
- Testing and adjusting position of hydraulic ladder position sensor plate
- Testing and adjusting clearance to service arm proximity switch
- Testing and adjusting, Part 3
- Special functions of machine monitor
- Handling controller voltage circuit
- Testing and adjusting, Part 4
- VHMS controller initial setting procedure
- Precautions for replacing VHMS controller
- Preparation work for troubleshooting of electrical system
- Pm-clinic service
- Measurement procedure
- 40 Troubleshooting
- Failure code table and fuse locations
- Failure code table
- Before carrying out troubleshooting of electrical system
- General information on troubleshooting
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Checks before troubleshooting
- Checking water pump for water leakage
- Classification and procedures of troubleshooting
- Connection table for connector pin numbers
- T- branch box and T- branch adapter table
- Troubleshooting by failure code, Part 1
- Failure code [0410KA] Fuel LV. Sensor Failure
- Failure code [0410KB] Fuel LV. Sensor Failure
- Failure code [6014NX] Hydraulic Oil Filter Clogging (or change of VHMS-LED display from n5 to 51)
- Failure code [8800ZG] Auto grease abnormally
- Failure code [7@HAZL] VR1/P1F Relief Press Abnormality
- Failure code [7@HBZL] VL1/P1R Relief Press Abnormality
- Failure code [7@HCZL] VR2/P2F Relief Press Abnormality
- Failure code [7@HDZL] VL2/P2R Relief Press Abnormality
- Failure code [AA10NX] Aircleaner Clogging
- Failure code [AB00KE] Charge Voltage Low
- Failure code [aB00KE] Low Upper ALR Charge Voltage (or change of VHMS-LED display from n9 to 11)
- Failure code [B@BAZG] Eng. Oil Press. Low
- Failure code [B@BAZK] Eng. Oil Level Low
- Failure code [B@BCNS] Eng. Water Overheat
- Failure code [B@BCZK] Eng. Water Lvl Low
- Failure code [B@CBNS] PTO Oil Overheat (or change of VHMS-LED display from n5 to 61)
- Failure code [B@HANS] Hydr. Oil Overheat
- Failure code [B@HAZK] Low Hydraulic Oil Level (or change of VHMSLED display from n5 to 52)
- Failure code [CA111] ECM Critical Internal Failure
- Failure code [CB111] ECM Critical Internal Failure
- Failure code [CA115] Eng. Ne and Bkup Speed Sens Error
- Failure code [CB115] Eng. Ne and Bkup Speed Sens Error
- Failure code [CA122] Chg Air Press Sensor High Error
- Failure code [CA123] Chg Air Press Sensor Low Error
- Failure code [CA131] Throttle Sensor High Error
- Failure code [CA132] Throttle Sensor Low Error
- Failure code [CA135] Eng Oil Press Sensor High Error
- Failure code [CA141] Eng Oil Press Sensor Low Error
- Failure code [CA144] Coolant Temp Sens High Error
- Failure code [CA145] Coolant Temp Sens Low Error
- Failure code [CA153] Chg Air Temp Sensor High Error
- Failure code [CA154] Chg Air Temp Sensor Low Error
- Failure code [CA187] Sens Supply 2 Volt Low Error
- Failure code [CB187] Sens Supply 2 Volt Low Error
- Failure code [CA212] Eng Oil Temp Sensor High Error
- Failure code [CA213] Eng Oil Temp Sensor Low Error
- Troubleshooting by failure code, Part 2
- Failure code [CA221] Ambient Press Sens High Error
- Failure code [CA222] Ambient Press Sens Low Error
- Failure code [CA227] Sens Supply 2 Volt High Error
- Failure code [CB227] Sens Supply 2 Volt High Error
- Failure code [CA234] Eng Over Speed
- Failure code [CA238] Ne Speed Sens Supply Volt Error
- Failure code [CB238] Ne Speed Sens Supply Volt Error
- Failure code [CA263] Fuel Temp Sensor High Error
- Failure code [CB263] Fuel Temp Sensor High Error
- Failure code [CA265] Fuel Temp Sensor Low Error
- Failure code [CB265] Fuel Temp Sensor Low Error
- Failure code [CA271] IMV/PCV1 Short Error
- Failure code [CB271] IMV/PCV1 Short Error
- Failure code [CA272] IMV/PCV1 Open Error
- Failure code [CB272] IMV/PCV1 Open Error
- Failure code [CA273] PCV2 Short Error
- Failure code [CB273] PCV2 Short Error
- Failure code [CA274] PCV2 Open Error
- Failure code [CB274] PCV2 Open Error
- Failure code [CA322] Inj #1(L/B#1) Open/Short Error
- Failure code [CA323] Inj #5(L/B#5) Open/Short Error
- Failure code [CA324] Inj #3(L/B#3) Open/Short Error
- Failure code [CA325] Inj #6(L/B#6) Open/Short Error
- Failure code [CA331] Inj #2(L/B#2) Open/Short Error
- Failure code [CA332] Inj #4(L/B#4) Open/Short Error
- Failure code [CA342] Calibration Code Incompatibility
- Failure code [CB342] Calibration Code Incompatibility
- Failure code [CA351] Injectors Drive Circuit Error
- Failure code [CB351] Injectors Drive Circuit Error
- Failure code [CA352] Sens Supply 1 Volt Low Error
- Failure code [CB352] Sens Supply 1 Volt Low Error
- Failure code [CA386] Sens Supply 1 Volt High Error
- Failure code [CB386] Sens Supply 1 Volt High Error
- Failure code [CA441] Battery Voltage Low Error
- Failure code [CB441] Battery Voltage Low Error
- Failure code [CA442] Battery Voltage High Error
- Failure code [CB442] Battery Voltage High Error
- Failure code [CA449] Rail Press Very High Error
- Failure code [CB449] Rail Press Very High Error
- Troubleshooting by failure code, Part 3
- Failure code [CA451] Rail Press Sensor High Error
- Failure code [CB451] Rail Press Sensor High Error
- Failure code [CA452] Rail Press Sensor Low Error
- Failure code [CB452] Rail Press Sensor Low Error
- Failure code [CA553] Rail Press High Error
- Failure code [CB553] Rail Press High Error
- Failure code [CA554] Rail Press Sensor In Range Error
- Failure code [CB554] Rail Press Sensor In Range Error
- Failure code [CA559] Rail Press Low Error
- Failure code [CB559] Rail Press Low Error
- Failure code [CA689] Eng Ne Speed Sensor Error
- Failure code [CB689] Eng Ne Speed Sensor Error
- Failure code [CA691] Intake Air Temp Sens High Error
- Failure code [CA692] Intake Air Temp Sens Low Error
- Failure code [CA731] Eng Bkup Speed Sens Phase Error
- Failure code [CB731] Eng Bkup Speed Sens Phase Error
- Failure code [CA757] All Persistent Data Lost Error
- Failure code [CB757] All Persistent Data Lost Error
- Failure code [CA778] Eng Bkup Speed Sensor Error
- Failure code [CB778] Eng Bkup Speed Sensor Error
- Failure code [CA781] CEN Communication Error
- Failure code [CB781] CEN Communication Error
- Failure code [CA1257] Harness Key Error
- Failure code [CB1257] Harness Key Error
- Failure code [CB1548] Inj #7(R/B#1) Open/Short Error
- Failure code [CB1549] Inj #8(R/B#2) Open/Short Error
- Failure code [CB1551] Inj #10(R/B#4) Open/Short Error
- Failure code [CB1552] Inj #11(R/B#5) Open/Short Error
- Failure code [CB1553] Inj #12(R/B#6) Open/Short Error
- Failure code [CB1622] Inj #9(R/B#3) Open/Short Error
- Failure code [CA1633] KOMNET Data link Time out Error
- Failure code [CA2185] Throt Sens Sup Volt High Error
- Failure code [CA2186] Throt Sens Sup Volt Low Error
- Failure code [CA2249] Rail Press Very Low Error
- Failure code [CB2249] Rail Press Very Low Error
- Failure code [CA2555] Grid Heater Relay Volt Low Error
- Failure code [CA2556] Grid Heater Relay Volt High Error
- Troubleshooting by failure code, Part 4
- Failure code [D110KB] Battery Relay Drive S/C
- Failure code [D163KB] Flash Light Relay S/C
- Failure code [D195KA] Step Light Relay Disc
- Failure code [D195KY] Step Light Relay S/C
- Failure code [D1E9KB] Wiper Drive Relay 1 S/C
- Failure code [D1EAKB] Wiper Drive Relay 2 S/C
- Failure code [D1EBKB] Lower Wiper Brake Relay Short Circuit
- Failure code [D1ECKB] Upper Wiper Brake Relay Short Circuit
- Failure code [DA22KK] Pump 1 Solenoid Power Low Error
- Failure code [dA22KK] Pump 2 Solenoid Power Low Error
- Failure code [DA25KP] Pump 1 Sens Supply Vol Low Error
- Failure code [dA25KP] Pump 2 Sens Supply Vol Low Error
- Failure code [DA26KP] 5V Sensor 2 Power Abnormality
- Failure code [DA29KQ] Pump 1 Model Select Abnormality
- Failure code [dA29KQ] Pump 2 Model Select Abnormality
- Failure code [DA2RMC] CAN Discon (Pump 1 Con Detected)
- Failure code [dA2RMC] CAN Discon (Pump 2 Con Detected)
- Failure code [DAFRMC] CAN Discon (Monitor Detected)
- Failure code [DA2TMC] Pump Comm. ECM Child Abnormality
- Failure code [DBB0KK] VHMS Source Voltage Error (or change of VHMS-LED display from n9 to 01)
- Failure code [DBB0KQ] VHMS Connector Mismatch (or change of VHMS-LED display from nF to 11)
- Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMSLED display from n9 to 04)
- Failure code [DBB6KP] VHMS 24V source sys Error (or change of VHMS-LED display from n9 to 02)
- Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02)
- Failure code [DGE5KX] Ambient Air Temp Sensor Failure (or change of VHMS-LED display from n4 to 01)
- Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C
- Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMSLED display from n5 to 01)
- Troubleshooting by failure code, Part 5
- Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 12)
- Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 22)
- Failure code [DGT5KB] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 11)
- Failure code [dGT5KB] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 21)
- Failure code [DGT6KA] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 24)
- Failure code [dGT6KA] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26)
- Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 23)
- Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26)
- Failure code [DH25KX] VR1/P1F J/S Dif Press Sensor Abnormality
- Failure code [DH26KX] VL1/P1R J/S Dif Press Sensor Abnormality
- Failure code [DH27KX] VR2/P2F J/S Dif Press Sensor Abnormality
- Failure code [DH28KX] VL2/P2R J/S Dif Press Sensor Abnormality
- Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 32)
- Failure code [DHE5KY] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 31)
- Failure code [DHH2KA] Hydraulic oil filter Sensor Failure (or change of VHMS-LED display from n5 to 53)
- Failure code [DHPEKX] VR1/P1F Pump P. Sensor Abnormality
- Failure code [DHPFKX] VL1/P1R Pump P. Sensor Abnormality
- Failure code [DHPGKX] VR2/P2F Pump P. Sensor Abnormality
- Failure code [DHPHKX] VL2/P2R Pump P. Sensor Abnormality
- Failure code [DHPSKX] Auto Grease Press Sensor Abnormality
- Failure code [DHPTKX] Fan(RAD) Pump P. Sensor Open Circuit
- Failure code [DHPUKX] Fan(O/C) Pump P. Sensor Open Circuit
- Failure code [DHS3KX] Arm Dig PPC Press Sensor Abnormality
- Failure code [DHS4KX] Bucket Curl PPC Press Sensor Abnormality
- Failure code [DHS8KX] Boom Raise PPC Press Sensor Abnormality
- Failure code [DHS9KX] Boom Lower PPC Press Sensor Abnormality
- Failure code [DHSAKX] Swing Right PPC Press Sensor Abnormality
- Failure code [DHSBKX] Swing Left PPC Press Sensor Abnormality
- Failure code [DHSCKX] Arm Dump PPC Press Sensor Abnormality
- Failure code [DHSDKX] Bucket Dump PPC Press Sensor Abnormality
- Troubleshooting by failure code, Part 6
- Failure code [DUM3KB] Auto Grease Caution LED Short Circuit
- Failure code [DUM4KB] FAN Reverse LED Short Circuit
- Failure code [DV20KB] Travel Alarm S/C
- Failure code [DW41KA] Swing Priority Sol Open Circuit
- Failure code [DW41KB] Swing Priority Sol Short Circuit
- Failure code [DW45KA] Swing Brake Sol. Disc.
- Failure code [DW45KB] Swing Brake Sol. S/C
- Failure code [DW91KA] Straight-Travel Sol. Disc.
- Failure code [DW91KB] Straight-Travel Sol. S/C
- Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc.
- Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C
- Failure code [DW7BKA] Fan Motor (RAD) Reverse Sol Open Circuit
- Failure code [DW7BKB] Fan Motor (RAD) Reverse Sol. S/C
- Failure code [DW7HKA] Fan Motor(O/C) Reverse Sol Open Circuit
- Failure code [DW7HKB] Fan Motor(O/C) Reverse Sol Short Circuit
- Failure code [DWA3KA] Arm throttle Valve/L Sol Open Circuit
- Failure code [DWA3KB] Arm throttle Valve/L Sol Short Circuit
- Failure code [DWA4KA] Arm throttle Valve/R Sol Open Circuit
- Failure code [DWA4KB] Arm throttle Valve/R Sol Short Circuit
- Failure code [DWA5KA] Auto Grease Sol Open Circuit
- Failure code [DWA5KB] Auto Grease Sol Short Circuit
- Failure code [DWA6KA] Boom throttle Valve Sol Open Circuit
- Failure code [DWA6KB] Boom throttle Valve Sol Short Circuit
- Failure code [DWK0KA] 2-stage Relief Sol. Disc.
- Failure code [DWK0KB] 2-stage Relief Sol. S/C
- Failure code [DWK2KA] Back Press Comp Valve Sol Open Circuit
- Failure code [DWK2KB] Back Press Comp Valve Sol Short Circuit
- Troubleshooting by failure code, Part 7
- Failure code [DWN5KA] Fan(RAD) Pump EPC Sol Open Circuit
- Failure code [DWN5KB] Fan(RAD) Pump EPC Sol Short Circuit
- Failure code [DWNCKA] Fan(O/C) Pump EPC Sol Open Circuit
- Failure code [DWNCKB] Fan(O/C) Pump EPC Sol Short Circuit
- Failure code [DXAAKA] P1F EPC Sol Disc
- Failure code [DXAAKB] P1F EPC Sol S/C
- Failure code [DXABKA] P1R Pump EPC Sol. Disc.
- Failure code [DXABKB] P1R Pump EPC Sol. S/C
- Failure code [DXACKA] P2F Pump EPC Sol. Disc.
- Failure code [DXACKB] P2F Pump EPC Sol. S/C
- Failure code [DXADKA] P2R Pump EPC Sol. Disc.
- Failure code [DXADKB] P2R Pump EPC Sol. S/C
- Failure code [DY2CKB] Washer Drive S/C
- Failure code [DY20MA] Low Wiper Working Abnormality
- Failure code [DY2FMA] Upper Wiper Working Abnormality
- Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38)
- Failure code [F@BYNR] Very High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 62)
- Failure code [f@BYNR] Very High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 72)
- Failure code [F@BYNS] High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 61)
- Failure code [f@BYNS] High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 71)
- Failure code [F@BZNR] Very High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 82)
- Failure code [f@BZNR] Very High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 92)
- Failure code [F@BZNS] High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 81)
- Failure code [f@BZNS] High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 91)
- Failure code [LA10ZL] RAD system fan pump relief pressure high error
- Failure code [LA20ZL] O/C system pump relief pressure high error
- Troubleshooting of electrical system (E-mode)
- Before carrying out troubleshooting of electrical system
- Contents of troubleshooting table
- E-1 When starting switch is turned ON, machine monitor displays nothing
- E-2 When starting switch turned ON (before starting engine), basic check item lights up
- E-3 Engine does not start (Engine does not turn)
- E-4 Auto-decelerator does not operate
- E-5 Automatic warm-up system does not operate
- E-6 Preheater does not work
- E-7 Whole work equipment, swing operation and machine travel operation are disabled
- E-8 Machine push-up function does not work
- E-9 Boom shockless function cannot be released
- E-10 Machine monitor does not display some items
- E-11 Contents of display by machine monitor are different from applicable machine
- E-12 Fuel level monitor lights up in red while engine is running
- E-13 Hydraulic oil temperature gauge does not indicate normally
- E-14 Fuel level gauge does not indicate normally
- E-15 Swing lock monitor does not indicate normally
- E-16 Machine monitor display anything even when operated on monitor switch section
- E-17 Wiper does not work
- E-18 Monitoring function does not display "Travel" normally
- E-19 Travel alarm does not sound
- E-20 All of room lamp, headlamp and working lamp do not light up
- E-21 Air conditioner does not work
- E-22 Step light does not light up or goes off
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Before troubleshooting for hydraulic and mechanical systems
- Table of failure modes and causes
- Information in troubleshooting table
- H-1 Speed or power of whole work equipment, travel, and swing is low
- H-2 Engine speed lowers remarkably or engine stalls
- H-3 Work equipment, swing, and travel mechanism do not move
- H-4 Abnormal noise comes from around hydraulic pump
- H-5 Speed or power of boom is low
- H-6 Speed or power of arm is low
- H-7 Speed or power of bucket is low
- H-8 Boom does not move
- H-9 Arm does not move
- H-10 Bucket does not move
- H-11 Hydraulic drift of work equipment is large.
- H-12 Time lag of work equipment is large
- H-13 Heavy lift function does not work or is not reset.
- H-14 Machine push-up function does not work or is not reset
- H-15 Boom shockless function does not work or is not reset
- H-16 Machine gradually deviates during traveling
- H-17 Machine deviates excessively when started to travel
- H-18 Machine deviates excessively during multiple operations
- H-19 Traveling speed or power is low
- H-20 Travel system does not move (only one side)
- H-21 Upper structure does not swing
- H-22 Swing speed or acceleration is low
- H-23 In compound operation of work equipment, swing speed or acceleration is low
- H-24 Upper structure overruns remarkably when it stops swinging
- H-25 Large shock is made when upper structure stops swinging
- H-26 Large abnormal sound comes from when upper structure stops swinging
- H-27 Hydraulic drift of work equipment is large in swing operation
- H-28 Fan rotation is abnormal (large noise or vibration of fans, or fan overheating)
- H-29 Bottom dump speed or power is lower (Loading shovel specification)
- H-30 Bottom dump cylinder does not move (Loading shovel specification)
- Troubleshooting of mechanical system (S-mode)
- Method of using troubleshooting charts
- S-1 Starting performance is poor
- S-2 Engine does not start
- S-3 Engine does not pick up smoothly
- 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
- 50 Disassembly and assembly
- General information on disassembly and assembly
- How to read this manual
- Coating materials list
- Special tool list
- Sketches of special tools
- Engine and cooling system
- Removal and installation of power container assembly
- Removal and installation of engine, PTO and hydraulic pump assembly
- Removal and installation of radiator assembly
- Removal and installation of aftercooler assembly
- Removal and installation of hydraulic oil cooler assembly
- Removal and installation of fuel cooler assembly
- Removal and installation of cooling assembly
- Removal and installation of fan motor assembly
- Removal and installation of fuel tank assembly
- Engine
- Removal and installation of fuel supply pump assembly
- Removal and installation of cylinder head assembly
- Removal and installation of fuel injector
- Removal and installation of engine front oil seal
- Removal and installation of engine rear oil seal
- Power train
- Removal and installation of PTO assembly
- Disassembly and assembly of PTO assembly
- Removal and installation of swing motor and swing machinery assembly
- Disassembly and assembly of swing machinery assembly
- Removal and installation of swing circle assembly
- Removal and installation of final drive assembly
- Disassembly and assembly of final drive assembly
- Undercarriage and frame
- Removal and installation of track shoe assembly
- Removal and installation of idler assembly
- Disassembly and assembly of idler assembly
- Disassembly and assembly of idler adjust cylinder assembly
- Removal and installation of idler cushion cylinder assembly
- Disassembly and assembly of idler cushion cylinder assembly
- Removal and installation of track roller assembly
- Disassembly and assembly of track roller assembly
- Removal and installation of carrier roller assembly
- Disassembly and assembly of carrier roller assembly
- Removal and installation of revolving frame assembly
- Removal and installation of counterweight assembly
- Removal and installation of hydraulic ladder
- Hydraulic system
- Removal and installation of hydraulic tank assembly
- Removal and installation of hydraulic pump assembly
- Removal and installation of hydraulic pump input shaft oil seal
- Removal and installation of control valve assembly
- Disassembly and assembly of control valve assembly
- Removal and installation of center swivel joint assembly
- Disassembly and assembly of center swivel joint assembly
- Removal and installation of swing motor assembly
- Removal and installation of travel motor assembly
- Disassembly and assembly of work equipment PPC valve assembly
- Disassembly and assembly of travel PPC valve assembly
- Disassembly and assembly of hydraulic cylinder assembly (Backhoe specification)
- Disassembly and assembly of hydraulic cylinder assembly (Loading shovel specification)
- Removal and installation of grease pump
- Disassembly and assembly of grease pump
- Work equipment
- Removal and installation of bucket cylinder assembly (Backhoe specification)
- Removal and installation of bucket cylinder assembly (Loading shovel specification)
- Removal and installation of bucket assembly (Backhoe specification)
- Removal and installation of bucket assembly (Loading shovel specification)
- Removal and installation of arm cylinder (Backhoe specification)
- Removal and installation of arm cylinder (Loading shovel specification)
- Removal and installation of arm assembly (Backhoe specification)
- Removal and installation of arm assembly (Loading shovel specification)
- Removal and installation of boom cylinder assembly (Backhoe specification)
- Removal and installation of boom cylinder assembly (Loading shovel specification)
- Removal and installation of boom assembly (Backhoe specification)
- Removal and installation of boom assembly (Loading shovel specification)
- Removal and installation of bottom dump cylinder assembly (Loading shovel specification)
- Cab and its attachments
- Removal and installation of operator cab assembly
- Removal and installation of operator cab glass (adhesion glass)
- Removal and installation of operator cab (assembly-type)
- Removal and installation of cab base assembly
- Removal and installation of service center
- REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY
- Electrical system
- Removal and installation of air conditioner unit assembly
- Removal and installation of monitor assembly
- Removal and installation of engine controller assembly
- Removal and installation of pump controller assembly
- Removal and installation of VHMS controller assembly
- Removal and installation of Orbcomm terminal assembly for VHMS
- 90 Diagrams and drawings
- Hydraulic diagrams and drawings
- Hydraulic circuit diagram (Backhoe specification) Serial No.: 20001 to 2019
- Hydraulic circuit diagram (Backhoe specification) Serial No.: 20198 and up
- Hydraulic circuit diagram (Loading shovel specification) Serial No.: 20001 to 20197
- Hydraulic circuit diagram (Loading shovel specification) Serial No.: 20198 and up
- Electrical diagrams and drawings
- Electrical circuit diagram (1/14)
- Electrical circuit diagram (2/14)
- Electrical circuit diagram (3/14)
- Electrical circuit diagram (4/14)
- Electrical circuit diagram (5/14)
- Electrical circuit diagram (6/14)
- Electrical circuit diagram (7/14)
- Electrical circuit diagram (8/14)
- Electrical circuit diagram (9/14)
- Electrical circuit diagram (10/14)
- Electrical circuit diagram (11/14)
- Electrical circuit diagram (12/14)
- Electrical circuit diagram (13/14)
- Electrical circuit diagram (14/14)
- Connector list and stereogram
Komatsu
