Shop Manual Pc2000-8 Sen01607-00pd

SEN01607-00
Shop
Manual
PC2000-8
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC2000-8 20001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2006 Komatsu

Printed in U.S.A.
Komatsu America Corp.
October 2006
SEN01609-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC2000-8
Machine model Serial number

PC2000-8 20001 and up
00 Index and foreword 1

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

Table of contents .................................................................................................................................. 3
PC2000-8 1
SEN01609-00 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN01607-00
00 Index and foreword SEN01608-00

Index SEN01609-00
Foreword and general information SEN01610-00
01 Specification SEN01611-00
Specification and technical data SEN01612-00
10 Structure, function and maintenance standard SEN01613-00

Engine and cooling system SEN01614-00
Power train SEN01615-00
Undercarriage and frame SEN01616-00
Hydraulic system, Part 1 SEN01618-00
Work equipment SEN01621-00
Cab and its attachments SEN01622-00
Electrical system SEN01623-00
90 Diagrams and drawings SEN01628-00

Hydraulic diagrams and drawings SEN01629-00
Electrical diagrams and drawings SEN01630-00
2 PC2000-8
Table of contents 1
00 Index and foreword
Index SEN01609-00
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN01610-00

Foreword and general information .............................................................................................. 2
Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 6
Explanation of terms for maintenance standard ...................................................................... 8
Handling electric equipment and hydraulic component ........................................................... 10
How to read electric wire code ................................................................................................ 18
Method of disassembling and connecting push-pull type coupler ........................................... 21
Standard tightening torque table.............................................................................................. 24
Conversion table...................................................................................................................... 28
01 Specification
Specification and technical data SEN01612-00
Specification and technical data.................................................................................................. 2
Specification drawings ............................................................................................................. 2
Specifications........................................................................................................................... 4
Weight table............................................................................................................................. 6
Table of fuel, coolant and lubricants ........................................................................................ 9
10 Structure, function and maintenance standard

Engine and cooling system SEN01614-00
Engine and cooling system ......................................................................................................... 2
Radiator and oil cooler............................................................................................................. 2
PTO ......................................................................................................................................... 4
PTO lubrication system............................................................................................................ 6
Power train SEN01615-00
Power train .................................................................................................................................. 2
Power train .............................................................................................................................. 2
Swing machinery ..................................................................................................................... 4
Swing circle ............................................................................................................................. 6
Final drive ................................................................................................................................ 8
Sprocket................................................................................................................................... 10
Undercarriage and frame SEN01616-00
Undercarriage and frame ............................................................................................................ 2
Track frame.............................................................................................................................. 2
Idler.......................................................................................................................................... 4
Carrier roller............................................................................................................................. 6
Track roller............................................................................................................................... 7
Track shoe ............................................................................................................................... 8
HIC system .............................................................................................................................. 13
PC2000-8 3

Hydraulic system, Part 1 ............................................................................................................. 4
Hydraulic piping drawing.......................................................................................................... 4
Hydraulic tank .......................................................................................................................... 6
Oil cooler.................................................................................................................................. 8
Line oil filter.............................................................................................................................. 10
Pilot oil filter ............................................................................................................................. 11
Return oil filter.......................................................................................................................... 12
Motor drain oil filter .................................................................................................................. 13
Pump drain filter....................................................................................................................... 14
Accumulator............................................................................................................................. 15
Travel junction valve ................................................................................................................ 17
Solenoid valve ......................................................................................................................... 20
Hydraulic cylinder .................................................................................................................... 26
Greasing system...................................................................................................................... 28
Center swivel joint.................................................................................................................... 38
Control valve............................................................................................................................ 2
Electronic OLSS system .......................................................................................................... 30
Swing motor............................................................................................................................. 34
Cooling fan motor (For radiator and oil cooler) ........................................................................ 42
Cooling fan pump..................................................................................................................... 48
Travel motor............................................................................................................................. 2
Hydraulic pump........................................................................................................................ 14
PPC valve ................................................................................................................................ 32
Variable back pressure valve................................................................................................... 44
Suction selector valve.............................................................................................................. 48
PPC cut-off valve ..................................................................................................................... 52
Work equipment SEN01621-00
Work equipment .......................................................................................................................... 2
Work equipment....................................................................................................................... 2
Dimensions of work equipment................................................................................................ 4
Cab and its attachments SEN01622-00
Cab and its attachments.............................................................................................................. 2
Air conditioner piping ............................................................................................................... 2
Cab .......................................................................................................................................... 3
Electrical system SEN01623-00
Electrical system ......................................................................................................................... 2
Engine control.......................................................................................................................... 2
Electrical control system .......................................................................................................... 13
Monitor system ........................................................................................................................ 55
Sensor ..................................................................................................................................... 83
ORBCOMM terminal................................................................................................................ 95
4 PC2000-8
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN01629-00
Hydraulic diagrams and drawings ............................................................................................... 3
Hydraulic circuit diagram ......................................................................................................... 3
Electrical diagrams and drawings SEN01630-00
Electrical diagrams and drawingss.............................................................................................. 3
Electrical circuit diagram (1/2) ................................................................................................. 3
Electrical circuit diagram (2/2) ................................................................................................. 5
PC2000-8 5
SEN01609-00
PC2000-8 Hydraulic excavator
Form No. SEN01609-00
6
SEN01610-00
PC2000-8

PC2000-8 20001 and up
00 Index and foreword 1

Foreword and general information
Foreword and general information .................................................................................................................. 2
Safety notice ........................................................................................................................................ 2
How to read the shop manual .............................................................................................................. 6
Explanation of terms for maintenance standard................................................................................... 8
Handling electric equipment and hydraulic component...................................................................... 10
How to read electric wire code ........................................................................................................... 18
Method of disassembling and connecting push-pull type coupler...................................................... 21
Standard tightening torque table ........................................................................................................ 24
Conversion table ................................................................................................................................ 28
PC2000-8 1
Foreword and general information (Rev. 2005/11)
Safety notice 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 situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w eld in g wo rk , alw ay s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to 1 Good arrangement
keep tools and removed parts. Always
2 Correct work clothes
keep the tools and parts in their correct
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water, 4 Making and checking signs
or oil on the floor. Smoke only in the areas Prohibition of operation and handling by
5
provided for smoking. Never smoke while unlicensed workers
working. 6 Safety check before starting work
3) When carrying out any operation, always Wearing protective goggles
wear safety shoes and helmet. Do not 7
(for cleaning or grinding work)
wear loose work clothes, or clothes with
Wearing shielding goggles and protectors
buttons missing. 8
(for welding work)
q Always wear safety glasses when hit-
ting parts with a hammer. 9 Good physical condition and preparation
q Always wear safety glasses when Precautions against work which you are
10
grinding parts with a grinder, etc. not used to or you are used to too much
4) When carrying out any operation with 2 or
more workers, always agree on the oper-
ating procedure before starting. Always 2. Preparations for work
inform your fellow workers before starting 1) Before adding oil or making any repairs,
any step of the operation. Before starting park the machine on hard and level
work, hang UNDER REPAIR signs in the ground, and apply the parking brake and
operator's compartment. block the wheels or tracks to prevent the
5) Only qualified workers must carry out work machine from moving.
and operation which require license or 2) Before starting work, lower the work
qualification. equipment (blade, ripper, bucket, etc.) to
6) Keep all tools in good condition, learn the the ground. If this is not possible, insert
correct way to use them, and use the the lock pin or use blocks to prevent the
proper ones of them. Before starting work, work equipment from falling. In addition,
thoroughly check the tools, machine, fork- be sure to lock all the control levers and
lift, service car, etc. hang warning signs on them.
2 PC2000-8
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
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 cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot 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
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r l y c a r e fu l t o c he c k t h a t t h ey ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
PC2000-8 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with one rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 PC2000-8
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
PC2000-8 5
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

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

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

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

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

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

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

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
6 PC2000-8
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

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

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
PC2000-8 7
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

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

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

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
8 PC2000-8
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the size of a hole is smaller than the be replaced or repaired.
size of a shaft because of the standard
size and tolerance, the difference between
these sizes 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

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 must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
PC2000-8 9
Handling electric equipment and hydraulic component 1

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

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

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
10 PC2000-8
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
splash water over the connector. The con-
nector 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 con-
nector, the pins will be short-circuited by
the water, so if any water gets in, immedi-
ately dry the connector or take other
appropriate action before passing electric-
ity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
PC2000-8 11
3. Removing, installing, and drying connec-

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

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

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

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
12 PC2000-8
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3) Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
1. Male connector
2. Female connector
q Normal locking state (Horizontal): a,
b, d
q Incomplete locking state (Diagonal): c
PC2000-8 13
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om th e c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
14 PC2000-8
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
PC2000-8 15
Points to remember when handling hydraulic equipment

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

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

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

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
16 PC2000-8
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
PC2000-8 17
How to read electric wire code 1

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

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

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

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
18 PC2000-8
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
PC2000-8 19
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
20 PC2000-8
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC2000-8 21
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
22 PC2000-8
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
PC2000-8 23
Standard tightening torque table 1

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

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
24 PC2000-8
2. Table of tightening torques for split flange bolts

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

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

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

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

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

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
PC2000-8 25
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolt BANJO bolt
mm Nm kgm Nm kgm
6 10 ± 2 1.02 ± 0.20 8± 2 0.81 ± 0.20
8 24 ± 4 2.45 ± 0.41 10 ± 2 1.02 ± 0.20
10 43 ± 6 4.38 ± 0.61 12 ± 2 1.22 ± 0.20
12 77 ± 12 7.85 ± 1.22 24 ± 4 2.45 ± 0.41
14 – – 36 ± 5 3.67 ± 0.51
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
26 PC2000-8
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
PC2000-8 27
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

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

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

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
28 PC2000-8
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC2000-8 29
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
30 PC2000-8
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC2000-8 31
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to 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.
If it is desired to 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.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
32 PC2000-8
PC2000-8 33
SEN01610-00
34
SEN01612-00
PC2000-8

PC2000-8 20001 and up
01 Specification 1
Specification and technical data
Specification and technical data...................................................................................................................... 2
Specification drawings.......................................................................................................................... 2
Specifications ....................................................................................................................................... 4
Weight table ......................................................................................................................................... 6
Table of fuel, coolant and lubricants ..................................................................................................... 9
PC2000-8 1
SEN01612-00 01 Specification
Specification and technical data 1

Specification drawings 1
Backhoe specification 1
Item Unit PC2000-8

A Overall length mm 17,030
B Overall height mm 7,135
With slide ladder Without slide ladder
C Overall width mm
7,550 7,235
D Track shoe width mm 810
E Height of machine cab mm 5,970
F Height of operator’s cab mm 7,030
G Tail swing radius mm 5,980
H Track overall length mm 7,445
J Length of track on ground mm 5,780
K Min. ground clearance mm 825
2 PC2000-8
Working range drawing
Item Unit PC2000-8

A Max. digging height mm 13,410
B Max. dumping height mm 8,650
C Max. digging depth mm 9,235
D Max. vertical wall depth mm 2,710
E Max. reach at ground level mm 15,305
F Max. digging reach mm 15,780
Min. swing radius of
G mm 7,500
work equipment
PC2000-8 3
Specifications 1
Backhoe specification
Machine model PC2000-8

Serial number 20001 and up
Bucket capacity m 3
12.0
Weight of machine kg 200,000
Max. digging depth mm 9,235
Working range
Max. vertical wall depth mm 2,710

Max. digging reach mm 15,780
Max. reach at ground level mm 15,305
Max. digging height mm 13,410
Performance
Max. dumping height mm 8,650

Max. digging force kN {kg} 697 {71,100}
Swing speed rpm 4.8
Swing max. slope angle deg. 9.0
Travel speed km/h 2.7
Gradeability deg. 33
Ground pressure (standard shoe) kPa {kg/cm }2
190 {1.94}
With work equipment mm 17,030
Overall height Overall length
Upper structure only mm 8,500

Lower crawler only
mm 7,440
(equipped with standard shoe)
With work equipment mm 7,135
Upper structure only mm 5,170

Lower crawler only
mm 2,840
With slide ladder Without slide ladder
Overall width
Dimensions
With work equipment mm

7,550 7,235
Upper structure only mm
Lower crawler only
mm 5,650 (with step)
Overall width of crawler mm 5,410
Ground clearance of upper structure mm 2,095
Min. ground clearance mm 825
Tail swing radius mm 5,980
Min. swing radius of work equipment mm 7,500
Height of work equipment at min. swing radius mm 11,880
Length of track on ground mm 5,780
Track gauge mm 4,600
Height of machine cab mm 5,970
Standard shoe width mm 810
4 PC2000-8

Model SAA12V140E-3
4-cycle, water-cooled, V type,
Type direct injection, with turbocharger and
aftercooler (air cooled)
No. of cylinders – bore × stroke mm 12 – 140 × 165
Piston displacement l {cc} 30.48 {30,480}
Flywheel horsepower kW/rpm {HP/rpm} 728/1,800 {976/1,800}
Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 4,510/1,350 {460/1,350}

High idle rpm 1,980 ± 50
Low idle rpm 825 ± 25
Min. fuel consumption g/kWh {g/HPh} 207 {154}
Starting motor 24 V, 11 kW × 2
Alternator 24 V, 50 A × 2
Battery 12 V, 170 Ah × 4
Radiator fan type Aluminum wave 4-row
Carrier roller 3 on each side
carriage
Under-
Track roller 8 on each side

Assembly-type double grouser,
Track shoe
49 on each side
Type Main pump: variable displacement tan-
dem piston type 2 (HPV375 + 375)
Fan pump: variable displacement tandem
piston type 1 (HPV95 + 95)
Hydraulic
PTO lubrication pump: gear type 1

Delivery
pump
(SBL (1) 21)

Main pump P1: 629 + 629, P2: 518 + 518
l/min Fan pump: 160 + 160
PTO lubrication pump: 35
Main pump: 29.6 {300},
Set pressure MPa {kg/cm2}
Fan pump: 24.5 {250}
Type × No. 5-spool + 5-spool type × 2
Hydraulic Control
valve
Hydraulic system
Control method Hydraulic type

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

Swing motor
2 (KMF230)
Boom Arm Bucket
Hydraulic cylinder
Cylinder type Double-acting piston

Inside diameter of cylinder mm 300 250 200
Outside diameter of piston rod mm 200 160 140
Stroke mm 2,647 2,134 2,170
Max. distance between pins mm 6,480 5,267 5,420
Min. distance between pins mm 3,833 3,133 3,250
Hydraulic tank Box-shaped, with breather
Hydraulic filter Pump outlet, tank return side
Hydraulic cooler Air cooled
PC2000-8 5
Weight table 1
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Power container assembly 16,238
q Engine body 3,375
q Engine mount bracket, engine oil drain 364
q Air cleaner, muffler, tail pipe 488
q PTO 1,092
q PTO lubrication piping, PTO drain 30
q Radiator, radiator drain 1,249
q Oil cooler 1,124
q Fuel piping 55
q Harness 58
q Main pump (F) 490
q Second pump (R) 490
q Fan pump 220
q Delivery line 212
q Oil cooler line 57
q Pump drain line, pump drain filter 83
q PPC delivery line, pilot filter 27
q Air conditioner compressor, air conditioner piping,
40
heater piping
q Engine hood, cooling duct,
3,789
power container exterior
q Power container base frame 2,668
q Power container partition 142
q Underguard 185
Operator’s cab assembly 4,135
q Harness 50
q VHMS controller, pump controller,
ORBCOMM controller, PHMS controller, 20
power distribution
q Horn 5
q PPC return line, safety lock, accumulator 42
q Junction joint 17
q PPC travel control line 3
q PPC work equipment control line, boom shockless 14
q Operator’s seat 50
q Sub seat 11
q Seat belt 1
q Operator’s cab body, wiper, left rearview mirror 1,540
q Floor mat 16
q Air conditioner 95
q Fire extinguisher 4
q First aid box 5
6 PC2000-8
Unit: kg
q Cab mount (viscous mount) 108
q Work equipment PPC valve (LH and RH),
130
control stand (LH and RH), left gauge panel
q Travel PPC valve, travel lever, travel pedal 22
q Cab base, cab round step,
2,002
emergency refuge ladder
Left deck (with battery) with power assist ladder 2,097
without power assist ladder 1,674
Right deck (incl. counterweight handrail) 1,085
Fuel tank 2,112
Fuel piping 26
Harness 40
Travel alarm 3
Grease piping, injector 62
Hydraulic tank, return oil filter, oil level sensor 1,884
Main valve, valve bracket 1,732
Suction line 290
Delivery line, in-line filter 128
Oil cooler line 127
Return line (excl. return filter) 111
PPC drain line 34
Boom line 195
Arm line 171
Bucket line 93
Travel line 91
Straight travel line 11
Swing line 49
Solenoid valve 22
Solenoid valve line 8
Shuttle valve line 51
PPC control line 8
PPC main line 38
PPC delivery line 26
Revolving frame 19,355
Boom foot pin, boom cylinder bottom pin 475
Air conditioner piping, heater piping,
70
electronic controller, receiver dryer
Cab rear floor, revolving frame front step,
511
center maintenance floor, drum can cover
Right rearview mirror 6
Counterweight 24,000
Swing machinery 2,136
Swing motor 210
Swivel joint 290
Pump, drum can bracket, oil piping, grease reel line 309
PC2000-8 7
Unit: kg
Track frame assembly 68,051
q Swing circle 3,633
q Travel piping 139
q Idler cushion oil pressure part 332
q Travel final drive 6,514
q Idler 2,462
q Idler cushion cylinder part 946
q Track roller 5,586
q Carrier roller 762
q Track Standard triple shoe (810 mm) 17,020
Wide triple shoe (1,010 mm) 21,040
q Center frame, grease bus 13,562
q Crawler frame 14,331
q Center cover (if equipped) 646
q Travel motor cover 515
q Travel motor guard 937
q Track frame step 81
q Track roller guard Single type 1,231
Divided welding type
2,328
(if equipped)
Boom 18,389
Hose between machine and boom foot 118
Arm cylinder hose 74
Boom cylinder 4,790
Boom cylinder hose 73
Arm cylinder 2,470
Arm 8,699
Hose between boom and arm 97
Bucket cylinder 1,752
Link 2,030
Bucket Bucket body (incl. tooth, shroud) 9,737
Wear kit (if equipped) 2,508
8 PC2000-8
Table of fuel, coolant and lubricants 1

a For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
Unit: l
Swing
Engine oil Final drive Hydraulic Cooling
PTO case machinery Fuel tank Grease
pan case system system
case
(Each of (Each of
Specified capacity (l) 128 36 front and right and 2400 3400 180 200
rear) 30 left) 85
(Each of (Each of
Refill capacity (l) 120 36 front and right and 1300 — — 200
rear) 30 left) 85
PC2000-8 9
SEN01612-00
10
SEN01614-00
PC2000-8

PC2000-8 20001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine and cooling system ............................................................................................................................. 2
Radiator and oil cooler ......................................................................................................................... 2
PTO ...................................................................................................................................................... 4
PTO lubrication system ........................................................................................................................ 6
PC2000-8 1
SEN01614-00 10 Structure, function and maintenance standard
Engine and cooling system

Radiator and oil cooler 1
2 PC2000-8
1. Reservoir tank
2. Aftercooler outlet tube
3. Aftercooler inlet tube
4. Radiator inlet hose
5. Radiator
6. Radiator bypass tube
7. Fan pump
8. Aftercooler
9. Fan drive motor (radiator side)
10. Fan guard
11. Fan (radiator side)
12. Engine return hose
Specifications
1. Fan
(Radiator side)
Outside diameter:1,450 mm
No. of vanes: 6
Rotating speed: Variable
(Standard. spec.: Max. 840 rpm)
(+55°C spec: Max. 1,100 rpm)
2. Radiator
Core type: Aluminum wave 4-row, 3.5/2P
Fin pitch: 3.5 mm
Releasing pressure for pressure valve:
0.05 MPa {0.5 kg/cm2}
Releasing pressure for vacuum valve:
–0.005 MPa {–0.05 kg/cm2}
3. Aftercooler
Core type: Aluminum wave 4.0/2P
Fin pitch: 4.0 mm
PC2000-8 3
PTO
4 PC2000-8
1. Drive gear (No. of teeth: 57)

2. Coupling
3. Main shaft
4. Connection plate
5. PTO case
6. Driven gear (No. of teeth: 72, 60)
7. Driven gear (No. of teeth: 56)
8. Breather
A. Center of No. 1 pump (HPV375 + 375) shaft

B. Center of No. 2 pump (HPV375 + 375) shaft
C. Center of fan pump (HPV95 + 95) shaft
D. Center of input shaft
Specifications
Lubricating oil : 36 l
Reduction ratio : Input shaft: 1.0
No. 1 pump (HPV375 + 375): 60/57 = 1.053
No. 2 pump (HPV375 + 375): 72/57 = 1.263
Fan pump (HPV95 + 95): 56/57 = 0.982
Unit: mm
No. Check Item Criteria Remedy
Backlash between main shaft Standard size Repair limit Replace
9
and drive gear coupling 0.09 – 0.26 —
Backlash between driven gear
10 0.14 – 0.29 —
and hydraulic pump Adjust
Backlash between driven gear
11 0.14 – 0.29 —
and fan pump shaft
PC2000-8 5
PTO lubrication system
1. PTO case Hydraulic circuit diagram

2. PTO oil reservoir
3. Gear pump (SAL(1)020)
4. PTO oil filter
Outline
The lubricating oil sucked by gear pump (3) from
PTO oil reservoir (2) passes through PTO oil filter
(4) to PTO case (1), is divided in PTO case to lubri-
cate and cool the gears.
6 PC2000-8
PC2000-8 7
SEN01614-00
8
SEN01615-00
PC2000-8

PC2000-8 20001 and up

Power train
Power train...................................................................................................................................................... 2
Power train ........................................................................................................................................... 2
Swing machinery.................................................................................................................................. 4
Swing circle .......................................................................................................................................... 6
Final drive............................................................................................................................................. 8
Sprocket ............................................................................................................................................. 10
PC2000-8 1
Power train
Power train
2 PC2000-8
1. Idler
2. Center swivel joint
3. Swing motor (KMF230)
4. 5-spool control valve (L1)
5. 5-spool control valve (L2)
6. 5-spool control valve (R1)
7. 5-spool control valve (R2)
8. Final drive, sprocket
9. Travel motor (KMF340)
10. Engine (SAA12V140E)
11. PTO
12. P1 pump (HPV375+375)
13. P2 pump (HPV375+375)
14. PF pump (HPV95+95+SAL (1) 020)
15. Swing brake solenoid valve
16. Swing machinery
17. Swing circle
PC2000-8 3
Swing machinery
4 PC2000-8
1. Swing pinion (No. of teeth: 16)

2. Cover
3. Case
4. Coupling
5. No. 2 planetary gear (No. of teeth: 32)
6. No. 2 ring gear (No. of teeth: 83)
9. Cover
10. Dipstick
11. Swing motor
12. No. 1 sun gear (No. of teeth: 35)
13. No. 1 planetary carrier
16. Drain plug
Specification
Reduction ratio: (35 + 190)/35 × (17 + 83)/17 = 37.815
Unit: mm
Backlash between swing motor Standard clearance Clearance limit
17
shaft and No. 1 sun gear 0.177 – 0.282 —
Backlash between No. 1 sun
18 0.14 – 0.39 —
gear and No. 1 planetary gear
Backlash between No. 1
19 0.20 – 0.57 —
planetary gear and ring gear
20 planetary carrier and No. 2 sun 0.41 – 0.72 —
gear
Backlash between No. 2 sun Replace
21 0.15 – 0.38 —
Backlash between No. 2 plane-
22 0.23 – 0.67 —
tary gear and ring gear
23 0.06 – 0.24 —
planetary gear and coupling
Backlash between coupling and
24 0.09 – 0.25 —
swing pinion
Backlash between swing pinion
25 0.18 – 1.58 —
and swing circle
Clearance between plate and
26 0.50 – 1.00 —
coupling
Clearance between No. 1 sun Repair hard
27 2.22 – 4.68 — chrome plating
gear and ring
or replace
Wear of swing pinion oil seal Standard size Repair limit
28
contact surface –0
180 –0.115 —
PC2000-8 5
Swing circle
1. Swing circle inner race (No. of teeth: 131) a. Inner race soft zone “S” position
2. Swing circle outer race (Upper side) b. Outer race soft zone “S” position
3. Roller
4. Swing circle outer race (Lower side)
Unit: mm
Clearance of bearing in axial Standard clearance Clearance limit
5 direction (when mounted on Replace
machine) 0.5 – 1.5 2.0
Specifications
Reduction ratio: 131/16 = 8.1875
Amount of grease: 80 l (G2-LI)
6 PC2000-8
PC2000-8 7
Final drive
1. No. 2 planetary carrier Specifications

2. No. 2 ring gear (No. of teeth: 69) Reduction ratio:
3. Housing –67/12 × (13 + 80)/31 × (15 + 69)/15 = –223.677
4. Floating seal Amount of final drive oil: 85 l (each) (TO30)
5. Sprocket
6. Hub
7. Housing
10. Drive gear (No. of teeth: 12)
11. Travel motor case
12. Travel motor
13. No.1 sun gear (No. of teeth 13)
14. Driven gear (No. of teeth: 67)
15. Case
8 PC2000-8
Unit: mm
Backlash between drive gear Standard clearance Clearance limit
19
and driven gear 0.21 – 0.73 —
20 0.085 – 0.207 —
gear and driven gear
21 0.25 – 0.46 —
22 0.089 – 0.293 —
gear and No. 2 planetary carrier Replace
Backlash between No. 2 plane-
23 0.24 – 0.62 —
tary gear and No. 2 sun gear
24 Backlash of housing 0.067 – 0.258 —
Backlash between housing and
25 0.276 – 0.808 —
No. 2 ring gear
Clearance between housing
26 10 —
and hub
Standard shim thickness of
27 2 Adjust
cover mounting part
PC2000-8 9
Sprocket
Unit: mm
Standard size Repair limit
1 Wear of tooth tip
482.7 470.7 Build-up
2 Thickness of tooth root 40 34 welding or
3 Width of tooth 140 130 replace
4 Wear of tooth shape Repair limit: 6 (measure with sprocket tooth shape)
10 PC2000-8
a The above drawing is reduced to 41%. Enlarge it to 244% to return it to the full scale and make a copy
on an OHP sheet.
PC2000-8 11
SEN01615-00
12
SEN01616-00
PC2000-8

PC2000-8 20001 and up

Undercarriage and frame
Undercarriage and frame ................................................................................................................................ 2
Track frame .......................................................................................................................................... 2
Idler ...................................................................................................................................................... 4
Carrier roller ......................................................................................................................................... 6
Track roller ........................................................................................................................................... 7
Track shoe............................................................................................................................................ 8
HIC system......................................................................................................................................... 13
PC2000-8 1
Undercarriage and frame 1

Track frame 1
1. Idler 6. Track roller

2. Track frame 7. Track shoe
3. Carrier roller 8. Idler cushion
4. Center frame 9. Roller guard
5. Final drive 10. Accumulator
Unit: mm
Standard size Tolerance Repair limit
Track Rebuild
Top-to-bottom width 253 ±2 233
11 frame
of idler guide
Idler
250 ± 0.5 215 Replace
support
Track
420 ±2 430 Rebuild
Left-to-right width of frame
12
idler guide Idler +1.0
416 408 Replace
support +0
2 PC2000-8
Specification
810 mm shoe 1,010 mm shoe
Item
Width of shoe 810 mm 1,010 mm
Type Double grouser Triple grouser
Link pitch 317.5 mm 317.5 mm
Number of shoes 49 49
PC2000-8 3
Idler 1
4 PC2000-8
Unit: mm
No. Check item Criteria Remedy
Outside diameter of Standard size Repair limit
1
protruding part 1,072 —
Outside diameter of tread
2 1,030 1,018 Rebuild or
surface
replace
3 Thickness of tread — —
4 Height of tread 21 27
5 Overall width 311 —
6 Width of tread 85 —
Standard Tolerance Standard Clearance
Clearance between shaft and size Shaft Hole clearance limit
7
bushing –0.060 +0.37
165 0.29 – 0.49 —
–0.120 –0.23
Replace
Standard Tolerance Standard Interfer- bushing
Interference between idler size Shaft Hole interference ence limit
8
and bushing +0.134 –0.123 0.209 –
175 —
+0.086 –0.175 0.309
Standard clearance Clearance limit
9 Play of axial direction
0.65 – 1.07 —
PC2000-8 5
Carrier roller 1
Unit: mm
1 Outside diameter of flange
275 —
2 Outside diameter of tread 240 220 Rebuild or
3 Width of tread 85 — replace
4 Thickness of tread 47 37
5 Width of flange 25 —
size Shaft Hole clearance limit
Clearance between –0.060 +0.360 0.280 –
6 Outside 95 —
shaft and bushing –0.120 +0.220 0.480
–0.060 +0.390 0.205 –
Inside 125
–0.150 +0.145 0.540
Standard Tolerance Standard Interference Replace
size Shaft Hole interference limit bushing
Interference between +0.087 +0.035 0.022 –
7 Outside 102.5 —
roller and bushing +0.057 +0.035 0.087
+0.180 +0.053 0.027 –
Inside 135
+0.080 –0.010 0.190
Play of roller in axial Standard clearance Clearance limit
8
direction 0.40 – 0.76 —
6 PC2000-8
Track roller 1
Unit: mm
1 Outside diameter of flange
400 —
Outside diameter of tread
2 340 328
surface Rebuild or
3 Thickness of tread 92.5 86.5 replace
4 Overall width 394 —
5 Width of tread 85 —
6 Width of flange 41.5 —
Clearance between shaft and size Shaft Hole clearance limit
7
bushing –0.060 +0.482 0.421 –
145 —
–0.120 +0.361 0.602 Replace
Standard Tolerance Standard Interference bushing
Interference between roller and size Shaft Hole interference limit
8
bushing +0.115 +0.025 0.042 –
155 —
+0.067 –0.015 0.130
Standard clearance Clearance limit
9 Play of axial direction Replace
0.29 – 0.68 —
PC2000-8 7
Track shoe 1
a P portion shows the link of bushing press fitting end.
8 PC2000-8
Unit: mm
1 Link pitch
317.8 320.8
Reverse or
When turned
Standard size replace
2 Bushing outside diameter Normal load Heavy load
116 — 111
Standard size Repair limit Adjust or
3 Thickness of bushing metal
22.5 17.5 replace
Rebuild or
4 Link height 195 182
replace
Thickness of link metal
5 49.5 36.5
(bushing press-fitting portion)
6 274 Replace
7 Shoe bolt pitch 96
8 33
Inside
9 148
width
Overall Repair or
10 Link 83
width replace
Tread
11 78
width
12 Protrusion of pin 2.9
13 Protrusion of regular bushing 10.75
Adjust or
14 Overall length of pin 353
replace
15 Overall length of bushing 247.4
16 Thickness of spacer —
17 Bushing 235 – 647 kN {24 – 66 ton}
Regular
18 470 – 1176 kN {48 – 120 ton}
Press-fitting force pin —
Master
*19 235 – 686 kN {24 – 70 ton}
pin
*Dry type track link
PC2000-8 9
Unit: mm
Tightening torque Additional tightening
a. Regular (Nm {kgm}) angle (deg.)
link 686.5 ± 68.6
120 ± 10
20 Shoe bolt {70 ± 7} Retighten
Tightening torque Additional tightening Lower limit torque
b. Master (Nm {kgm}) angle (deg.) (Nm {kgm})
link
— — —
Tolerance Standard
Standard size
Interference between bushing Shaft Hole interference
21
and link +0.652 +0.087
113 0.435 – 0.652
+0.522 +0.087
Interference between regular +0.496 –0.126
22 70 0.522 – 0.696
pin and link +0.396 –0.200
Tolerance Standard
Standard size
Clearance between regular pin Shaft Hole clearance
23
and bushing +0.496 +1.236 Adjust or
70 0.240 – 0.840
+0.396 +0.736 replace
Tolerance Standard
Standard size
Interference between master Shaft Hole interference
*24
pin and link +0.216 –0.126
70 0.302 – 0.416
+0.176 –0.200
Tolerance Standard
Standard size
Clearance between master pin Shaft Hole clearance
*25
and bushing +0.050 +1.436
69.8 0.886 – 1.486
–0.050 +0.936
*Dry type track link
10 PC2000-8
Double shoe
Unit: mm
1 Height of shoe
108 87
2 Height of grouser 23 2
Rebuild or
3 Thickness 8
replace
4 50
5 Length at tip 44
6 —
PC2000-8 11
Triple grouser shoe
Unit: mm
1 Height of shoe
127 109
2 Height of grouser 20 2
Rebuild or
3 Thickness 8
replace
4 44
5 Length at tip 35
6 35
12 PC2000-8
HIC system 1
1. Idler
2. Yoke
3. Plunger A
4. Plunger B
5. Cylinder
6. Stop valve
7. Relief-check valve
8. Accumulator
9. Check valve
10. Stop valve
11. Pressure reducing valve
12. Check valve
13. Right travel motor
15. Control valve (R.H.)
16. Line oil filter
17. Hydraulic pump (front)
Operation
q The space between yoke (2) and plunger (3) is q If idler (1) returns forward, the oil is returned by
filled with grease. The space between plunger (4) the gas pressure in the accumulator through
and cylinder (5) is filled with hydraulic oil at the the check valve of the relief-check valve to cyl-
constant pressure of 17.7 MPa {180 kg/cm2}. inder (5). The cushion force decreases and the
This hydraulic oil is connected through relief- system returns to the original condition accord-
check valve (7) to accumulator (8). ing to the forward movement of the idler.
q If idler (1) is moved back by external force,
plunger (4) is pressed and the pressure in cyl-
inder (5) increases. If this pressure increases
above the set pressure, relief-check valve (7)
opens and the oil flows into accumulator (8).
q The volume of the nitrogen gas in the accumula-
tor is reduced by the quantity of the oil pushed by
plunger (4). Since the gas pressure increases as
a result, the cushion force increases according to
movement of plunger (4).
PC2000-8 13
Accumulator (HIC system)
1. Valve
2. Body
3. Bladder
4. Check valve
Specification
Capacity: 32, 500 cc
Actuation pressure: 29.4 MPa {300 kg/cm2}
14 PC2000-8
PC2000-8 15
SEN01616-00
16
SEN01618-00
PC2000-8

PC2000-8 20001 and up

Hydraulic system, Part 1
Hydraulic system, Part 1 ................................................................................................................................. 4
Hydraulic piping drawing ...................................................................................................................... 4
Hydraulic tank ...................................................................................................................................... 6
Oil cooler .............................................................................................................................................. 8
Line oil filter ........................................................................................................................................ 10
Pilot oil filter.........................................................................................................................................11
Return oil filter .................................................................................................................................... 12
Motor drain oil filter............................................................................................................................. 13
Pump drain filter ................................................................................................................................. 14
Accumulator ....................................................................................................................................... 15
Travel junction valve........................................................................................................................... 17
Solenoid valve.................................................................................................................................... 20
Hydraulic cylinder............................................................................................................................... 26
PC2000-8 1
Greasing system ................................................................................................................................ 28

Center swivel joint .............................................................................................................................. 38
2 PC2000-8
PC2000-8 3
Hydraulic system, Part 1 1

Hydraulic piping drawing 1
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Line oil filter
5. L1 control valve (5-spool)
6. L2 control valve (5-spool)
7. R1 control valve (5-spool)
8. R2 control valve (5-spool)
9. No. 1 pump (HPV375 + 375)
10. No. 2 pump (HPV375 + 375)
11. Fan pump (HPV95 + 95 + SAL (1) 020)
12. Swing motor
14. Travel motor
15. Oil cooler
16. Pump drain filter
17. Pilot oil filter
18. 8-spool solenoid valve assembly
18A. Back pressure compensation valve
selector solenoid valve
18B. Swing priority solenoid valve (right)
18C. 2-stage main relief solenoid valve
18D. Arm throttle solenoid valve (L1)
18E. Arm throttle solenoid valve (R2)
18F. Boom throttle solenoid valve (R1)
18G. Straight-travel valve
18H. Machine push-up solenoid valve
19. Swing holding brake solenoid valve
20. Bucket high cancel solenoid valve
21. Motor drain oil filter
22. Pilot selector valve (L1)
23. Pilot selector valve (R1)
24. Pilot selector valve (R2)
25. PPC cut-off valve
26. Travel shuttle valve
27. Travel junction valve
28. Variable back pressure compensation valve
29. Hydraulic tank
30. Return oil filter
31. Fan motor (Oil cooler)
32. Fan motor (Radiator)
33. Grease pump
34. HIC cylinder
35. Lock valve
36. PPC accumulator
37. Boom damper valve
38. Work equipment PPC valve (LH)
39. Work equipment PPC valve (RH)
40. Travel PPC valve
41. Accumulator (for oil cooler pressure)
4 PC2000-8
PC2000-8 5
Hydraulic tank 1
6 PC2000-8
1. Suction strainer proximity switch

2. Breather
3. Hydraulic tank
4. Suction strainer
5. Oil filler cap
6. Strainer
7. Hydraulic oil level sensor
8. Hydraulic oil temperature sensor
9. Hydraulic oil low temperature sensor
Specifications
Tank capacity: 1,910 l
Quantity of oil in tank: 1,215 l
Breather
Relief cracking pressure:
0.07 ± 0.01 MPa {0.7 ± 0.1 kg/cm2}
Suction cracking pressure:
Max. 0.002 MPa {0.02 kg/cm2}
Adjustment method for suction strainer proximity switch
PC2000-8 7
Oil cooler 1
8 PC2000-8
1. Fuel cooler
2. Oil cooler
3. Fan pump
4. Drain filter
5. Hydraulic motor for fan drive (oil cooler side)
6. Fan guard
7. Fan (oil cooler side)
Specifications
1. Fan
(Oil cooler side)
Outside diameter:1,450 mm
No. of vanes: 6
Rotating speed: Variable
(Standard. spec.: Max. 760 rpm)
(+55°C spec: Max. 1,100 rpm)
2. Oil cooler
Core type: PF 4-6, 3.0P
Fin pitch: 3.0 mm
3. Fuel cooler
Core type: CF 40-1, 4.5/2P
Fin pitch: 4.5 mm
PC2000-8 9
Line oil filter 1
1. Element Outline
2. Case There are 4 line oil filters installed to the discharge
3. Cover side of the hydraulic pump. They protect the circuit
and equipment by removing all dirt and dust from
A: From hydraulic pump the oil.
B: To control valve
10 PC2000-8
Pilot oil filter 1
1. Bracket
2. Cartridge
3. Safety valve
PC2000-8 11
Return oil filter 1
1. Cover Outline
2. Spring q There are 3 return oil filters installed to the side
3. Bypass valve face of the hydraulic tank. They remove the dirt
4. Bypass valve spring and dust in the return oil.
5. Element q Bypass valve set pressure:
6. Housing 0.15 ± 0.03 MPa {1.5 ± 0.3 kg/cm2}
A: From control valve

B: To hydraulic tank
12 PC2000-8
Motor drain oil filter 1
1. Bracket Outline
2. Safety valve q This filter is installed between the swing motor,
3. Cartridge travel motor, and hydraulic tank. It acts to
4. Element remove the dirt and foreign matter in the oil
coming from the drain port of each motor.
q Safety valve set pressure: 0.1 MPa {1.0 kg/cm2}
PC2000-8 13
Pump drain filter 1
1. Head Outline
2. Relief valve q The pump drain filter is installed between the
3. Cartridge hydraulic pump, fan pump and hydraulic tank.
4. Element It removes dirt and foreign matter from the oil
flowing in from each pump drain port.
q Safety valve set pressure:
147 ± 29 kPa {1.5 ± 0.3 kg/cm2}
14 PC2000-8
Accumulator 1
PPC accumulator
1. Cap Specifications
2. Nut Gas capacity: 5,100 cc
3. Cap Gas pressure: 1.18 MPa {12 kg/cm2}
4. Body
5. Bladder
6. Port
7. Nut
PC2000-8 15
Accumulator (for oil cooler pressure)
1. Accumulator System diagram

2. Oil cooler
3. Hydraulic tank
4. Control valve
5. Cooler check valve
6. Variable back pressure valve
7. Return filter
Outline
The accumulator is installed in the oil cooler
hydraulic circuit to cut the peak hydraulic pressure
of the oil cooler and secure the durability and reli-
ability.
1. Body
2. Bladder
3. Poppet
4. Film
5. Holder
6. Port
7. Plug
Specifications
Volume of gas: 500 cm3
Charge pressure: 0.098 MPa {1 kg/cm2}
16 PC2000-8
Travel junction valve 1
1. Valve body Specifications

2. Spool Spool change pressure:
3. Retainer 0.2 ± 0.05 MPa {2 ± 0.5 kg/cm2}
4. Spring
Outline
q The travel junction valve is used for the travel
circuit.
q When the machine travels straight, the travel
junction valve connects the travel circuits to
prevent travel deviation caused by the differ-
ence between the oil flow rates in the right and
left motors.
PC2000-8 17
System diagram
1. Travel PPC valve a. LH travel reverse

2. Control valve b. LH travel forward
3. Shuttle valve c. RH travel reverse
4. Travel junction valve d. RH travel forward
5. Swivel joint
6. RH travel motor
7. LH travel motor
18 PC2000-8
PC2000-8 19
Solenoid valve 1
1. For back pressure compensation, 2-stage main relief, arm throttle, swing priority, straight travel, and
machine push-up
20 PC2000-8
1. Back pressure compensation valve solenoid valve Operation

2. Swing priority switching valve solenoid valve When solenoid is de-energized
3. 2-stage main relief solenoid valve q Since the signal current does not flow from the
4. Arm throttle valve (L1) solenoid valve controller to solenoid, coil (11) is de-energized.
5. Arm throttle valve (L2) solenoid valve For this reason, spool (12) is pushed to the left
6. Boom throttle valve (R1) solenoid valve by spring (14).
7. Straight travel solenoid valve q By this operation, the pass from port (P) to port
8. Machine push-up solenoid valve (A) is closed and the pressurized oil from the
9. Connector main pump does not flow into the actuator.
10. Movable core q At this time, the oil from the actuator is drained
11. Coil through ports (A) and (T) into the tank.
12. Spool
13. Block
14. Spring
A1: To back pressure compensation valve

A2: To PPC cutoff valve (CV2)
A3: To main relief valve
A4: To pilot valve (PV1)
A7: To PPC cutoff valves (CV1), (CV2)
A8: To main valves (L1), (R1)
P1: From pump
T: To hydraulic tank
ACC: Plug
When solenoid is energized
q The signal current flows from the controller to
solenoid, and coil (11) is energized. Accord-
ingly, spool (12) is pressed against to the right
side.
q By this operation, the pressurized oil from the
main pump flows through port (P) and spool (4)
to port (A), then flows into the actuator.
q At the same time, port (T) closes and stops the
oil from flowing to the tank.
PC2000-8 21
2. For swing holding brake and lock valve
22 PC2000-8
1. Swing holding brake solenoid valve

2. Connector
3. Coil
4. Movable core
5. Body
6. Plug
7. Spring
8. Spool
9. Body
10. Plug
11. Spring
12. Spool
T: To tank
A: To front and rear swing motors
(for swing holding brake)
To PPC valve (for safety lock)
P: From control pump
Operation
When solenoid is de-energized
q While the signal current is not flowing in from
the controller, coil (3) is de-energized. Accord-
ingly, spool (12) is pushed up by spring (11)
and spool (8) is pushed to the left by spring (7).
q Since port (P) is closed at this time, the oil from
the control pump does not flow to the actuator.
q The oil from the actuator flows through ports
(A) and (T) to the tank.
When solenoid is energized

q If the signal current flows in from the controller
and coil (3) is energized, spool (12) is pushed
down.
q Accordingly, the oil from the control pump flows
through port (P) to port (A) and spool (8) is
pushed to the right.
q If spool (8) is pushed to the right, the oil from
the control pump flows through ports (P) and
(A) to the actuator.
q Since port (T) is closed at this time, the oil
does not flow to the tank.
PC2000-8 23
3. For bucket high cancel
1. Connector When solenoid is energized

2. Movable core q If the signal current flows in from the controller,
3. Solenoid solenoid (3) is energized and movable core (2)
4. Spool is pushed to the right. Accordingly, spool (4) is
5. Body pushed to the right.
6. Spring q If spool (4) is pushed to the right, port (P) is
7. Plug closed and the oil from the PPC valve does not
flow to the control valve.
Operation q Since port (A) and port (T) are connected at
When solenoid is de-energized this time, the oil from the control valve flows to
q While the signal current is not flowing in from the tank.
the controller, solenoid (3) is de-energized and
spool (4) is set in the neutral position by spring
(6).
q At this time, port (P) and port (A) are con-
nected and the oil from the PPC valve flows to
the control valve.
24 PC2000-8
PC2000-8 25
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
Bucket cylinder
26 PC2000-8
Unit: mm
Name of Standard Tolerance Standard Clearance
cylinder size Shaft Hole clearance limit
–0.050 +0.257 0.089 –
Boom 200 —
Clearance between –0.122 +0.039 0.379 Replace
1
piston rod and bushing –0.043 +0.228 0.089 – bushing
Arm 160 —
–0.105 +0.046 0.334
–0.043 +0.035 0.048 –
Bucket 140 —
–0.106 +0.005 0.141
–0.043 +0.025 0.043 –
Boom 180 1.0
Clearance between –0.106 +0.025 0.131
piston rod –0.043 +0.025 0.043 –
2 Arm 140 1.0
support shaft and –0.106 +0.025 0.131
bushing –0.043 +0.245 0.188 –
Bucket 140 1.0
–0.106 +0.145 0.351 Replace pin,
–0.043 +0.025 0.043 – bushing
Boom 180 1.0
Clearance between –0.106 +0.025 0.131
cylinder bottom –0.043 +0.025 0.043 –
3 Arm 140 1.0
support shaft and –0.106 +0.025 0.131
bushing –0.036 +0.457 0.406 –
Bucket 120 1.0
–0.090 +0.370 0.547
PC2000-8 27
Greasing system 1
28 PC2000-8
PC2000-8 29
Injector distribution valve line

Grease point Delivery

1 Front link + Bucket pin 1.30 cc/rev × 2
2 Front link + wrist pin 1.30 cc/rev × 4
3 Arm B boss 1.30 cc/rev × 4
4 Arm A boss + Bucket pin 1.30 cc/rev × 4
Arm 1.30 cc/rev × 2
5 Arm C boss + Bucket top pin
Boom 0.72 cc/rev × 2
6 Bucket cylinder bottom pin 0.97 cc/rev × 2
7 Arm cylinder head pin 1.30 cc/rev × 2
8 Boom foot pin 0.97 cc/rev × 4
9 Boom cylinder head pin 1.30 cc/rev × 2
10 Arm cylinder bottom pin 1.30 cc/rev × 2
11 Boom cylinder bottom pin 0.13 cc/rev × 2
12 Swing circle 1.30 cc/rev × 10
30 PC2000-8
Outline
q Auto grease function
If the grease mode selector switch is in the
auto grease position, the controller operates
the grease pump at constant time intervals and
the icon of the grease pump operating at the
set pressure is displayed on the monitor.
q Manual grease function
If the grease mode selector switch is in the
manual grease position, the controller oper-
ates the grease pump continuously.
q Grease level warning function
If the grease level lowers, the low-level switch
signal is inputted to the controller and warning
is displayed on the monitor and the grease
warning lamp blinks.
q Auto grease intervals
Auto grease interval Time from stop of pump to start
SMR 100 hours or less 5 minutes
Above SMR 100 hours 10 minutes
PC2000-8 31
Components
Grease pump
1. Vent valve Outline

2. Pump q In the auto grease system, this hydraulic pump
3. Follower plate supplies the grease from grease chamber (B).
4. Tube q This pump is double-action type, that is, it dis-
5. Cover charges grease in both upward and downward
6. Grease tank strokes.
7. Pressure gauge q This pump is operated automatically by the oil
pressure switch and controller.
A. Oil inlet port a When the grease is supplied, if pressure gauge
B. Grease chamber (7) indicates 4.9 – 19.6 MPa {50 – 200 kg/cm2},
C. Grease feed port the operation is normal.
(if equipped: with refill function) a If the pressure gauge indicates below 4.9 MPa
D. Grease drain port {50 kg/cm2}, grease tank is empty.
(if equipped: with refill function) a If the grease tank or vent valve is broken, the
T. Pump drain port caution lamp lights up and the contents of the
trouble are displayed on the machine monitor.
Grease delivery (Max.): 28 l/min

Set pressure (reducing valve):
2.3 ± 1.0 MPa {23.5 ± 1 kg/cm2}
Grease tank capacity: Approx. 180 kg
32 PC2000-8
Auto grease indicator Grease gun

q If the grease mode selector switch is set in q Use the grease gun to grease the parts which
“AUTO”, “AUTO” indicator (1) is displayed on are not greased by the auto grease system
the normal screen of the monitor. (trunnion at the front of the engine and tracks)
and the local parts which are greased by the
auto grease system.
Manual grease indicator

q If the grease mode selector switch is set in
“MANUAL”, “MANUAL” indicator (2) is dis-
played on the normal screen of the monitor.
PC2000-8 33
Hose reel
q The hose reel is used to store the grease gun
hose. It is the auto winder type.
34 PC2000-8
Injector distribution valve
1. Adjustment screw
2. Injector body
3. Injector piston
4. Piston spring
5. Slide valve
6. Manifold
Delivery: 0.13 – 1.31 cc/rev
PC2000-8 35
Operation
q Stage 1 q Stage 2
The grease pressurized by the pump pushes The grease flowing through passage (P)
up slide valve (5) and connects manifold (6) pushes down injection piston (3) and dis-
and passage (P). charges the grease in discharge chamber (D)
to oil hole (h).
36 PC2000-8
q Stage 3 q Stage 4
Injector piston (3) lowers to slide valve (5) and If slide valve (5) is pushed down, passage (P)
then pushes it down to disconnect manifold (6) is connected to discharge chamber (D) by
and passage (P). valve port (q) and the grease in measuring
chamber (M) is sent to discharge chamber (D)
for the next supply. The operation cycle is com-
pleted at this point.
PC2000-8 37
Center swivel joint 1
1. Cover B2 : To R.H. travel motor port PB

2. Body C1 : From L.H. travel control valve port A5
3. Slipper seal C2 : To L.H. travel motor port PB
4. Oil seal D1 : From L.H. travel control valve port B5
5. Shaft D2 : To L.H. travel motor port PA
P1 : To hydraulic tank
A1 : From R.H. travel control valve port A5 P2 : From L.H. and R.H. travel motor port T
A2 : To R.H. travel motor port PA T1 : To hydraulic tank
B1 : From R.H. travel control valve port B5 T2 : From L.H. and R.H. travel motor port T
Unit: mm
Clearance between rotor and Standard size Standard clearance Clearance limit
6 Replace
shaft 110 0.056 – 0.105 0.111
38 PC2000-8
PC2000-8 39
SEN01618-00
40
SEN01619-00
PC2000-8

PC2000-8 20001 and up

Control valve ........................................................................................................................................ 2
Electronic OLSS system .................................................................................................................... 30
Swing motor ....................................................................................................................................... 34
Cooling fan motor (For radiator and oil cooler) .................................................................................. 42
Cooling fan pump ............................................................................................................................... 48
PC2000-8 1

Control valve 1
L.H. 10-spool valve
2 PC2000-8
A1 : To arm cylinder head

A2 : To boom cylinder head
A3 : To bucket cylinder head
A4 : –
A5 : To L.H. travel motor [Port (PB)]
B1 : To arm cylinder bottom
B2 : To boom cylinder bottom
B3 : To bucket cylinder bottom
B4 : –
B5 : To L.H. travel motor [Port (PA)]
CN-P27: To controller
NCA1 : Pressure pick-up port (Jet sensor upstream pressure)
NCB1 : Pressure pick-up port (Jet sensor downstream pressure)
P1 : From P1 rear pump
P2 : From P2 rear pump
PA11 : From PPC valve (Arm IN)
PA21 : From PPC valve (Boom RAISE)
PA31 : From PPC valve (Bucket CURL)
PA41 : –
PA51 : From PPC valve (L.H. travel reverse)
PB11 : From PPC valve (Arm OUT)
PB21 : From PPC valve (Boom LOWER)
PB31 : From PPC valve (Bucket DUMP)
PB41 : –
PB51 : From PPC valve (L.H. travel forward)
PA42 : –
PA52 : From PPC valve (L.H. travel reverse)
PB22 : Drain
PB42 : –
PB52 : From PPC valve (L.H. travel forward)
PC1 : From boom priority selector valve
PP1 : From solenoid valve (Main relief valve)
PS1 : From solenoid valve (Machine push-up)
T : To tank (Main drain)
TC1 : Drain
TS : To swing motor [Port (S)]
1. L1 valve
2. L2 valve
PC2000-8 3
Sectional view
4 PC2000-8
L1 valve
PC2000-8 5
Sectional view
6 PC2000-8

A21: To boom cylinder head
A31: To bucket cylinder head
A41: –
A51: To L.H. travel motor [Port (PB)]
B21: To boom cylinder bottom
B31: To bucket cylinder bottom
B41: –
B51: To L.H. travel motor [Port (PA)]
1. Main relief valve

2. Spool (Arm Lo)
3. Spool (Boom Lo)
4. Spool (Bucket Hi)
5. –
6. Spool (L.H. travel Hi)
7. Valve body
8. Jet sensor and orifice
9. Jet sensor and relief valve
10. Jet sensor and differential pressure sensor
11. Orifice check valve
12. Check valve
13. Piston
14. Check valve
15. Check valve
Unit: mm
Free length
Installed Installed Installed
× outside Free length
16 Spool return spring length load load
diameter
431 N 345 N
69.9 × 57 63 —
{44 kg} {35.2 kg}
If damaged or
541 N 433 N
17 Spool return spring 74.5 × 38.1 71.5 — deformed,
{55.2 kg} {44.2 kg}
replace spring
18.8 N 15.1 N
18 Check valve spring 65.28 × 14 46 —
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
19 Check valve spring 78.2 × 26.6 52 —
{1.92 kg} {1.54 kg}
12.7 N 10.2 N
20 Check valve spring 20.8 × 12.2 13.5 —
{1.3 kg} {1.04 kg}
PC2000-8 7
8 PC2000-8
1. Arm Lo valve
2. Boom Lo valve
3. Bucket Hi valve
4. –
5. L.H. travel Hi valve
6. Safety-suction valve
7. 2-stage safety-suction valve
8. Suction valve
PC2000-8 9
L2 valve
10 PC2000-8
Sectional view
PC2000-8 11
A12: To arm cylinder head

A42: –
A52: To L.H. travel motor [Port (PB)]
B12: To arm cylinder bottom
B42: –
B52: To L.H. travel motor [Port (PA)]

2. Spool (Arm Hi)
3. Spool (Boom Hi)
4. Spool (Bucket Lo)
5. Spool (–)
6. Spool (L.H. travel Lo)
7. Valve body
11. Check valve
12. Check valve
Unit: mm
Free length
diameter
431 N 345 N
69.9 × 57 63 — If damaged or
{44 kg} {35.2 kg}
deformed,
541 N 433 N replace spring
14 Spool return spring 74.5 × 38.1 71.5 —
{55.2 kg} {44.2 kg}
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
12.7 N 10.2 N
{1.3 kg} {1.04 kg}
12 PC2000-8
PC2000-8 13
14 PC2000-8
1. Arm Hi valve
2. Boom Hi valve
3. Bucket Lo valve
4. –
5. L.H. travel Lo valve
7. Suction valve
PC2000-8 15
R.H. 10-spool valve
16 PC2000-8

A2 : To boom cylinder head
A3 : To bucket cylinder head
A4 : To swing motor [Port (MB)]
A5 : To R.H. travel motor [Port (PA)]
B2 : To boom cylinder bottom
B3 : To bucket cylinder bottom
B4 : To swing motor [Port (MA)]
B5 : To R.H. travel motor [Port (PB)]
P1 : From P1 front pump
P2 : From P2 front pump
PA41 : From PPC valve (Right swing)
PA51 : From PPC valve (R.H. travel reverse)
PB21 : Drain
PB41 : From PPC valve (Left swing)
PB51 : From PPC valve (R.H. travel forward)
PA42 : –
PA52 : From PPC valve (R.H. travel reverse)
PB22 : From PPC valve (Boom LOWER)
PB42 : –
PB52 : From PPC valve (R.H. travel forward)
PC1 : From swing priority selector valve
PC2 : From boom priority selector valve
PS2 : From solenoid valve (Machine push-up)
T : To tank (Main drain)
TC1 : Drain
TC2 : Drain
TS : To swing motor [Port (S)]
1. R1 valve
2. R2 valve
PC2000-8 17
Sectional view
18 PC2000-8
R1 valve
PC2000-8 19
Sectional view
20 PC2000-8

A41: To swing motor [Port (MB)]
A51: To R.H. travel motor [Port (PA)]
B41: To swing motor [Port (MA)]
B51: To R.H. travel motor [Port (PB)]

2. Spool (Arm Lo)
3. Spool (Boom Hi)
4. Spool (Bucket Lo)
5. Spool (Swing)
6. Spool (R.H. travel Hi)
7. Valve body
12. Check valve
13. Piston
14. Check valve
15. Check valve
Unit: mm
Free length
diameter
431 N 345 N
69.9 × 57 63 —
{44 kg} {35.2 kg}
If damaged or
541 N 433 N
{55.2 kg} {44.2 kg}
replace spring
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
12.7 N 10.2 N
{1.3 kg} {1.04 kg}
PC2000-8 21
22 PC2000-8
1. Arm Lo valve
2. Boom Hi valve
3. Bucket Lo valve
4. Swing valve
5. R.H. travel Hi valve
7. Suction valve
PC2000-8 23
R2 valve
24 PC2000-8
Sectional view
PC2000-8 25
A12: To arm cylinder head

A42: To swing motor [Port (MB)]
A52: To R.H. travel motor [Port (PA)]
B12: To arm cylinder bottom
B42: To swing motor [Port (MA)]
B52: To R.H. travel motor [Port (PB)]

2. Spool (Arm Hi)
3. Spool (Boom Lo)
4. Spool (Bucket Hi)
5. –
6. Spool (R.H. travel Lo)
7. Valve body
12. Check valve
13. Piston
14. Check valve
15. Check valve
Unit: mm
Free length
diameter
431 N 345 N
69.9 × 57 63 —
{44 kg} {35.2 kg}
If damaged or
541 N 433 N
{55.2 kg} {44.2 kg}
replace spring
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
12.7 N 10.2 N
{1.3 kg} {1.04 kg}
26 PC2000-8
PC2000-8 27
28 PC2000-8
1. Arm Hi valve
2. Boom Lo valve
3. Bucket Hi valve
4. –
5. R.H. travel Lo valve
7. 2-stage safety-suction valve
8. Suction valve
PC2000-8 29
Electronic OLSS system 1
30 PC2000-8
Function
q The electronic OLSS system converts signals
from the jet sensor to electronic signals by use
of the differential pressure sensor to enable
EPC valve to directly control the swash plate of
the variable displacement pump.
q Conventional OLSS used to control the flow
rate by conducting the signal pressures from
TVC valve, CO valve and NC valve to the
pump servo piston.
q The electronic OLSS system controls TVC, CO
and NC digitally. And sensing the lever signals,
jet sensor signals, pump discharge pressure
and engine speed, this system controls the
flow rate to ensure more efficient use of the q Output voltage (E) from the differential pres-
engine horsepower than available from the sure sensor is conducted to the controller.
hydraulic control. q Current (IEPC) being conducted from the con-
q As the spool stroke of the control valve troller to EPC valve increases output voltage
increases, carry-over flow rate (QC) (PI) of EPC. As the result, pump delivery (Q)
decreases, decreasing the differential pressure increases.
(PT – PD) output from the jet sensor. q The figure shows the relationship between the
control valve spool stroke and pump delivery (Q).
q Pump delivery (Q) increases roughly in propor-
tion to increase in the control valve spool
stroke.
Features
q Favorable fuel consumption results in the fine
control mode because the pump delivers the only
necessary flow rate, the reducing power loss.
q Favorable fuel consumption also results when
the lever is set to the neutral position since the
flow rate is kept at minimum and, thus, the
power loss is reduced.
q Startability of the pump increases significantly
q Voltage is output as output differential pressure since the pump driving torque at startup is small.
(PT – PD) is conducted to the differential pres- q Small spool stroke of the control valve enhances
sure sensor. the fine steering control since it decreases the
q The figure shows the relation between the pump delivery.
input and output signals, indicating that q This system saves power loss since it allows
decrease in output differential pressure (PT – setting a different speed on individual work
PD) results in increasing output voltage (E). equipment basis.
q Adding the digitized modulation enhances the
operability.
PC2000-8 31
Arm and boom throttle valves
Function Operating condition table

q When the sections with a high operating pres- Operating condition
sure and a low operating pressure are oper- No. Section
(*: throttling side)
ated simultaneously in the compound
Arm IN* + Boom RAISE
operation, the throttle valve brings balance to Arm throttle
Arm IN* + Bucket DUMP
the flow rate to respective work equipment by 1 valve
Arm IN* + Bucket CURL
preventing the operating pressure from flowing (L1 valve)
Arm OUT* + Boom RAISE
more to the low-pressure side.
Arm throttle
Arm IN* + Boom RAISE
2 valve
Arm OUT* + Boom Raise
(R2 valve)
Boom throttle
3 valve Swing + Boom RAISE*
(R1 valve)
32 PC2000-8
Operation
q As the output pressure to respective PPC valves
is generated according to a combination listed in
the operating condition table, the solenoid valve
outputs the pilot pressure responding to the sig-
nal from the controller and, as the result, the
selector valve is switched.
When the signal from the controller is present

q The selector valve is switched by the pilot
pressure from the solenoid valve and the pump
pressure is introduced at the result.
q Piston (4) is pushed down due to the area dif-
ference between (φd1) and (φd2).
q Stroke of orifice check valve (1) is disabled by
piston (4).
q The pressurized oil from the pump flows
through orifice (a) of orifice check valve (1),
retracting spring (3) and pushing up check
valve (2) in the process. Then it flows through
orifice (b) to the cylinder port.
q Flow of the pressurized oil to the cylinder port
is restricted by orifices (a) and (b).
When the signal from the controller is absent

q Port (PC) is drained. Thus, piston (4) does not
operate.
q As long as piston (4) remains inactive, the
pressurized oil from the pump flows to the cyl-
inder port by retracting spring (3) and pushing
up orifice check valve (1) and check valve (2).
q In this case, flow of the pressurized oil to the
cylinder port is not restricted.
PC2000-8 33
Swing motor 1
Type: KMF230AB-5
B : From swing holding brake solenoid valve Specifications

MA : From control valve Type : KMF230AB-5
MB : From control valve Theoretical displacement : 229.4 cm3/rev
S : From control valve Safety valve set pressure : 27.9 MPa {290 kg/cm2}
T : To tank Rated speed : 1,315 rpm
Brake release pressure : 1.9 MPa {19 kg/cm2}
1. Plate
2. Safety valve
34 PC2000-8
PC2000-8 35
36 PC2000-8
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10. Cylinder block
11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Shuttle valve
Unit: mm
Free length
16 Check valve spring length load load If damaged or
diameter
deformed,
6.96 N 5.59 N replace spring
66.5 × 25.6 45.0 —
{0.71 kg} {0.57 kg}
7.45 N 5.98 N
17 Shuttle valve spring 24.5 × 11.6 14.5 —
{0.76 kg} {0.61 kg}
PC2000-8 37
Swing holding brake
1. When solenoid valve is de-energized 2. When solenoid valve is energized
Operation Operation
q As the swing holding brake is de-energized, q As the swing brake solenoid valve is ener-
the pressurized oil from the self pressure gized, the valve is switched.
reducing valve is shut off. q The pressurized oil from the self pressure
q Port (B) is connected to tank circuit (T). reducing valve is conducted brake chamber (a)
q Brake piston (7) is pushed down by brake through port (B).
spring (1). q After entering chamber (a), the pressurized oil
q Disc (5) and plate (6) are pushed together, and compresses brake spring (1) and pushes
the brake is applied. brake piston (7) up.
q Disc (5) is separated from plate (6), releasing
the brake.
38 PC2000-8
Relief valve
Outline
q The relief valve consists of check valves (2)
and (3), shuttle valves (4) and (5), and relief
valve (1).
Function
q When the machine is in the swing holding
mode, control valve (6) closes the motor outlet
circuit, but the motor rotation is continued by
inertial force.
q The motor output, therefore, is abnormally
increased, resulting in damaging the motor.
q In order to prevent the motor damages, the
relief valve relieves the abnormally high pres-
sure to port (S) from the motor outlet side
(high-pressure side) of the motor.
Operation
1. When starting swing
q When the swing control lever is operated to the
right-swing, the pressurized oil from the pump is
supplied to port (MA) through control valve (6).
q The pressure on port (MA) rises, the starting
torque is generated in the motor, and the motor
starts to rotate.
q The pressurized oil from the outlet port of the
motor passes from port (MB) through control
valve (6) and returns to the tank.
PC2000-8 39
2. When swing is stopped

q When the swing control lever is returned to
neutral, the supply of pressurized oil from the
pump to port (MA) is stopped.
q The pressurized oil from the motor outlet can't
return to the tank since the returning circuit to
the tank is closed from control valve (6). Thus,
pressure on port (MB) increases.
q Rotation resistance is generated on the motor
and hence the brake starts working.
q The pressure on port (MB) pushes shuttle
valve (4) as it goes higher than that on port
(MA).
q The pressure on chamber (C) is increased to
the s et pres su re of re lie f v alv e (1) a nd
becomes the same as that of port (MB).
q A high braking torque works on the motor,
thereby stopping the motor.
q When relief valve (1) is being actuated, the
relieved pressurized oil and the pressurized oil
from port (S) are fed to port (MA) through
check valve (3).
q Above prevents cavitation on port (MA).
40 PC2000-8
PC2000-8 41
Cooling fan motor

(For radiator and oil cooler) 1
Type: LMF110
P : From fan pump

T : From cooler to tank
TC : To tank
Specifications
Type: LMF110
Capacity: 110.7 cm3/rev
Rated speed: 1,050 rpm
Rated flow rate: 116.2 l/min
Check valve clacking pressure: 78.5 kPa {0.8 kg/cm2}
Safety valve cracking pressure: 24.5 MPa {250 kg/cm2}
42 PC2000-8
1. Output shaft 8. End cover

2. Case 9. Center spring
3. Thrust plate 10. Suction valve
4. Shoe 11. Pilot valve
5. Piston 12. Reversible valve spool
6. Cylinder block 13. Safety valve
7. Valve plate
Unit: mm
Free length
14 Spool return spring length load load If damaged or
diameter
deformed,
146 N 117 N replace spring
62.66 × 19.8 53.5 —
{14.9 kg} {11.9 kg}
13.7 N 11.0 N
15 Suction valve spring 16.4 × 8.9 11.5 —
{1.4 kg} {1.12 kg}
PC2000-8 43
1. Hydraulic motor
Function
q 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
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The hydraulic oil conducted to one side of cyl-
inder block (5) pushes respective pistons (4) to
generate force (F1) [F1 = P × xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a°) to
output shaft (1), the force is divided into com-
ponents (F2) and (F3).
q The radial component (F3) generates torque
[T = F3 × ri] against the (Y–Y) line connect-
ing the top dead center and bottom dead
center.
q The combined force of all torque [T = Σ (F3 × ri)]
rotates cylinder block (5) through the piston.
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
44 PC2000-8
2. Suction valve
Function 2) When the pump is stopped

q If the fan pump stops, the pressurized oil does q If the engine is stopped and the input revolu-
not flow into the motor. Since the motor contin- tion of the fan pump lowers to 0 rpm, the
ues revolution because of the force of inertia, hydraulic oil from the pump is not supplied to
however, the pressure on the outlet side of the port (P) any more. As the hydraulic oil is not
motor rises. supplied to the (MA) side of the motor, the
q When the oil stops flowing in from inlet port (P), motor speed lowers gradually to stop.
suction valve (1) sucks in the oil on the outlet q If the motor shaft is revolved by the force of
side and supplies it to port (MA) where there is inertia while the oil flow in the port (P) is reduc-
not sufficient oil to prevent cavitation. ing, the oil in port (T) on the outlet side is sent
by suction valve (1) to the (MA) side to prevent
Operation cavitation.
1) When pump is started

q When the hydraulic oil from the pump is sup-
plied to port (P) and the pressure on the (MA)
side rises and starting torque is generated in
the motor, the motor starts revolution. The oil
on the outlet (MB) side of the motor returns
through port (T) to the tank.
PC2000-8 45
3. Operation of reversible valve
1) When the ON-OFF solenoid is de-energized 2) When ON-OFF solenoid is energized

q If ON-OFF solenoid (1) is “de-energized”, the q If ON-OFF solenoid (1) is “energized”, ON-
pressurized oil from the pump is blocked by OFF selector valve (2) changes to let the pres-
ON-OFF selector valve (2), and port (C) opens sured oil from the pump flow through port (C)
for the tank circuit. into spool chamber (D).
q Spool (3) is pushed to the right by spring (4). q The pressurized oil in chamber (D) pushes
q Motor port (MA) opens and pressurized oil valve spool (3) to the left against spring (4).
flows in to revolve the motor in forward (clock- q Motor port (MB) opens and pressurized oil
wise). flows in to revolve the motor in reverse (coun-
terclockwise).
46 PC2000-8
4. Safety valve
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) exceeds the cracking
pressure of safety valve (1), valve (2) of safety
valve (1) opens to relieve the oil into port (T).
q By this operation, generation of abnormal pres-
sure in port (P) is prevented.
PC2000-8 47
Cooling fan pump 1

Type: HPV95+95+SBL (1) 21
48 PC2000-8
Outline
q The pump unit is composed of 2 variable-
capacity swash plate-type piston pumps, PC
valves, EPC valves and a single gear pump.
IMF : Front side swash plate control current

IMR : Rear side swash plate control current
PAF : Front pump discharge port
PAG : Gear pump discharge port
PAR : Rear pump discharge port
PBF : Pump pressure output port
PBR : Pump pressure output port
PD1F : Case drain port
PD1R : Air bleeder
PD2F : Drain plug
PD2R : Drain plug
PENF : Control pressure pick-up port
PENR: Control pressure pick-up port
PEPC: EPC basic pressure port
PFC : Front pump discharge pressure pick-up port
PMF : EPC output pressure pick-up port for front
side swash plate control
PMR : EPC output pressure pick-up port for rear
side swash plate control
PPF : Front pump pressure sensor installation port
PPR : Pump pressure sensor installation port
PRC : Rear pump discharge pressure pick-up port
PRF : Pilot pressure input port
PRR : Pilot pressure input port
PS : Pump suction port
PSG : Gear pump suction port
1. Front pump
2. Rear pump
3. Gear pump
4. PC valve
5. EPC valve
6. Sequence valve
PC2000-8 49
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. Servo piston
13. PC valve
50 PC2000-8
Function q Rocker cam (4) conducts high pressure oil to

q The engine speed and torque are transmitted cylinder surface (B) with cradle (2), which is
to the shaft of this pump. Then, this pump con- secured to the case, and forms a static pres-
verts the speed and torque into oil pressure sure bearing when it slides.
and discharges pressurized oil according to q Piston (6) carries out relative movement in the
the load. axial direction inside each cylinder chamber of
q It is possible to change the delivery by chang- cylinder block (7).
ing the swash plate angle. q Cylinder block (7) seals the pressurized oil to
valve plate (8) and carries out relative rotation.
Structure q This surface is designed so that the oil pres-
q Cylinder block (7) is supported to shaft (1) by sure balance is maintained at a suitable level.
spline (14). q The oil inside each cylinder chamber of cylin-
q Shaft (1) is supported by front and rear bear- der block (7) is suctioned and discharged
ings (15). through valve plate (8).
q The end of piston (6) has a spherical hollow
and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
PC2000-8 51
Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves along plate angle = 0), the difference between vol-
cylindrical surface (B), so angle (a) between cen- umes (E) and (F) inside cylinder block (7)
ter line (X) of rocker cam (4) and the axial direc- becomes 0.
tion of cylinder block (7) changes. q Suction and discharge of pressurized oil is not
q Angle (a) is called the swash plate angle. carried out in this state. Namely pumping
action is not performed. (Actually, however, the
swash plate angle is not set to 0)
q With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) sucks and discharges the oil
by amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
52 PC2000-8
Control of delivery
q If swash plate angle (a) becomes larger, the dif-
ference between volumes (E) and (F) becomes
larger and pump delivery (Q) increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pressure
chamber of the small diameter piston side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
PC2000-8 53
1. PC valve
PA : Pump port 1. Plug

PDP : Drain port 2. Servo piston assembly
PM : EPC pressure input port 3. Pin
PPL : Control pressure output port 4. Spool
(To servo piston large diameter end) 5. Retainer
6. Seat
7. Cover
8. Wiring
Function
q The PC valve controls the pump delivery (Q)
according to the EPC valve output pressure
(PM).
q If the EPC valve output pressure (PM) rises,
the PC valve increases the pump delivery (Q).
q If the EPC valve output pressure (PM) lowers,
the PC valve decreases the pump delivery (Q).
54 PC2000-8
1) Action of EPC valve solenoid (1)
Operation
q PC mode selector current (IM) from the pump
controller is conducted to EPC valve solenoid (1).
q PC mode selector current (IM) works on EPC
valve to have it generate the signal pressure in
order to change piston (2) pushing force.
q Spool (3) stops at a position where the force of
spring (4) is balanced with the force applied to
piston (2) according to the EPC valve signal
pressure.
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The level of PC mode selector current (IM) is
determined by the engine oil temperature,
hydraulic oil temperature, engine speed, and
set value of the hydraulic fan.
q The spring set force of spring (4) varies as
servo piston (9) expands and compresses
spring (4).
PC2000-8 55
2) When PC mode selector current is decreased (When EPC output pressure lowers)
q Port (C) of PC valve is connected to the large q The pressure on port (C) rises and the pres-
diameter end of servo piston (9). sure on the large diameter end of the piston
q Pump discharge pressure (PA) is applied to the also rises. Thus, the leftward move of servo
small diameter end of servo piston (9) and port piston (9) is stopped.
(B). q The stop position of servo piston (9) (= pump
q When EPC output pressure (PM) is decreased, delivery) is determined by the position where
spool (3) moves to the left. the pressing force generated by the EPC valve
q Ports (C) is connected to port (D) and the pres- output pressure is balanced with the force of
sure applied to the large diameter end of the spring (4).
piston becomes drain pressure (PT) and servo q When the stop position of servo piston (9) (=
piston (9) moves to the left. pump delivery) is at a middle position between
q The pump delivery will be set to the increasing the maximum and minimum pump delivery
trend. positions, the pressure on the large diameter
q Accompanied with move of servo piston (9), end of the piston is about a half of pump dis-
spring (4) will be expanded and the spring charge pressure (PA). When the former is at
force becomes weaker. the maximum pump delivery position, the latter
q As the spring force is weakened, spool (3) becomes drain pressure (PT).
moves to the right, the connecting between
port (C) and port (D) is shut off and the pump
discharge pressure ports (B) and (C) are con-
nected.
56 PC2000-8
3) When PC mode selector current is increased (When EPC output pressure rises)
Operation q When the stop position of servo piston (9) (=

q When EPC output pressure (PM) is increased, pump delivery) is at a middle position between
spool (3) moves to the right. the maximum and minimum pump delivery
q If ports (C) is connected to port (B), the pres- positions, the pressure on the large diameter
sure on the large diameter end of the piston end of the piston is about a half of pump dis-
rises and servo piston (9) moves to the right. charge pressure (PA). When the former is at
q The pump delivery is decreased. the minimum pump delivery position, the latter
q As servo piston (9) moves, spring (4) is com- becomes pump discharge pressure (PA).
pressed and its force is increased.
q If the spring force is increased, spool (3)
moves to the left, port (C) is disconnected from
port (B), and draining port (D) is connected to
port (C).
q If the pressure in port (C) lowers, the pressure
on the large diameter end of the piston lowers
and consequently servo piston (9) stops mov-
ing to the right.
q The stop position of servo piston (9) (= pump
delivery) is determined by the position where
the pressing force generated by the EPC valve
output pressure is balanced with the force of
spring (4).
PC2000-8 57
q The relationship between PC mode selector

current (IM) and pump delivery (Q) becomes
as shown below.
58 PC2000-8
2. EPC valve
C: To PC valve
P: From pilot relief valve
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
PC2000-8 59
Function Operation
q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion. 1) When signal current is 0 (Coil is de-ener-
q When it receives signal current (i) from the gized)
controller, it generates the EPC output pres- q When there is no signal current flowing from the
sure in proportion to the size of the signal, and controller to coil (2), coil (2) is de-energized.
outputs it to the PC valve. q Spool (5) is pushed to the left by spring (4).
q Port (P) is closed and the pressurized oil from the
pilot relief valve does not flow to the PC valve.
q The pressurized oil from the PC valve is drained
to the tank through port (C) and port (T).
60 PC2000-8
2) When signal current is very small (coil is 3) When signal current is maximum (coil is
energized) energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressures on port (C) increases and the force q Spool (5) is pushed toward the right side by rod
to act on spool (5) surface and the spring load (6).
on spring (4) become larger than the propul- q The maximum volume of pressurized oil is
sion force of plunger (7). conducted from port (P) to port (C), increasing
q Spool (5) is pushed to the left, and port (P) is the circuit pressure across the EPC valve and
shut off from port (C). PC valve to the maximum level.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves so that the propulsion force of not flow to the tank.
plunger (7) may be in balance with pressure of
port (C) + spring load of spring (4).
q The circuit pressure between the EPC valve
and PC valve is controlled in proportion to the
size of the signal current.
PC2000-8 61
SEN01619-00
62
SEN01620-00
PC2000-8

PC2000-8 20001 and up

Travel motor ......................................................................................................................................... 2
Hydraulic pump .................................................................................................................................. 14
PPC valve .......................................................................................................................................... 32
Variable back pressure valve ............................................................................................................. 44
Suction selector valve ........................................................................................................................ 48
PPC cut-off valve ............................................................................................................................... 52
PC2000-8 1

Travel motor 1
Type: KMF340-5
B : Pressure pick-up port Specifications

MA : Pressure pick-up port Type : KMF340-5
MB : Pressure pick-up port Theoretical displacement: 337.2 cm3/rev
PA : From control valve Rated pressure : 32.8 MPa {335 kg/cm2}
PB : From control valve Rated speed : 2,461 rpm
PAI : Pressure pick-up port Brake release pressure : 1.31 MPa {13.4 kg/cm2}
PBI : Pressure pick-up port
T : To tank
2 PC2000-8
PC2000-8 3
4 PC2000-8
1. Output shaft
2. Motor case
3. Piston
4. Cylinder block
5. Valve plate
6. Housing
7. Plate
8. Disc
9. Oil seal
10. Counterbalance valve spool
11. Retainer
12. Brake spring
13. Brake piston
14. Safety valve
15. Check valve
Unit: mm
Free length
16 Check valve spring length load load If damaged or
diameter
deformed,
66.5 × 25.6 45 —
{0.71 kg} {0.67 kg}
520 N
17 Spool return spring 63 × 44.5 61.5 — —
{53 kg}
PC2000-8 5
Operation of parking brake
1) When starting travel
q As the travel lever is operated, pressurized oil

from the pump actuates counterbalance valve
spool (10) to open the parking brake circuit.
q The pressurized oil flows to chamber (e) of
brake piston (13), compressing brake spring
(12) and pushing brake piston (13) to the right.
q Pressing force so far allied to plate (7) and disc
(8) is eliminated. Thus, plate (7) disengages
from disc (8), releasing the brake.
6 PC2000-8
2) When travel is stopped
q When the travel lever is set to the neutral posi- q Returning brake piston (13) reduces flow of the
tion, and counterbalance valve spool (10) pressurized oil with slow return valve (18).
returns to the neutral position, closing the park- q The specified time lag actuates the brake after
ing brake circuit. the machine has been stopped.
q The pressurized oil in chamber (e) of brake
piston (13) keeps flowing through the throttle of
slow return valve (18) until counterbalance
valve spool (10) returns to the neutral.
q As counterbalance valve spool (10) returned to
the neutral, the oil is drained from the throttle
(f) of brake piston (13) to the case.
q Brake piston (13) is pressed by spring (12) to
the left.
q Plate (7) and disc (8) are compressed to each
other, actuating the brake.
PC2000-8 7
Brake valve
q The brake valve is consisted of check valves Operation when pressurized oil is supplied
(1) and (2), counterbalance valve (3) and q Operating the travel lever conducts the pres-
safety valve (4). surized oil from the control valve to port (PA).
q Functions and operations of respective compo- q The pressurized oil pushes open check valve
nents shall conform to the following. (1) and flows through motor inlet port (MA) to
motor outlet port (MB).
1) Counterbalance valve and check valve q Since the motor outlet side is closed by check
valve (2) and spool (3), the pressure on the
Function supply side rises.
q When traveling downhill, the machine travel
speed tends to get faster than the motor
(engine) speed because of the downward force
generated from its own weight.
q If the machine travels with the engine at low
speed, the motor may rotate without load, caus-
ing the machine to run away; resulting in a very
dangerous situation.
q These valves are used to prevent above by
controlling the machine to travel according to
the engine speed (pump delivery).
q The pressurized oil on the supply side flows to

chamber (S1) through orifices (E1) and (E2) of
spool (3).
q As the pressure in chamber (S1) rises above
the spool selector pressure, spool (3) is
pushed to the right.
8 PC2000-8
q Port (MB) and port (PB) are connected, open- Operation of brake during travelling downhill
ing the motor outlet port side and starting the q If indication of the machine runaway is sensed
motor rotating. while travelling downhill, the motor will be
caused to rotate without load to decrease the
inlet side oil pressure.
q Pressure in chamber (S1) is released through
orifices (E1) and (E2).
q When the pressure in chamber (S1) drops
below the spool selector pressure, spool (3) is
returned to the left, in the direction of the arrow
by spring (6), and outlet port (MB) is throttled.
q The pressure at the outlet port side rises, gen-
erating rotation resistance on the motor to pre-
vent the machine from running away.
q The spool moves to a position where the pres-
sure on the outlet port (MB) can be balanced
against the machine's own weight and the inlet
port pressure.
q Oil flow from the outlet circuit is reduced to
ensure the travel speed corresponded to the
pump delivery.
PC2000-8 9
2) Safety valve
(bidirectional 2-stage set safety valve)
Function q As the pressure goes above the set pressure,

q As long as the machine travel is stopped (or it [Difference in areas of circles (D1) and (D2) ×
is travelling downhill), the counterbalance Pressure] compresses spring (2).
valve closes the inlet and outlet circuits of the q Poppet (1) is moved leftward and the pressur-
motor. ized oil flows into chamber (MA) of the oppo-
q Since the motor is rotated by inertial force, site circuit.
pressure in the motor outlet port side is abnor-
mally increased, potentially resulting in dam-
ages on the motor and piping.
q The safety valve releases this abnormal pres-
sure to the inlet port side of the motor in order
to prevent damages to the equipment.
Bidirectional action
(1) When pressure in chamber (MB) has become
high (when rotating clockwise)
q As long as the machine travel is stopped (or it
is travelling downhill), the check valve of coun-
terbalance valve closes chamber (MB) of the
outlet port circuit.
q The motor tries to continue rotation resorting to
inertial force, thus pressure on the outlet port
(MB) is increased.
10 PC2000-8
(2) When pressure in chamber (MA) has become Operation of mechanism for varying set pressure
high (when rotating counterclockwise) (1) When starting travel (high-pressure setting)
q As long as the machine travel is stopped (or it q As the travel lever is operated, the pressurized oil
is travelling downhill), the check valve of coun- from the pump moves spool (10) to the right.
terbalance valve closes chamber (MA) of the q Above opens the pilot circuit to the safety
outlet port circuit. valve, conducting the pressurized oil to cham-
q The motor tries to continue rotation resorting to ber (J) through chamber (G) and passage (H).
inertial force, thus pressure on the outlet port q Piston (3) is pushed rightward, spring (2) is
(MA) is increased. compressed and the set load is increased.
q High pressure is turned on the safety valve,
providing a large tractional force to the valve.
q As the pressure goes above the set pressure,

[Difference in areas of circles (D1) and (D3) ×
Pressure] compresses spring (2).
q Poppet (1) is moved leftward and the pressur-
ized oil flows into chamber (MB) of the oppo-
site circuit.
PC2000-8 11
(2) When travel is stopped (low-pressure setting)

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

High pressure set: 40.2 MPa {410 kg/cm2}
(At start and during travel)
Low pressure set: 27.5 MPa {280 kg/cm2}
(When stopped)
12 PC2000-8
PC2000-8 13
Hydraulic pump 1
Type: HPV375+375
14 PC2000-8
Outline
q The pump unit is composed of 2 variable-
capacity swash plate-type piston pumps, VC
valves, EPC valves and self pressure reducing
valves.
CE1 : Front EPC output pressure pick-up port

CE2 : Rear EPC output pressure pick-up port
CH1 : Front EPC basic pressure pick-up port
CH2 : Rear EPC basic pressure pick-up port
CP1 : Front pump discharge pressure pick-up port
CP2 : Rear pump discharge pressure pick-up port
CPR: Pilot basic pressure pick-up port
CS1 : Front control pressure pick-up port
CS2 : Rear control pressure pick-up port
E1 : Front EPC command current
E2 : Rear EPC command current
P1 : Discharge port
P2 : Discharge port
PF : Self pressure reducing valve basic pressure port
PR3 : Pilot basic pressure input port (succeeding to the inline filter attached to the machine)
PR4 : Pilot basic pressure output port (preceding the inline filter attached to the machine)
PR5 : Pilot basic pressure pick-up port
S : Suction port
T1 : Drain port
T2 : Drain plug
T3 : Drain plug
T4 : Drain plug
T5 : Drain plug
T6 : Air bleeder
T7 : Drain branch piping port
T8 : Drain plug
T9 : Drain plug
T10 : Drain plug
T11 : Drain plug
1. Front pump
2. Rear pump
3. VC valve
4. EPC valve
5. Self pressure reducing valve
6. Filter
PC2000-8 15
16 PC2000-8
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Servo piston
9. Valve plate
10. End cap
11. Rear case
12. Rear shaft
13. Bevel gear
14. Impeller pump
15. Impeller shaft
16. Impeller pinion
PC2000-8 17
Function q Rocker cam (4) brings high pressure oil at cyl-

q The engine speed and torque are transmitted inder surface with cradle (2), which is secured
to the shaft of this pump. Then, this pump con- to the case, and forms a static pressure bear-
verts the speed and torque into oil pressure ing when it slides.
and discharges pressurized oil according to q Piston (6) carries out relative movement in the
the load. axial direction inside each cylinder chamber of
q It is possible to change the delivery by chang- cylinder block (7).
ing the swash plate angle. q Cylinder block (7) seals the pressurized oil to
valve plate (9) and carries out relative rotation.
Structure q This surface is designed so that the oil pres-
q Cylinder block (7) is supported to shaft (1) by sure balance is maintained at a suitable level.
spline (17). q The pressurized oil inside each cylinder cham-
q Shaft (1) is supported by front and rear bear- ber of cylinder block (7) is sucked in and dis-
ings (18). charged through valve plate (9).
q The end of piston (6) has a spherical hollow q Impeller pump (14) and impeller pinion (16) are
and is combined with shoe (5). united by impeller shaft (15) and connected to
q Piston (6) and shoe (5) form a spherical bearing. shaft (1) through bevel gear (13).
q Rocker cam (4) has flat surface (A), and shoe q They rotate along with the shaft. Thus, they
(5) is always pressed against this surface while help supplying the sucked pressurized oil to
sliding in a circular movement. cylinder block (7) and also help sucking it there
by use of centrifugal force.
18 PC2000-8
Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle = 0), the difference between vol-
along cylindrical surface (B), so angle (a) umes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
the ax ial di rec tio n of cy li nder b loc k (7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q Angle (a) is called the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
q With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
PC2000-8 19
Control of delivery
q If the swash plate angle (a) becomes larger, q The relationship in the size of pressure (PH) at
the difference between volumes (E) and (F) the small diameter piston end and pressure
b ec o me s l ar g er a n d pu m p d el i v e r y ( Q ) (PS) at the large diameter piston end, and the
increases. ratio between the area receiving the pressure
q Swash plate angle (a) is changed with servo of the small diameter piston and the large
piston (8). diameter piston controls the movement of
q Servo piston (8) moves in a reciprocal move- servo piston (8).
ment according to the signal pressure from the
pump controller.
q This linear motion is transmitted to rocker cam
(4) through rod (19).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q With servo piston (8), the area receiving the
pressure is different on the left and the right.
The pump discharge pressure (self pressure)
(PH) is constantly led to the pressure chamber
of the small diameter piston end.
q The pressure chamber of the large diameter
piston end is supplied with the VC valve output
pressure (PS).
20 PC2000-8
Pump controller
System diagram
PC2000-8 21
Pump control signal
22 PC2000-8
Servo valve
CE : Control pressure pick-up port 1. VC valve

CH : Servo actuator pressure pick-up port 2. EPC valve
CS : Servo actuator pressure pick-up port 3. Spool
PA : Main pump pressure port 4. Sleeve
PH : Servo actuator port 5. Spring
PR : Servo basic pressure port
PS : Pump control pressure output port
T : Drain port
PC2000-8 23
1. VC valve
Outline Move of servo piston to the maximum side

q VC valve controls servo piston (4) position q As the EPC valve output pressure increases,
(pump delivery) responding to the EPC valve sleeve (2) compresses spring (1) to move
output pressure (controller command current). upward.
q As long as the swash plate angle is set to max-
Operation imum, the large diameter end pressure (PS)
q Sleeve (2) moves to and stops at a position functions as the drain pressure. [The servo pis-
where the EPC valve output pressure and the ton is pushed toward the maximum side by the
force of spring (1) are balanced. small diameter end pressure (PH).]
q The large diameter end pressure is changed q Move of servo piston (4) toward the maximum
by the changes of the opening area on the side is stopped at a position where it contacts
notches (A) and (B) between sleeve (2) and against the MAX adjustment screw (5).
spool (3) plus by the switching of the connec-
tion port. As the result, servo piston (4) is
moved.
24 PC2000-8
Move of servo piston to the minimum side Stop of servo piston move in halfway toward
q As the EPC valve output pressure decreases, the swash plate maximum or minimum position
sleeve (2) elongates spring (1) to move down- q Move of servo piston (4) is feed back to VC
ward. valve by spool (3).
q Opening (B) between sleeve (2) and spool (3) q Move of servo piston (4) changes the space of
opens [Opening (A) closes], connecting the opening of the notch (throttle) between spools
large diameter end port to the shuttle valve (3) and sleeve (2), changing the large diameter
output pressure [= Small diameter end pres- end pressure.
sure (PH)]. Thus, servo piston (4) is moved q Servo piston (4) is stopped as the pressure
toward the minimum side by the difference in ratio between the small diameter piston and
the force resulting from the difference in the large diameter piston becomes 2 : 1 (Ratio of
pressure receiving areas. pressure receiving areas between small diam-
q Move of servo piston (4) toward the minimum eter piston and large diameter piston = 1 : 2).
side is stopped at a position where it contacts
against the MIN adjustment screw (6).
PC2000-8 25
2. Servo piston
Outline Operation of servo piston

q Port (PA) pressure or port (PR) pressure, q When sleeve (4) moves upward, port (PH) is
whichever is higher, is applied to port (PH) by disconnected from port (PS) and port (PS) and
the shuttle valve. port (TD) are connected.
q Relation of pressure receiving area (A) of q Since chamber (a) is connected to drain port
chamber (a) and pressure receiving area (B) of (TD), servo piston (3) is moved to the right by
chamber (b) is expressed as (A) C [2 × (B)]. (PH) pressure.
q Pressure of port (PH) is constantly applied to q When servo piston (3) moves to the right, cam
chamber (b). (6) which is coupled with servo piston (3)
PA : Main pump discharge pressure moves to the right.
PR : Pilot basic pressure q Spool of VC valve (1) moves upward.
PH : PA or PR pressure whichever is higher q When spool of VC valve (1) moves upward,
port (PS) is disconnected from port (TD).
Operation of VC valve q Port (PS) starts connecting to port (PH) and pres-
q The command current from the pump control- sures of chambers (a) and (b) are balanced.
ler is conducted to EPC solenoid (E1). q Servo piston (3) stops its move.
q This command current reduces the control q Move of servo piston (3) changes in proportion to
basic pressure applied to EPC valve (2). the moving distance of sleeve (4) of VC valve (1).
q EPC valve (2) transmits the command current
specified pilot pressure. When EPC valve is not operated
q The pilot pressure goes to chamber (se1) q Sleeve (4) of VC valve (1) does not operate if the
through port (SE1). pilot pressure from EPC valve (2) is not present.
q Sleeve (4) of VC valve (1) is maintained at a q In this case, ports (PH) and (PS) are con-
position where the EPC valve (2) pilot pressure nected and the connection between ports (PS)
and the spring (5) force are balanced. and (TD) is cut off.
q The pump controller controls magnitude of the q Since the pressure in chambers (a) and (b) is
command current sent to EPC valve (2). set to the same level, servo piston (4) is moved
to the left.
q The pump delivery is kept at the minimum.
26 PC2000-8
3. EPC valve
C : To VC valve 1. Body
P : From pump 2. Spool
T : To hydraulic tank 3. Spring
4. Rod
5. Coil
6. Plunger
7. Connector
PC2000-8 27
Function Operation
q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion.
q When it receives signal current (i) from the 1. When signal current is 0 (coil is de-
controller, it generates the EPC output pres- energized)
sure in proportion to the size of the signal, and q When there is no signal current flowing from the
outputs it to the VC valve. controller to coil (5), coil (5) is de-energized.
q Spool (2) is pushed to the right by spring (3).
q Port (P) closes the pressurized oil from the self
pressure reducing valve does not flow to the
control valve.
q The pressurized oil from the VC valve is drained
to the tank through port (C) and port (T).
28 PC2000-8
2. When signal current is very small 3. When signal current is maximum

(coil is energized) (coil is energized)
q When a very small signal current flows to coil q As the signal current flows to coil (5), coil (5) is
(5), coil (5) is energized, and a propulsion force energized.
is generated on the left side of plunger (6). q When this happens, the signal current is at its
q Rod (4) pushes spool (2) to the left, and the maximum, so the propulsion force of plunger
pressurized oil flows from port (P) to port (C). (6) is also at its maximum.
q Pressure on port (C) increases and the force to q Spool (2) is pushed to the left by rod (4).
act on surface (a) of spool (2) + the spring load q The maximum volume of pressurized oil is
on spring (3) become larger than the propul- conducted from port (P) to port (C), increasing
sion force of plunger (6). the circuit pressure across EPC valve and VC
q Spool (2) is pushed to the right, and port (P) is valve to the maximum level.
shut off from port (C). q Since port (T) is closed, pressurized oil does
q Port (C) and port (T) are connected. not flow to the tank.
q Spool (2) moves up and down so that the pro-
pulsion force of plunger (6) may be balanced
with pressure of port (C) + the spring load of
spring (3).
q The circuit pressure between the EPC valve
and the VC valve is controlled in proportion to
the size of the signal current.
PC2000-8 29
Self pressure reducing valve
Function 2. Fan pump discharge pressure (P3F)

q This valve reduces the discharge pressure of the is reduced
fan pump and supplies it as the control pressure a When the load pressure (P3) is lower than output
for the solenoid valve, EPC valve, etc. pressure (PR) of self pressure reducing valve
Operation q Valve (1) receives the force of spring (2) and

pressure (PR) (which is {0 MPa {0 kg/cm 2 }
1. When engine is stopped when engine is stopped) in the direction to
q Since poppet (4) is pressed against the seat by close the circuit between ports (P3F) and (P3).
spring (3), the portion of the circuit from port q As the pressurized oil flows in from port (P3F),
(PR) to port (T) is cut off. following balance is reached: [(φd area × P3F
q Since valve (6) is pressed to the left by spring pressure) = the force of spring (2) + (φd area ×
(5), the portion of the circuit from port (P3F) to PR pressure)].
port (PR) is open. q Opening of valve (1) is adjusted to maintain
q Since valve (1) is pressed to the left by spring pressure (P3F) at a constant pressure above
(2), the portion of the circuit from port (P3F) to pressure (PR).
port (P3) is closed. q As (PR) pressure reaches a level higher than
the set pressure, poppet (4) opens.
q The pressurized oil flows from port (PR) to inter-
nal orifice (a) of spool (6) and then flows to tank
drain port (T) through the opening of poppet (4).
q The differential pressure is generated through
internal orifice (a) of spool (6), actuating spool (6)
to close the opening from port (P3F) to (PR).
q Referencing the given open area, the self pres-
sure reducing valve reduces pressure (P3F) to
a specific level (set pressure) in order to supply
the difference as pressure (PR).
30 PC2000-8
3. When load pressure (P3F) is high 4. When abnormally high pressure is

q Change in the fan revolution speed increases generated
load pressure (P3) and, as the result, pump q If pressure (PR) of the self pressure reducing
delivery is increased. valve turns to an abnormally high pressure,
q Since pressure (P3F) increases, [(φd area × valve (1) compresses spring (2).
P3F pressure) > the force of spring (2) + (φd q Port (A) opens and ports (PR) and (TS) are
area × PR pressure)]. As the result, valve (1) is connected.
moved to the right up to the stroke end. q Allows the pressurized oil to (TS) from port
q Since the opening between ports (P3F) and (PR) and lowers pressure (PR).
(P3) increases, resistance along the passage q Protects PPC valve, solenoid valve and other
is reduced and the loss horsepower of the devices from abnormal pressure.
engine is reduced.
q As pressure (PR) reaches a level higher than
the set pressure, poppet (4) opens.
q The pressurized oil flows from port (PR) to
internal orifice (a) of spool (6) and then flows to
tank drain port (T) through the opening of pop-
pet (4).
q The differential pressure is generated through
internal orifice (a) of spool (6), actuating spool
(6) to close the opening from port (P3F) to
(PR).
q The self pressure reducing valve reduces pres-
sure (P3F) to a specific level (set pressure) in
order to supply the difference as pressure
(PR).
PC2000-8 31
PPC valve 1
Work equipment and swing PPC valve 1
P : From self pressure reducing valve

P1 : Left PPC valve: Arm OUT/Right PPC valve: Boom LOWER
P2 : Left PPC valve: Arm IN/Right PPC valve: Boom RAISE
P3 : Left PPC valve: Swing LEFT/Right PPC valve: Bucket CURL
P4 : Left PPC valve: Swing RIGHT/Right PPC valve: Bucket DUMP
T : To tank
32 PC2000-8
PC2000-8 33
34 PC2000-8
1. Spool
2. Piston
3. Disc
4. Nut (for connection of lever)
5. Joint
6. Plate
7. Retainer
8. Body
Unit: mm
Free length
Centering spring × outside Free length
9 length load load
(For ports P3 and P4) diameter
If damaged or
11.8 N 9.41 N
45.85 × 15.5 34.0 — deformed,
{1.2 kg} {0.96 kg}
replace spring
Centering spring 3.92 N 3.14 N
10 37.95 × 15.5 34.0 —
(For ports P1 and P2) {0.4 kg} {0.32 kg}
26.3 N 21.0 N
11 Metering spring 27.08 × 8.14 24.9 —
{2.68 kg} {2.14 kg}
PC2000-8 35
Operation 2. During fine control

(Neutral o fine control)
1. When in neutral q When piston (4) is pushed by disc (5), retainer
q Ports (A) and (B) of the control valve and ports (9) is pushed, spool (1) is also pushed by
(P1) and (P2) of PPC valve are connected to metering spring (2), and moves down.
drain chamber (D) at the bottom. q If port (P1) is disconnected from drain chamber
(D), it connects, almost in that instant, to pump
pressure chamber (PP).
q Pilot pressurized oil of the control pump is con-
ducted from port (P1) to port (A).
q When the pressure at port (P1) becomes higher,
spool (1) is pushed back and port (P1) is shut off
from pump pressure chamber (PP). At almost the
same time, it is connected to drain chamber (D)
to release the pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
q The relationship of the position of spool (1) and
body (10) does not change until retainer (9)
contacts spool (1).
q Metering spring (2) contracts in proportion to
the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force
of the return spring of the control valve spool
are balanced.
36 PC2000-8
3. During fine control 4. At full stroke

(When control lever is returned) q Disc (5) pushes down piston (4), and retainer
q When disc (5) starts to be returned, spool (1) is (9) pushes down spool (1).
pushed up by the force of centering spring (3) q Port (P1) is disconnected from drain chamber
and the pressure at port (P1). (D) and connected to pump pressure chamber
q Port (P1) is connected to drain chamber (D), (PP).
and the pressurized oil of port (P1) is released. q The pilot pressurized oil from the self pressure
q If the pressure of port (P1) is lowered exces- reducing valve is conducted from port (P1) to
sively, spool (1) is pushed down by metering chamber (A) to push the control valve spool.
spring (2). q Return oil from chamber (B) flows from port
q Port (P1) is disconnected from drain chamber (P2) to drain chamber (D).
(D) and then, almost in that instant, connected
to pump pressure chamber (PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns, oil
in drain chamber (D) flows in from the valve on
the side that is not working. The oil passes
through port (P2) and enters chamber (B) to fill
the chamber with the pressurized oil.
PC2000-8 37
Travel PPC valve 1
P : From self pressure reducing valve

P1 : L.H. reverse
P2 : L.H. forward
P3 : R.H. reverse
P4 : R.H. forward
T : To tank
38 PC2000-8
PC2000-8 39
40 PC2000-8
1. Plate
2. Body
3. Piston
4. Seal
5. Centering spring
6. Metering spring
7. Valve
8. Damper
Unit: mm
Free length
9 Centering spring length load load If damaged or
diameter
deformed,
108 N 86.3 N replace spring
47.6 × 15.5 32.5 —
{11.0 kg} {8.8 kg}
16.7 N 13.7 N
10 Metering spring 26.5 × 8.15 24.9 —
{1.7 kg} {1.4 kg}
PC2000-8 41
Operation q The relationship of the position of spool (1) and

body (10) [fine control hole (f) is in the middle
1. When in neutral between drain chamber (D) and pump pres-
q Ports (A) and (B) of the control valve and ports sure chamber (PP)] does not change until
(P1) and (P2) of the PPC valve are connected retainer (9) contacts spool (1).
to drain chamber (D) through fine control hole q Metering spring (2) contracts in proportion to
(f) in spool (1). the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force
of the return spring of the control valve spool
are balanced.
2. During fine control

q When piston (4) is pushed by lever (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1) through fine control
hole (f).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
42 PC2000-8
3. During fine control 4. At full stroke

(When control lever is returned) q Lever (5) pushes down piston (4), and retainer
q When lever (5) starts to be returned, spool (1) (9) pushes down spool (1).
is pushed up by the force of centering spring q Fine control hole (f) is shut off from drain
(3) and pressure at port (P1). chamber (D), and is interconnected to pump
q Because of this, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D), and the pressur- q Therefore, the pilot pressure oil from the self
ized oil at port (P1) is released. pressure reducing valve passes through fine
q If the pressure of port (P1) is lowered exces- control hole (f) and flows to chamber (A) from
sively, spool (1) is pushed down by metering port (P1) to push the control valve spool.
spring (2). q The oil returning from chamber (B) passes
q Fine control hole (f) is shut off from drain cham- from port (P2) through fine control hole (f') and
ber (D), and it is almost simultaneously intercon- flows to drain chamber (D).
nected to pump pressure chamber (PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the cham-
ber with pressurized oil.
PC2000-8 43
Variable back pressure valve 1
TA : From main valve port (T) PI : From solenoid valve

TB : To oil cooler TS : To tank
1. Block
2. Valve
Unit: mm
Free length ×
Installed Installed
outside Installed load Free length
3 Valve return spring length load If damaged or
diameter
deformed,
1,370 N 1,098 N replace spring
187.48 × 38.5 130 —
{140 kg} {112 kg}
231 N 185 N
4 Valve return spring 116.18 × 19.5 90 —
{23.6 kg} {18.9 kg}
44 PC2000-8
1. When travel operation or swing operation is turned on
Function
q In the travel operation or swing operation, back
pressure must be generated in the drain circuit
in order to prevent cavitation.
q In order to reduce power loss, back pressure
must be reduced in the drain circuit for any
operation other than the travel and swing.
Operation
q The pressure is not generated in pilot circuit (a)
since pressurized oil is not fed from solenoid
valve (4).
q The pressurized oil from the main valve works
on the left end face (AB) of valve (1) to gener-
ate back pressure in drain circuit (b) by actuat-
ing springs (2) and (3).
PC2000-8 45
2. In an operation other than travel or swing
Operation
q The pressurized oil being led from solenoid
valve (4) to pilot circuit (a) works on the left
toric surface (Aa) of valve (1) to push springs
(2) and (3).
q The back pressure in drain circuit (b) that is
generated by pressurized oil from main valve
goes low due to the right stroke of valve (1).
46 PC2000-8
PC2000-8 47
Suction selector valve 1
48 PC2000-8
C1 : To bucket CURL (Pilot port of control valve)

C2 : To bucket DUMP (Pilot port of control valve)
C3 : To arm IN (Pilot port of control valve)
C4 : To arm OUT (Pilot port of control valve)
C5 : To boom RAISE (Pilot port of control valve)
C6 : To boom LOWER (Pilot port of control valve)
PP1 : From R.H. PPC valve (Bucket CURL port)
PP2 : From R.H. PPC valve (Bucket DUMP port)
PP3 : From L.H. PPC valve (Arm IN port)
PP4 : From L.H. PPC valve (Arm OUT port)
PP5 : From R.H. PPC valve (Boom RAISE port)
PP6 : From R.H. PPC valve (Boom LOWER port)
PP1 : From R.H. PPC valve (Tank port)
PP2 : From L.H. PPC valve (Tank port)
T : To hydraulic tank
1. Spool
2. Body
3. Flange
4. Retainer
5. O-ring
Unit: mm
Free length
Installed Installed Installed If damaged or
6 Centering spring length load load deformed,
diameter
replace spring
14.7 N 11.8 N
31.72 × 17 24 —
{1.5 kg} {1.2 kg}
PC2000-8 49
Operation 2. During fine control

1. When in neutral q Operating lever (3) conducts the pilot pressur-
q Ports (A) and (B) of control valve (6) and ports ized oil to chamber (E1) through ports (P1) and
(C1), (C2) and (PT1) of suction selector valve (PP1).
(1) are connected to the hydraulic tank through q As the pressure in chamber (E1), which is
port (T) of selector valve (1). used to press spool (4) of selector valve (1),
q Ports (PP1) and (PP2) of selector valve (1) and goes larger than the opposing force of spring
ports (P1) and (P2) of PPC valve (2) are con- (5), spool (4) is actuated and opens the circuit
nected to drain chamber (D). from port (PP1) to port (C1).
q Spool (7) of control valve (6) moves to a posi-
tion where the pressure in chamber (A) [equal
to the pressure in port (P1)] is balanced
against the force of spool return spring (8) of
control valve (6).
q Return oil from chamber (B) of control valve (6)
is returned to the tank from port (T) of selector
valve (1).
50 PC2000-8
3. During fine control

(Fine control o neutral)
q Returning lever (3) to the neutral decreases
port (P1) pressure of PPC valve [equal to
chamber (A) pressure], returning spool (7) of
control valve (6) to the neutral.
q The pressurized oil to be sucked by chamber
(B) of control valve (6) is supplied from port (T)
of selector valve (1).
q As pressure of ports (PP1) and (E1) goes low,
the load of spring (5) increases and spool (4)
returns to the neutral.
PC2000-8 51
PPC cut-off valve 1

1. For straight travel and swing priority
52 PC2000-8
AIN : From boom RAISE port of PPC valve

AOUT1: To R2 valve port (PB22) and L2 valve port (PA22)
AOUT2: To R1 valve port (PA21) and L1 valve port (PA21)
AOUT3: –
BIN : From bucket CURL port of PPC valve
BOUT1: To R2 valve port (PA32) and L2 valve port (PA32)
BOUT2: To L1 valve port (PA31)
BOUT3: To R1 valve port (PA31)
CIN : From arm IN port of PPC valve
COUT1: To R2 valve port (PA12) and L2 valve port (PA12)
COUT2: To L1 valve port (PA11)
COUT3: To R1 valve port (PA11)
DIN : From arm OUT port of PPC valve
DOUT1: To R2 valve port (PB12) and L2 valve port (PB12)
DOUT2: To L1 valve port (PB11)
DOUT3: To R1 valve port (PB11)
EIN : From bucket DUMP port of PPC valve
EOUT1: To R2 valve port (PB32) and L2 valve port (PB32)
EOUT2: To L1 valve port (PB31)
EOUT3: To R1 valve port (PB31)
PI1 : From solenoid valve
PI2 : From solenoid valve
T1 : To tank
T2 : To tank
1. Block
2. Spool
3. Block
4. Spool
Unit: mm
Free length
5 Spring length load load deformed,
diameter
replace spring
320 N 256 N
66.6 × 26.5 57.3 —
{32.7 kg} {26.2 kg}
PC2000-8 53
2. For straight travel
54 PC2000-8
AIN : From R.H. travel reverse port of PPC valve

AOUT1: To R1 valve port (PA51)
AOUT2: To R2 valve port (PA52)
BIN : From L.H. travel reverse port of PPC valve
CIN : From L.H. travel forward port of PPC valve
COUT1: To L1 valve port (PB51)
COUT2: To L2 valve port (PB52)
DIN : From R.H. travel forward port of PPC valve
EIN : From boom LOWER port of PPC valve
EOUT1: To R2 valve port (PB22)
EOUT2: To L1 valve port (PB21)
PI : From solenoid valve
T : To tank
1. Block
2. Spool
3. Block
Unit: mm
Basic dimensions Repair limit
Free length
4 Spring length load load deformed,
diameter
replace spring
320 N 256 N
66.6 × 26.5 57.3 —
{32.7 kg} {26.2 kg}
PC2000-8 55
Swing priority function
1. When operating work equipment (Arm, bucket and boom RAISE)
Operation
q The solenoid valve of the swing priority valve
does not output the pilot pressure. Swing prior-
ity valve (CV2) and selector valve (PV2) stay at
the neutral position.
q The pilot pressure from the bucket PPC valve
and arm PPC valve is led to R1 valve.
q The arm spool and bucket spool of R1 valve is
actuated by the above pressure.
q The boom throttle valve remains not actuated.
56 PC2000-8
2. Simultaneous operation of swing and work equipment

[Swing + Work equipment (Arm, bucket or boom RAISE)]
Operation
q Swing priority valve (CV2) and selector valve
(PV2) are switched by the pilot pressure from
the solenoid valve of the swing priority valve.
q The pilot pressure from bucket PPC valve and
arm PPC valve is cut off by the swing priority
valve.
q The arm spool and bucket spool of R1 valve
remain not actuated. The pilot pressure is con-
ducted to the swing spool.
q In the boom raise operation, the boom throttle
valve is actuated. Thus, the pressure keeps on
flowing to the swing spool.
PC2000-8 57
Straight-travel function
1. In boom, arm, bucket or swing operation excluding travel
Operation
q The solenoid valve of the straight travel valve
does not output the pilot pressure. The straight
travel valve spool stays at the neutral position.
q The pilot pressure from arm PPC valve, boom
PPC valve, bucket PPC valve, and L.H. and
R.H. travel PPC valves is led to L1 valve, L2
valve, R1 valve and R2 valve.
q Respective spools of L1 valve travel, L2 valve
bucket, boom, arm, R1 valve travel, R2 valve
bucket, boom, arm are actuated.
58 PC2000-8
2. In travel + operation (Boom, arm, bucket or swing)
Operation q L2 and R2 valves are actuated for the indepen-

q Both spools (CV1) and (CV2) of the straight dent L.H. or R.H. operation and L1 and R1
travel valve are switched by the pilot pressure valves are actuated for the operations other
from the solenoid valve of the straight travel than travel.
valve. q Any change in the work equipment operation
q Respective spools remain not actuated since (boom RAISE o boom LOWER, for instance)
the pilot pressure from arm, boom, bucket, during this period does not change the flow
R.H. and L.H. travel PPC valves is cut off. rate to the R.H. and L.H. travel. Thus, the
q Arm PPC valve: L2 valve and R2 valve straight traveling function of the machine is
q Boom PPC valve: L2 valve and R2 valve maintained.
q Bucket PPC valve: L2 valve and R2 valve
q R.H. and L.H. travel PPC valves: L1 valve
and R1 valve
PC2000-8 59
SEN01620-00
60
SEN01621-00
PC2000-8

PC2000-8 20001 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Work equipment ................................................................................................................................... 2
Dimensions of work equipment ............................................................................................................ 4
PC2000-8 1
Work equipment 1
Work equipment 1
2 PC2000-8
Unit: mm
Clearance between size clearance limit
Shaft Hole
1 boom-revolving frame
mounting pin and bushing –0.043 +0.456 0.386 –
160 1.5
–0.106 +0.343 0.562
Clearance between
–0.043 +0.172 0.128 –
2 boom-revolving frame 160 2.5
–0.106 +0.085 0.278
mounting pin and bushing
Clearance between
–0.043 +0.174 0.128 –
3 boom cylinder-revolving frame 180 3.5
–0.106 +0.085 0.280
Clearance between
–0.043 +0.160 0.128 –
4 boom-boom cylinder head 180 4.5
–0.106 +0.085 0.266
Clearance between
–0.043 +0.166 0.128 –
5 boom-boom cylinder head 180 5.5
–0.106 +0.085 0.272
Clearance between
–0.043 +0.172 0.128 –
6 boom-arm cylinder mounting 140 6.5
–0.106 +0.085 0.278
pin and bushing
Clearance between boom-arm –0.050 +0.581 0.520 –
7 200 7.5
mounting pin and bushing –0.122 +0.470 0.703
Clearance between boom-arm –0.050 +0.783 0.710 –
8 200 8.5
Clearance between Replace
–0.043 +0.172 0.128 –
9 arm-arm cylinder mounting pin 140 9.5
–0.106 +0.085 0.278
and bushing
Clearance between
–0.036 +0.190 0.121 –
10 arm-bucket cylinder mounting 120 10.5
–0.090 +0.085 0.280
pin and bushing
Clearance between
–0.043 +0.408 0.335 –
11 link-bucket mounting pin and 140 11.5
–0.106 +0.292 0.514
bushing
Clearance between
–0.043 +0.2 0.043 –
12 link-bucket mounting pin and 140 12.5
–0.106 +0.0 0.306
bushing
Clearance between
–0.043 +0.393 0.349 –
13 bucket cylinder-link mounting 140 13.5
–0.106 +0.306 0.499
pin and bushing
Clearance between
–0.043 +0.1 0.043 –
14 bucket cylinder-link mounting 140 14.5
–0.106 +0.1 0.206
pin and bushing
Clearance between arm-link –0.043 +0.430 0.342 –
15 140 15.5
Clearance between arm-link –0.043 +0.1 0.043 –
16 140 16.5
Clearance between
–0.043 +0.421 0.382 –
17 arm-bucket mounting pin and 140 17.5
–0.106 +0.339 0.527
bushing
PC2000-8 3
Dimensions of work equipment 1

1. Arm
4 PC2000-8
Unit: mm
PC2000-8
No.
3.9 m arm
1 140
2 110
3 936
4 200
5 489
6 672.8
7 1199
8 3,841.7
9 5,103
10 719
11 1,300
12 1,210
13 955
14 3,900
15 140
16 364
17 140
Arm as individual part 348
18
When press-fitting bushing 364
Min. 3,250
19
Max. 5,420
20 124
PC2000-8 5
2. Bucket
6 PC2000-8
Unit: mm
PC2000-8
No.
12 m3 bucket
1 940
2 170
3 100°
4 955
5 3069
6 518
7 1322
8 410
9 330
10 165
11 71
12 86
13 20
14 365
15 370
16 98
17 88
18 218
19 233
20 R180
21 R130
22 φ160
23 φ185
24 φ140
25 φ326
26 φ220
27 25°
28 134
29 55
30 φ248
31 12 × M36 × 3 THROUGH
32 45°
33 45°
34 22.5°
PC2000-8 7
SEN01621-00
8
SEN01622-00
PC2000-8

PC2000-8 20001 and up

Cab and its attachments
Cab and its attachments ................................................................................................................................. 2
Air conditioner piping............................................................................................................................ 2
Cab....................................................................................................................................................... 3
PC2000-8 1
Cab and its attachments 1

Air conditioner piping 1
1. Duct
2. Condenser
3. Air conditioner compressor
4. Hot water return piping
5. Hot water pickup piping
6. Refrigerant piping
7. Receiver tank
8. Air conditioner unit
A : Fresh air
B : Recirculated air
C : Hot air/cold air
2 PC2000-8
Cab 1
Wiper system
1. Washer tank
2. Washer hose
3. Lower wiper motor
4. Lower wiper blade, wiper
5. Upper wiper motor
6. Upper wiper blade, wiper
7. Proximity switch
8. Wiper relay
9. Controller
10. Machine monitor
PC2000-8 3
Wiper system
Function
q The wipers can be driven in the 3 modes of intermittent, continuous and continuous (only upper wiper)
with the machine monitor.
q The large wipers are used to wipe wider area of the window. The wiping ranges of the upper and lower
wipers are overlapped to eliminate an unwiped part.
q The controller receives the sensing signal from the proximity switch and the contact signals from the
wiper motors and operates the wiper motors separately through the wiper relays so that the upper and
lower wiper will not interfere with each other.
q When the wipers are operated, the wiper drive relays are shorted to supply the battery power to the
wiper motors.
q When the wipers are stopped, the wiper brake relays are shorted to connect the inverse current from the
wiper motors to the ground to brake the motors.
4 PC2000-8
PC2000-8 5
SEN01622-00
6
SEN01623-00
PC2000-8

PC2000-8 20001 and up

Electrical system
Electrical system ............................................................................................................................................. 2
Engine control ...................................................................................................................................... 2
Electrical control system .................................................................................................................... 13
Monitor system................................................................................................................................... 55
Sensor................................................................................................................................................ 83
ORBCOMM terminal .......................................................................................................................... 95
PC2000-8 1
Electrical system 1
Engine control 1
Operation of system
Starting engine
q If the starting switch is turned to the “START” position, the engine controller checks the state that the
engine stop switch is OFF and the lock lever is reset and the hydraulic tank strainer is installed and sup-
plies the start signal to the starting motor and then the starting motor rotates to start the engine.
At this time, the engine controller checks the signal voltage from the fuel control dial and controls the
engine speed to the set speed.
2 PC2000-8
Engine speed control

q The fuel control dial sends the signal voltage according to the set engine speed.
q The pump controller receives the information of the fuel control dial position from the engine controller
through the network.
q The pump controller calculates proper engine speed for the working mode, deceleration state, etc. and
outputs commands to the engine controller.
q The engine controller decides the fuel injection rate according to the commands from the pump control-
ler.
PC2000-8 3
Stopping engine
q If the engine controller senses that the starting switch or the engine stop switch is set in the “STOP”
position, it stops fuel injection to stop the engine.
4 PC2000-8
Component
Fuel control dial
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
Function
q A potentiometer is installed under the knob. As
the knob is turned, the potentiometer shaft is
turned.
q As the potentiometer shaft is turned, the resis-
tance of the variable resistor in potentiometer
(5) changes and a throttle signal is sent to the
engine controller.
q The hatched area in the graph shown at right is
the abnormality detection area.
While the throttle voltage is in this area, the
engine speed is in low idle.
PC2000-8 5
Engine controller, left bank
Input and output signals CN-CE01

q Meanings of signal classes in the terminal table Input/
Pin No. Signal name
shown below are as follows. output
A: Power supply 11 NC(*) —
B: Input 12 NC(*) —
C: Ground/Shield/Return 13 Engine oil pressure sensor B
D: Output 14 NC(*) —
E: Communication 15 Coolant temperature sensor B
CN-CE01 16 5V electric power supply for sensor A
Input/ 17 Engine oil level sensor B
Pin No. Signal name 18 NC(*) —
output
1 NC(*) — 19 NC(*) —
2 NC(*) — 20 NC(*) —
3 Atmosphere sensor B 21 NC(*) —
4 Supply pump #1 (+) D 22 NC(*) —
5 Supply pump #1 (–) C 23 Boost temperature sensor B
6 CAN (–) E 24 NC(*) —
7 NC (*) — 25 Common rail pressure sensor B
8 CAN (+) E 26 Bkup sensor (+) B
9 Supply pump #2 (–) D 27 NE sensor (+) B
10 Supply pump #2 (–) C *: Never connect to NC or malfunctions or failures will
*: Never connect to NC or malfunctions or failures will occur.
occur.
6 PC2000-8
CN-CE01 CN-CE02
Input/ Input/
Pin No. Signal name Pin No. Signal name
output output
28 NC(*) — 13 NC(*) —
29 NC(*) — 14 NC(*) —
30 Fuel temperature sensor B 15 NC(*) —
31 NC(*) — 16 NC(*) —
32 NC(*) — 17 NC(*) —
33 5 V electric power supply for sensor A 18 NC(*) —
34 NC(*) — 19 NC(*) —
35 NC(*) — 20 NC(*) —
36 NC(*) — 21 NC(*) —
37 5 V electric power supply for sensor A 22 Fuel control dial (+5V) A
38 GND C 23 Fuel control dial (–) C
39 NC(*) — 24 NC(*) —
40 NC(*) — 25 NC(*) —
41 NC(*) — 26 NC(*) —
42 NC(*) C 27 NC(*) —
43 Intake temperature sensor B 28 NC(*) —
44 Boost pressure sensor B 29 NC(*) —
45 Injector #1 (+) D 30 NC(*) —
46 Injector #5 (+) D 31 NC(*) —
47 Sensor GND C 32 NC(*) —
48 Ne sensor (–) C 33 NC(*) —
49 NC(*) — 34 GND C
50 NC(*) — 35 NC(*) —
51 Injector #2 (–) C 36 NC(*) —
52 Injector #3 (–) C 37 NC(*) —
53 Injector #1 (–) C 38 NC(*) —
54 Injector #2 (+) D 39 Key switch (ACC) B
55 Injector #3 (+) D 40 Electrical intake air heater relay drive D
56 Injector #4 (+) D 41 NC(*) —
57 Injector #6 (+) D 42 Electrical intake air heater relay GND C
58 Injector #4 (–) C 43 NC(*) —
59 Injector #6 (–) C 44 NC(*) —
60 Injector #5 (–) C 45 NC(*) —
*: Never connect to NC or malfunctions or failures will 46 CAN(+) E
occur. 47 CAN(–) E
48 NC(*) —
CN-CE02 49 NC(*) —
Input/ 50 NC(*) —
Pin No. Signal name
output *: Never connect to NC or malfunctions or failures will
1 NC(*) — occur.
2 NC(*) —
3 NC(*) — CN-CE03
4 NC(*) — Input/
Pin No. Signal name
5 NC(*) — output
6 NC(*) — 1 GND C
7 Model selection B 2 NC(*) —
8 NC(*) — Electric power supply
3 A
9 Fuel control dial (+) B (+24V constantly)
10 NC(*) — 4 NC(*) —
11 NC(*) — *: Never connect to NC or malfunctions or failures will
12 NC(*) — occur.
*: Never connect to NC or malfunctions or failures will
occur.
PC2000-8 7
Engine controller, right bank
Input and output signals CN-CE01

q Meanings of signal classes in the terminal Input/
Pin No. Signal name
table shown below are as follows. output
A: Power supply 11 NC(*) —
B: Input 12 NC(*) —
C: Ground/Shield/Return 13 NC(*) —
D: Output 14 NC(*) —
E: Communication 15 NC(*) —
CN-CE01 16 NC(*) —
Input/ 17 NC(*) —
Pin No. Signal name 18 NC(*) —
output
1 NC(*) — 19 NC(*) —
2 NC(*) — 20 NC(*) —
3 NC(*) — 21 NC(*) —
4 Right bank supply pump #1 (+) D 22 NC(*) —
5 Right bank supply pump #1 (–) C 23 NC(*) —
6 CAN (–) E 24 NC(*) —
7 NC (*) — 25 Common rail pressure sensor B
8 CAN (+) E 26 Bkup sensor (+) B
9 Right bank supply pump #2 (+) D 27 NE sensor (+) B
10 Right bank supply pump #2 (–) C *: Never connect to NC or malfunctions or failures will
*: Never connect to NC or malfunctions or failures will occur.
occur.
8 PC2000-8
CN-CE01 CN-CE02
Input/ Input/
output output
28 NC(*) — 13 NC(*) —
29 NC(*) — 14 NC(*) —
30 Fuel temperature sensor B 15 NC(*) —
31 NC(*) — 16 NC(*) —
32 NC(*) — 17 NC(*) —
34 NC(*) — 19 NC(*) —
35 NC(*) A 20 NC(*) —
36 NC(*) — 21 NC(*) —
38 NC(*) — 23 NC(*) —
39 NC(*) — 24 NC(*) —
40 NC(*) — 25 NC(*) —
41 NC(*) — 26 NC(*) —
42 NC(*) — 27 NC(*) —
43 NC(*) — 28 NC(*) —
44 NC(*) — 29 NC(*) —
45 Injector #1 (+) D 30 NC(*) —
46 Injector #5 (+) D 31 NC(*) —
47 Sensor GND — 32 NC(*) —
48 Ne sensor (–) C 33 NC(*) —
49 NC(*) — 34 GND C
50 NC(*) — 35 NC(*) —
51 Injector #2 (–) C 36 NC(*) —
52 Injector #3 (–) C 37 NC(*) —
53 Injector #1 (–) C 38 NC(*) —
54 Injector #2 (+) D 39 Key switch (ACC) B
55 Injector #3 (+) D 40 NC(*) —
56 Injector #4 (+) D 41 NC(*) D
57 Injector #6 (+) D 42 NC(*) —
58 Injector #4 (–) C 43 NC(*) —
59 Injector #6 (–) C 44 NC(*) —
60 Injector #5 (–) C 45 NC(*) —
*: Never connect to NC or malfunctions or failures will 46 CAN(+) E
occur. 47 CAN(–) E
48 NC(*) —
CN-CE02 49 NC(*) —
Input/ 50 NC(*) —
Pin No. Signal name
output *: Never connect to NC or malfunctions or failures will
1 NC(*) — occur.
2 NC(*) —
3 NC(*) — CN-CE03
4 NC(*) — Input/
Pin No. Signal name
5 NC(*) — output
6 NC(*) — 1 GND C
7 NC(*) — 2 NC(*) —
8 Model selection B Electric power supply
3 A
9 NC(*) — (+24V constantly)
10 NC(*) — 4 NC(*) —
11 NC(*) — *: Never connect to NC or malfunctions or failures will
12 NC(*) — occur.
*: Never connect to NC or malfunctions or failures will
occur.
PC2000-8 9
Fuel temperature sensor NE speed sensor (Crank angle sensor)

q The fuel temperature sensor senses the fuel q If the signal hole made on the flywheel passes
temperature and sends it to the engine control- the sensor, the magnetic line of force changes.
ler. The sensor unit is a thermistor, the resis- q If the magnetic line of force changes, the out-
tance of which changes according to the put of the Hall element sensor changes linearly
temperature. and it is converted into pulse of 0 – 5 V by the
q The engine throttle controller applies voltage to wave form shaping circuit in the sensor, and
the thermistor and senses the temperature by then output.
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
Atmospheric pressure sensor

q This sensor is used to correct altitude.
Common rail pressure sensor, oil pressure

sensor
10 PC2000-8
Bkup speed sensor (G sensor) Boost temperature sensor

q Similarly to the NE speed sensor, this sensor q The boost temperature sensor senses the
utilizes the pulses of 0 – 5 V generated by the intake air temperature (charge temperature)
change of the magnetic line of force crossing and sends it to the engine controller.
the sensor unit. q The sensor unit is a thermistor, the resistance
q The disc gear installed to the central part of the of which changes according to the tempera-
camshaft of the high-pressure pump has teeth ture. The engine controller applies voltage to
(cut parts) around it at intervals of 120°. the thermistor and senses the temperature by
q In addition to the above teeth, one more tooth the voltage divided by the resistance in the
is installed. Accordingly, 7 pulses are gener- computer and the resistance of the thermistor.
ated every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
Boost pressure sensor

q This sensor is used to sense the boost pres-
sure (charge pressure).
PC2000-8 11
Coolant temperature sensor

• The coolant temperature sensor senses the
coolant temperature and sends it to the engine
controller.
• The sensor unit is a thermistor the resistance of
which changes according to the temperature.
The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the compu-
ter and the resistance of the thermistor.
12 PC2000-8
Electrical control system 1
Engine output control function

Engine and pump compound
control function
Pump absorption torque control function
Auto-deceleration function OFF (Reset)

Auto-low idle function
ON
NC flow control
Electronic CLSS function PC characteristic flow control
Cut-off control
Cut-off reset
Emergency pump drive
Heavy lift function OFF (Reset)
ON
2-stage boom pushing force ON (High digging performance mode)

selector function
OFF (Machine push-up mode)
Swing control function

Electrical control
system
Engine automatic warming-up,
overheat prevention function,
turbo protect function, split
injection function
Boom shockless control function OFF (Reset)
ON
Straight travel function
Compound operation
compensation function
Variable back pressure

compensation function
Hydraulic fan control function
14
Fan reverse function
PC2000-8 13
System diagram
14 PC2000-8
PC2000-8 15
Engine and pump compound control function
16 PC2000-8
Function q The pump controller selects a proper engine

With this function, the engine output and pump output curve and pump absorption torque
absorption torque are controlled properly and according to the operation pattern.
excessive fuel consumption is reduced by using q The engine controller controls the fuel injection
multiple engine output curves and selecting proper to obtain the selected engine output curve and
matching points. reduces excessive fuel consumption.
PC2000-8 17
1) Control method in each mode

q As the working modes, 2 modes of P and E
(with the E mode adjustment function) are set.
Select either working mode with the working
mode selector switch on the machine monitor.
q P mode and E mode (E0, E1)

(Including maximum pump absorption horsepower in each mode and the fan pump absorption horse-
power at maximum fan speed)
Mode Matching point

All modes During travel
728 kW/1800 rpm
During work {976 HP/1800 rpm}
(Heavy lift ON)
P
During work 699 kW/1800 rpm [721 kW/1800 rpm]
(Heavy lift OFF) {937 HP/1800 rpm} [966 HP/1800 rpm]
691 kW/1700 rpm [706 kW/1700 rpm]
E0 During work
{927 HP/1700 rpm} [947 HP/1700 rpm]
E
610 kW/1700 rpm [632 kW/1700 rpm]
E1 During work
{818 HP/1700 rpm} [848 HP/1700 rpm]
[ ]: 55°C spec.
q If the work equipment pump load increases 2) E mode adjustment function

and the pressure rises, the engine speed q The matching point in control of engine speed
decreases. At this time, pump delivery (Q) is (N) and engine torque (T) in the E mode can
decreased to control engine speed (N) to a be adjusted by operating the machine monitor.
speed near the rated output point. q The matching point can be set to 2 levels of E0
If the pressure lowers reversely, pump delivery and E1. In E1, the fuel efficiency is higher than
(Q) is increased to control the engine speed to in E0 but the production in unit time is lower.
the rated output point. q In the E mode (E1), the engine speed and
The engine speed is kept near the rated output engine output are lowered and fuel efficiency is
point by repeating the above controls. higher in the P mode and E mode (E0). The
q The engine speed and engine torque are so production in unit time is lower, however.
matched that the maximum output will be
obtained for boom raising operation, digging
operation, etc. which need larger output. For
the other operations which do not need the
maximum output, the engine output is lowered
to decrease the fuel consumption.
q In the P mode and the E mode (E0), CO is
canceled so that delivery (Q) at high pressure
will be larger than in the E mode (E1).
18 PC2000-8
Auto-deceleration function
Function q While the auto-low idle setting is ON, if all the

q If all the control levers are set in neutral when control levers are set in neutral when waiting
waiting for a dump truck or a next work, the for a dump truck or a next work, the engine
engine speed is decreased to the medium speed is decreased to the medium automati-
speed automatically to reduce fuel consump- cally. If the levers are kept in neutral for 30 sec-
tion and noise. onds, the engine speed is decreased to the low
speed automatically to reduce fuel consump-
tion and noise further.
q If any lever is operated, the engine speed
increases instantaneously to the set speed.
PC2000-8 19
Operation
1) While auto-deceleration switch is ON
(with auto-low idle setting OFF)
When all levers are set in neutral
q While the engine is running at a speed above
the deceleration speed (approx. 1,400 rpm), if
all the control levers are set in neutral, the
engine speed decreases instantaneously to
the 1st deceleration speed which is about 100
rpm lower than the set speed.
q If this condition is kept for 4 seconds, the
engine speed decreases to the 2nd decelera-
tion speed (approx. 1,400 rpm) and then it is
kept at that speed until a lever is operated.
When any lever is operated

q While the engine speed is kept at the 2nd
deceleration speed, if any control lever is oper-
ated, the engine speed increases instanta-
neously to the speed set with the fuel control
dial.
20 PC2000-8
2) While auto-deceleration switch is ON

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

q While the engine speed is kept at the 2nd
deceleration speed or low idle speed, if any
control lever is operated, the engine speed
increases instantaneously to the speed set
with the fuel control dial.
PC2000-8 21
Electronic OLSS function
Function
The electronic OLSS system, which replaced the
TVC valve, CO valve and NC valve of the former
hydraulic OLSS system, converts the pump dis-
charge pressure and J/S differential pressure into
electric signals with sensors. The controller per-
forms NC control calculation, PC characteristic con-
trol calculation and CO control calculation and
controls the variable swash plate control EPC to
control the pump swash plate.
22 PC2000-8
PC2000-8 23
1) NC control function
q If the operation stroke is increased, the carry-
over flow is decreased (See Fig. 1) and the out-
put pressure difference of the jet sensor (Pt –
Pd) is decreased (See Fig. 2).
q The differential pressure (Pt – Pd) is applied to
the differential pressure sensor and a voltage
is output. The relationship between the input
and output signals is shown in Fig. 3. If the out-
put pressure difference (Pt – Pd) is decreased,
the output voltage is increased.
q The output voltage of the differential pressure
sensor is input to the controller.
q The pump swash plate capacity is set accord-
ing to Fig. 4 and the controller supplies a cur-
rent to the pump EPC valve according to the
characteristics in Fig. 5.
q Since output pressure (Pi) of the EPC is
increased, the pump delivery is increased.
24 PC2000-8
2) PC characteristic control function 5) Emergency pump drive function

q The absorption torque of each pump is set with q This function is used when the machine has a
the engine and pump compound function and trouble (when user mode E07 occurs). If the
the pump capacity is calculated according to emergency pump drive switch (1) is turned
the characteristics in Fig. 6. “ON”, the pump capacity is set constant.
If the load on the machine increases and the pump
pressure rises, the pump capacity is decreased and
the pump absorption torque on the whole machine
is controlled constant.
3) Cut-off control function (Only when E1 is

set in E mode)
q If the load increases and pump discharge pres-
sure (P) rises to near the relief pressure during
work, the pump controller decreases the pump
delivery to decrease the relief loss.
4) Cut-off reset function

q The cut-off reset function means the function of
stopping the cut-off function and secures the
pump delivery near the relief pressure to pre-
vent the speed from lowering.
q Each switch and cut-off function
The cut-off function is reset in the P mode and
E mode (when E0 is set).
Switch Travel lever Heavy lift

Function ON OFF ON OFF
Cut-off function Reset Used Reset Used
PC2000-8 25
Heavy lift function
Outline
q This function increases the boom lifting power
by approx. 10%.
q It can be actuated only when the boom RAISE
is being actuated independently. If the arm IN
or bucket CURL are operated at the same
time, the heavy-lift function is automatically
canceled.
q Heavy lift function and Cut-off cancel function
will act at the same time.
26 PC2000-8
Operation
Lever operation Heavy-lift Main relief CO control
Boom lifting
Heavy-lift switch Arm IN or solenoid valve set P and
Boom RAISE E1 mode force
bucket CURL valve pressure E0 mode
29.4 MPa
OFF Operated — De-energized Canceled Actuated Normal
{300 kg/cm2}
32.9 MPa
Neutral Energized Canceled 10% up
{335 kg/cm2}
ON Operated If the arm IN or bucket CURL is operated during boom
RAISE operations, this function is automatically can-
Operated Normal
celed, and the condition becomes the same as when
the switch is turned OFF.
a Heavy-lift solenoid valve

For details of the structure and function, see “Solenoid valve”.
a Main relief valve
For details of the structure and function, see “L.H. 5-spool control valve”.
PC2000-8 27
2-stage boom pushing force selector function
Outline
q This function switches the pushing force of the
boom. It is aimed to provide both increased
digging efficiency by reducing the digging
resistance of the boom, and increased ease of
operation by increasing the thrusting force for
excavation, digging square holes, carrying out
twist turns, or escaping from soft ground.
28 PC2000-8
Operation
q This function acts to change the set pressure of the safety valve at the boom cylinder end of the L1 and
L2 control valve boom Lo in 2 ways: to low pressure (12.3 MPa {125 kg/cm2}) and high pressure (27.9
MPa {285 kg/cm2}.
Machine push-
Machine push- Safety valve set
Mode up solenoid Effect
up switch pressure
valve
By reducing the boom pushing force, it
is made easier for the boom to escape
Boom pushing automatically in the RAISE direction and
12.3 MPa
force Energized to reduce the number of times that the
{125 kg/cm2}
(low mode) boom is operated. At the same time it
also makes the digging operation
smoother.
By increasing the thrust force for boom

Boom pushing LOWER, the ease of operation is
27.9 MPa
force De-energized improved for excavation, digging square
{285 kg/cm2}
(high mode) holes, carrying out twist turns, or escap-
ing from soft ground.
a Machine push-up solenoid valve

For details of the structure and function, see “Solenoid valve”.
a Boom safety valve
For details of the structure and function, see “L1 and L2 control valve”.
PC2000-8 29
Swing control function
1. Swing lock, swing holding brake function

q The swing lock (manual) can be locked at any
desired position, and the swing holding brake
(automatic) is interconnected with the swing,
so they prevent any hydraulic drift after the
swing is stopped.
q The swing holding brake and ladder are linked
together. While the ladder is lowered and not in
the retraction position, the swing lock is
applied to prevent breakage of the ladder and
secure safety when the operator climb up and
down the ladder.
While the ladder is lowered, the ladder lower
warning lamp in the cab lights up.
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”.
30 PC2000-8
Actuation
Swing lock Swing lock Swing brake
Mode Actuation
switch monitor solenoid valve
When swing and work equipment levers are placed
at neutral, swing brake is applied after approx. 12
sec; when any swing or work equipment lever is
operated, brake is canceled and swing can be oper-
ated freely.
Swing holding See diagram

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

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

q If any abnormality should occur in the control-
ler, and the swing holding brake is not actuated
normally and the swing cannot be operated,
the swing holding brake release switch (1) can
be operated to cancel the swing lock and allow
the swing to be operated.
a Even when the swing holding brake release
switch is turned ON, the swing lock switch
stays ON and the swing brake is not canceled.
a When the swing brake is canceled, the swing
has only a hydraulic brake operated by the
safety valve, so if the swing is stopped on a
slope, there may be hydraulic drift.
a Even if the swing holding brake release switch
is turned ON, the swing brake is not reset
unless the ladders is in the retraction position.
Swing hold-
ing brake ON OFF
release (when controller is (when controller is
switch abnormal) normal)
Swing lock ON — OFF — ON — OFF —
switch
position
position
Storing
Storing
Lower
Lower
Ladder — — — —
Swing Swing Swing Swing

Swing brake lock lock lock lock
applied canceled applied canceled
PC2000-8 31
Engine automatic warming-up, overheat prevention function, turbo protect function, split
injection function
Function
q If the coolant temperature is low, this automati-
cally raises the engine speed to warm up the
engine after it is started. In addition, if the cool-
ant temperature rises too high during opera-
tions, it reduces the load of the pump to
prevent overheating.
q To protect the turbocharger bearing during cold
weather, the engine speed is kept below the
fixed speed when the engine is started. In
addition, to improve the starting ability, a small
amount of fuel is injected two or more times
before the main injection.
32 PC2000-8
1. Engine automatic warming-up function

q 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

q 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.
q This system is actuated at 95°C and above.
Operating condition Operation/Remedy Resetting condition
Coolant temperature: Below 105°C
⇒ ⇒
Work mode: Any mode Fuel control dial: Return to low idle posi-
Coolant temperature: Engine speed: Low idle tion once.
Above 105°C Monitor alarm lamp: Lights up • Under above condition, controller is
Alarm buzzer: Sounds set to condition before operation of
function. (Manual reset)

Work mode: Any mode
⇒ ⇒
Engine speed: Keep as is. Coolant temperature: Below 102°C
Coolant temperature: Monitor alarm lamp: Lights up • Under above condition, controller is
Above 102°C Alarm buzzser: Does not sound set to condition before operation of
Lower pump delivery. function. (Automatic reset)

Work mode: Any mode Coolant temperature: below 100°C and
⇒ ⇒
Hydraulic oil temperature: Engine speed: Keep as is. hydraulic oil temperature: below 95°C
Above 95°C or Monitor alarm lamp: Does not light • Under above condition, controller is
Coolant temperature: Alarm buzzser: Does not sound set to condition before operation of
Above 100°C Lower pump delivery. function. (Automatic reset)

Work mode: Travel Coolant temperature below 95°C and
Hydraulic oil or coolant
temperature:
Above 95°C
⇒ Engine speed: Keep as is.
Monitor alarm lamp: Does not light
Alarm buzzser: Does not sound
⇒ hydraulic oil temperature below 95°C
• Under above condition, controller is
set to condition before operation of
Lower travel speed. function. (Automatic reset)
PC2000-8 33
3. Turbo protection function

q Function to protect turbocharger bearing dur-
ing cold weather by keeping engine speed
below fixed speed when engine is started.
Actuation condition
Engine coolant Turbo protect time
temperature (sec)
More than +10°C 0
Gradually changes
+10°C to –10°C
between 0 and 5
Less than –10°C 5
Engine speed: 1000 rpm
q Even if the fuel control dial is operated during the

above time, the engine speed will not change.
After the set time passes, the operation moves to
the automatic warming up function.
4. Split injection function

q To improve the ease of starting in cold weather,
a small amount of fuel is injected two or more
times within the set time after calculating in the
table below before starting the main injection.
As a result, the lower idle speed during this
time becomes slightly higher.
Actuation condition
Coolant temperature Split injection time (sec)
More than 20°C 0
20°C to –30°C 0 – 15
Less than –30°C 15
34 PC2000-8
Boom shockless control function

This function improves safety by preventing spillage of the load from the bucket and by reducing the shock
when the boom is stopped, thereby reducing operator fatigue.
Actuation
Boom shockless Cancel solenoid Boom shockless
Remarks
switch valve control
ON
De-energized ON Suitable for normal operations
(Contacts open)
OFF
Energized Canceled Suitable for compacting or skeleton work
(Contacts closed)
q If the boom is raised, the pilot pressure (A) q In this condition, if the boom RAISE operation
from the PPC valve is generated in line (A). is stopped, the spool of the control valve
When this happens, the pressure in line (A) moves in the opposite direction to the arrow
passes through check valve (2) and pushes and drains the oil from line (A). However, the
the spool of the control valve in the direction of action of check valve (2) means that the oil
the arrow. The pilot oil at the left end of the must pass through orifice (1). As a result, the
spool passes through line (B) and the PPC spool returns slowly to the neutral position to
valve, and returns to the tank. However, when prevent any shock.
this happens, check valve (4) is being pushed
open by the pressure in line (A), so it also
allows the oil to pass in the opposite direction.
For this reason, the boom can be raised with-
out any delay in response.
PC2000-8 35
Straight travel function

Outline
q If the travel system and boom, arm, bucket or
swing system are operated simultaneously,
some of the oil flowing into the right or left
travel circuits is delivered to the boom, arm,
bucket or swing circuit.
In the travel circuit, the oil in which is divided,
less oil is supplied to the travel motor than in
the travel circuit, the oil in which is not divided.
As a result, the pressure in the former circuit
lowers and the machine deviates.
To prevent this, the straight travel PPC cut-off
valve sets the valves L1 and R2 for the work
equipment system and valves L2 and R1 for
the travel system by setting the spools of those
valves in neutral.
Operation
When boom, arm, bucket or swing system is
operated and travel system is not operated
q The straight travel valve solenoid valve does
not output oil and the straight travel valve spool
is in neutral. The outputs from the arm PPC
lever, boom PPC lever, bucket PPC lever and
right and left travel PPC levers are input to
valves L1, L2, R1 and R2. Accordingly, the
travel spool of valve L1, bucket, boom and arm
spools of valve L2, travel spool of valve R1,
and bucket, boom and arm spools of valve R2
are operated.
36 PC2000-8
Operation
When travel system and boom, arm, bucket or
swing system are operated
q The output from the straight travel valve sole-
noid valve changes the spools of both straight
travel valves CV1 and CV2, and then the out-
puts from the PPC levers of the arm, boom,
bucket and both travel systems are cut off.
Accordingly, valves L2 and R2 are used for the
operations of the left travel and right travel sys-
tems respectively, and valves L1 and R1 are
used for the operations of the systems other
than the travel system.
Even if the work equipment is operated under
this condition, the oil flow to the right and left
travel systems does not change and the
machine travels straight.
PC2000-8 37
Compound operation of swing system and arm

or bucket system
q When the arm system or bucket system and
swing system are operated simultaneously, the
swing priority PPC cut-off valve cuts the PPC
pressure on the arm and bucket spools of control
valve R1. Accordingly, the oil is supplied to the
swing system first to keep the swing operation
performance during the compound operation.
Operation
q If the swing PPC pressure exceeds 8 kg/cm2 and
the arm or bucket PPC pressure exceeds 5 kg/
cm2, the controller energizes the swing priority
solenoid valve, which outputs oil of 30 kg/cm2.
The output hydraulic signal operates the swing
priority PPC cut-off valve spool to cut off the
arm and bucket PPC pressure applied to con-
trol valve R1.
38 PC2000-8
Compound operation of swing system and

boom raise system
q When the boom raise system and swing sys-
tem are operated simultaneously, the throttle
valve in the boom parallel circuit is operated to
supply the oil to the swing system first to keep
the swing operation performance during the
compound operation.
Operation
q If the swing PPC pressure exceeds 8 kg/cm2 and
the boom raise PPC pressure exceeds 5 kg/cm2,
the controller energizes the boom throttle sole-
noid valve, which outputs oil of 30 kg/cm2.
The high-pressure selector valve outputs the
main pump pressure according to the output
hydraulic signal to operate the boom throttle
valve of control valve R1, which throttles the
boom raise circuit. Accordingly, the oil in valve
R1 flows to the swing spool to maintain the
swing operation.
PC2000-8 39
Compound operation compensation function
Outline Operation of arm throttle valve “for valve L1”

q When the arm system and boom raise system q When the arm system and boom raise system
or bucket system are operated simultaneously, or bucket system are operated simultaneously,
the oil flow to the boom or bucket circuit is the controller energizes the arm throttle sole-
secured by the throttle valve in the arm circuit noid valve “for valve L1”, which outputs oil of
to maintain the compound operation perfor- 30 kg/cm2.
mance. The high-pressure selector valve outputs the
hydraulic pump pressure to lock the pilot check
valve of the arm throttle valve of control valve
L1, according to the output hydraulic signal.
q Under this condition, since the oil passage in
control valve L1 is a parallel circuit, the flow
into the arm circuit is throttled and the drive
pressure for the boom raise or bucket system
is increased.
Accordingly, the boom raise operation or
bucket operation is maintained.
40 PC2000-8
Operation of arm throttle valve “for valve R2”

q When the arm system and boom raise system
are operated simultaneously, the controller
energizes the arm throttle solenoid valve “for
valve R2”, which outputs oil of 30 kg/cm2.
The high-pressure selector valve outputs the
hydraulic pump pressure to lock the pilot check
valve of the arm throttle valve of control valve
R2, according to the output hydraulic signal.
q Under this condition, since the oil passage in
control valve R2 is a parallel circuit, the flow
into the arm circuit is throttled and the drive
pressure for the boom raise system is
increased.
Accordingly, the boom raise operation is main-
tained.
PC2000-8 41
Variable back pressure compensation

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

During swing or travel operation:The solenoid valve is turned OFF and the poppet is pressed by the spring
force as ever and back pressure is generated in the main valve return circuit.
During other operations: The solenoid valve is turned ON and the poppet moves in the direction of
the arrow to cancel the spring force. As a result, the resistance in the con-
trol valve return circuit is decreased and the back pressure is decreased
accordingly.
42 PC2000-8
Function
q During the travel or swing operation, back
pressure is generated in the drain circuit to
prevent cavitation.
q During the operations other than the travel and
swing operations, the back pressure in the
drain circuit is decreased to reduce the loss.
Operation
1. During travel or swing operation
q No oil is supplied from solenoid valve (4) and
no pressure is generated in pilot circuit (a).
q The oil from the control valve acts on left end
(Ab) of valve (1) and generates back pressure
in drain circuit (b) with springs (2) and (3).
PC2000-8 43
2. During operations other than 1

q The oil from solenoid valve (4) flows in pilot cir-
cuit (a) and acts on left ring surface (Aa) of
valve (1) to push back springs (2) and (3).
q Since valve (1) is moved to the right, the oil
from the control valve generates less back
pressure in drain circuit (b).
Unit: mm
Criteria
No. Check item Free length × Remedy
Outside Installed length Installed load Free length Installed load
diameter
1372. 8 N 1098. 3 N
2 Spring (2) 187.48 × 38.5 130 — If damaged or
{140 kg} {112 kg}
deformed,
3 Spring (3) 116.18 × 19.5 90 —
{23.6 kg} {18.9 kg}
44 PC2000-8
Hydraulic fan control function

1) Hydraulic fan speed control function
q The fan speed on the radiator side is controlled
according to the engine speed and coolant
temperature.
q The fan speed on the oil cooler side is con-
trolled according to the engine speed and
hydraulic oil temperature.
q When the coolant temperature and hydraulic oil
temperature are low, the fan speed is lowered to
decrease the noise and fuel consumption.
PC2000-8 45
2) Engine output control function

q The pump controller calculates the horsepower
consumed by the fans and controls engine out-
put curve (A) according to the fan speed to
decrease the fuel consumption.
46 PC2000-8
Fan reverse function

q The cooling devices can be cleaned easily by
rotating the fan in reverse.
q The heat in the power container can be dis-
charged before servicing by rotating the fan in
reverse.
q Upon receiving the fan reverse signal from the
machine monitor, the pump controller drives
the reverse EPC valve of the fan motor to
change the fan reverse valve. By this opera-
tion, the fan rotation direction is reversed.
q The fans on the radiator side and oil cooler
side cannot be reversed separately.
q The fan speed in reverse direction is controlled
by only the engine speed, regardless of the cool-
ant temperature and hydraulic oil temperature.
PC2000-8 47
Pump controller
Pump controller 1
48 PC2000-8
Input and output signals

CN1 CN2
Input/ Input/
Output Output
1 O/C FAN pump pressure sensor Input 1 NC Output
2 VL1/P1R J/S differential pressure sensor Input 2 NC Input
3 VL1/P1R pump pressure sensor Input 3 NC Input
4 GND_SIG_D — 4 232C_R x D Input
5 NC Input 5 Fuel level switch (Middle) Input
6 NC Input 6 NC Input
7 RAD_FAN pump pressure sensor Input 7 Machine select 4 Input
8 VR1/P1F J/S differential pressure sensor Input 8 NC Output
9 VR1/P1F pump pressure sensor Input 9 NC Output
10 GND_SIG_D — 10 NC Input
11 NC Input 11 NC Output
12 NC Input 12 CAN shield —
13 VL2/P2R J/S differential pressure sensor Input 13 Machine select 5 Input
14 VL2/P2R pump pressure sensor Input 14 232C_T x D Output
15 NC Input 15 Fuel level switch (H1) Input
16 NC Output 16 NC Input
17 Start switch (C) Input 17 Machine select 3 Input
18 Auto grease manual select switch Input 18 NC Output
19 VR2/P2F J/S differential pressure sensor Input 19 Manual grease operation lamp Output
20 VR2/P2F pump pressure sensor Input 20 NC Input
21 GND_SIG_A — Input/
21 S_NET
22 PWR_OUT_5V_0 Output Output
23 Key switch (ACC) Input Input/
22 COMM_CAN_L_0
Output
24 NC Input
Input/
23 COMM_CAN_L_1
Output
24 PWR_CTR_EXT Input
25 NC Input
26 NC Input
27 Machine select 2 Input
28 NC Input
29 GND_SIG_P —
30 NC Input
31 GND (S_NET_GND) —
Input/
32 COMM_CAN_H_0
Output
Input/
33 COMM_CAN_H_1
Output
34 GND (232C_GND) —
35 Auto grease low level switch Input
36 Fuel level switch (Low) Input
38 NC Input
39 GND_SIG_P —
40 NC Input
PC2000-8 49
CN3
Input/
Pin No. Signal name
Output
1 PWR_IN_BATT Input
2 PWR_IN_BRY Input
3 GND_ACT Input
4 Battery relay hold Output
5 RAD FAN EPC solenoid Output
6 P1F pump EPC solenoid Output
7 Auto grease solenoid Output
8 Auto grease caution LED Output
9 NC Input
10 NC Input
11 PWR_IN_BATT Input
12 PWR_IN_BRY Input
13 GND_ACT Input
14 PWR_CTR_KEY Input
15 O/C FAN EPC solenoid Output
16 P1R pump EPC solenoid Output
17 NC Output
18 FAN reverse caution LED Output
19 NC Input
20 NC Input
C21 GND_PWR Input
22 PWR_CTR_BRY Input
23 GND_ACT Input
25 RAD FAN reverse solenoid Output
26 P2F pump EPC solenoid Output
27 NC Output
28 NC Output
29 NC Input
30 NC Input
31 GND_PWR Input
32 GND_PWR Input
33 GND_PWR Input
34 PWR_OUT_5V_0 Output
35 O/C FAN reverse solenoid Output
36 P2R pump EPC solenoid Output
37 NC Output
38 NC Output
39 NC Input
40 NC Input
50 PC2000-8
Pump controller 2
PC2000-8 51

CN1 CN2
Input/ Input/
Output Output
1 Swing right PPC pressure sensor Input 1 NC Output
2 Arm dump PPC pressure sensor Input 2 Swing redundancy switch Input
3 Auto grease pressure sensor Input 3 NC Input
4 GND_SIG_D — 4 232C_R x D Input
6 Upper wiper proximity switch Input 6 NC Input
7 Swing left PPC pressure sensor Input 7 Machine select 4 Input
8 Arm digging PPC pressure sensor Input 8 Step light relay output Output
9 Hydraulic oil temperature sensor Input 9 NC Output
10 GND_SIG_D — 10 NC Input
11 Step light switch Input 11 NC Output
12 NC Input 12 CAN shield —
13 Bucket dump PPC pressure sensor Input 13 Machine select 5 Input
14 Boom down PPC pressure sensor Input 14 232C T x D Output
17 Start switch (C) Input 17 Machine select 3 Input
18 Horn switch Input 18 NC Output
19 Bucket digging PPC pressure sensor Input 19 NC Output
20 Boom up PPC pressure sensor Input 20 NC Input
21 GND_SIG_A — Input/
21 S_NET
22 PWR_OUT_5V_0 Output Output
23 Key switch (ACC) Input Input/
22 COMM_CAN_L_0
Output
24 Ladder down signal Input
Input/
23 COMM_CAN_L_1
Output
24 PWR_CTR_EXT Input
25 NC Input
26 NC Input
28 NC Input
29 GND_SIG_P —
30 NC Input
31 GND (S_NET_GND) —
Input/
32 COMM CAN_H_0
Output
Input/
33 COMM CAN_H_1
Output
34 GND (232C_GND) —
35 Service PPC pressure switch Input
36 NC Input
38 Swing lock switch Input
39 GND_SIG_P —
40 NC Input
52 PC2000-8
CN3
Input/
Pin No. Signal name
Output
1 PWR_IN_BATT Input
2 PWR_IN_BRY Input
3 GND_ACT Input
4 NC Output
5 Travel straight valve solenoid Output
6 Upper wiper lo output Output
7 Swing parking brake valve solenoid Output
8 Flash light relay output Output
9 NC Input
10 Upper wiper limit switch Input
11 PWR_IN_BATT Input
12 PWR_IN_BRY Input
13 GND_ACT Input
15 Two stage relief valve solenoid Output
16 Upper wiper lo brake output Output
17 Window washer output Output
18 Travel alarm output Output
19 NC Input
20 Lower wiper limit switch Input
21 GND_PWR Input
22 PWR_IN_BRY Input
23 GND_ACT Input
25 Bucket Hi cancel valve solenoid Output
26 Lower wiper lo output Output
27 Arm restriction L valve solenoid Output
28 Variable back pressure valve solenoid Output
29 Travel left PPC pressure switch Input
30 NC Input
31 GND_PWR Input
32 GND_PWR Input
33 GND_PWR Input
34 PWR_OUT_5V_0 Output
35 Boom restriction valve solenoid Output
36 Lower wiper lo brake output Output
37 Arm restriction R valve solenoid Output
38 Swing priority valve solenoid Output
39 Travel right PPC pressure switch Input
40 NC Input
PC2000-8 53
Pump emergency drive redundant resistor
1. Resistor Function
2. Connector q When the pump emergency drive switch is
turned ON, a proper current is supplied to the
Specification pump EPC through this resistor.
Resistance: 30 z
54 PC2000-8
Monitor system 1
q The monitor system notifies the operator of

machine status. It monitors the condition of the
machine with the sensors mounted on various
parts of the machine, processes and immedi-
ately displays the obtained information on the
panel.
Contents displayed on the panel are largely
divided into the following.
1. Alarm when an abnormality occurs on the
machine
2. Machine condition (Temperature of cool-
ant and hydraulic oil, fuel level, etc.)
q Also, the machine monitor is provided with var-
ious mode selector switches that function as
the operation unit of the machine control sys-
tem.
PC2000-8 55
Machine monitor 1
Outline
q The machine monitor has the functions to dis-
play various items and the functions to select
modes and electric parts.
q The machine monitor has a CPU (Central Pro-
cessing Unit) in it to process, display, and out-
put the information.
q The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
56 PC2000-8
CN-CM01 CN-CM04
Input/ Input/
output output
1 Battery power (+24V constantly) Input 1 GND —
2 Battery power (+24V constantly) Input 2 DOS Output
3 Battery power GND — 3 GND —
4 Battery power GND — 4 Communication 232C Output
Input/ 5 Communication 232C Input
5 Wake-up
Output 6 NC(*) —
6 Relay output Output 7 NC(*) —
7 Chassis signal GND — 8 NC(*) —
8 Hydraulic oil temperature Input 9 NC(*) —
9 Fuel level Input 10 NC(*) —
10 Coolant temperature Input 11 NC(*) —
11 Charge amount Input 12 PWR OUT Output
12 Chassis analog signal GND — *: Never connect to NC or malfunctions or failures
13 Light switch Input will occur.
14 Key switch (ACC) Input
15 Key switch (C) Input CN-CM05
16 Preheating Input
Input/
17 Power out Output Pin No. Signal name
output
18 GND power —
Electric power supply for cam-
*: Never connect to NC or malfunctions or failures 1 Output
era
will occur.
2 Camera NTSC signal input 1 Input
CN-CM02 3 Camera NTSC signal input 2 Input
Input/ 4 Camera NTSC signal input 3 Input
Pin No. Signal name
output Electric power supply GND for
1 Engine oil pressure sensor Input 5 —
camera
2 Engine oil level sensor Input
6 Camera signal GND1 —
3 Coolant level sensor Input
7 Camera signal GND2 —
4 Air cleaner clogging sensor Input
5 Swing lock Input 8 Camera signal GND3 —
6 NC(*) Input
7 Chassis signal GND —
8 CAN terminating resistance —
Input/
9 CAN_H
Output
Input/
10 CAN_L
Output
Input/
11 NC(*)
Output
Input/
12 NC(*)
Output
*: Never connect to NC or malfunctions or failures
will occur.
PC2000-8 57
Monitor control, display portion 1
q AA (1/2): Ordinary work screen (1/2) q BB: Check before starting screen
q AA (2/2): Ordinary work screen (2/2) q CC: Maintenance interval caution screen
1. Engine coolant temperature monitor 16. Truck counter 1

2. Engine coolant temperature gauge 17. Truck counter 2
3. Hydraulic oil temperature monitor 18. ECO indicator
4. Hydraulic oil temperature gauge 19. PTO oil temperature monitor
5. Fuel level monitor 20. PTO oil temperature gauge
6. Fuel gauge 21. Engine oil temperature monitor
7. Wiper monitor 22. Engine oil temperature gauge
8. Swing lock monitor 23. Engine oil pressure monitor
9. Engine pre-heating monitor 24. Engine oil pressure gauge
10. Auto-greasing monitor 25. Radiator coolant level monitor
11. Engine stop monitor 26. Charge level monitor
12. Time/service meter 27. Engine oil pressure monitor
13. Auto-deceleration monitor 28. Engine oil level monitor
14. Working mode monitor 29. Air cleaner clogging monitor
15. Heavy lift monitor 30. Maintenance interval monitor
58 PC2000-8
Precautions on the machine monitor display

q The liquid crystal display panel may have black
spots (which do not light up) or bright spots
(which stay on).
Products having 10 or less black or bright
spots conform the product specification; such
the condition is quite normal.
q Battery voltage may suddenly drop at engine-
start due to ambient temperature or the condi-
tion of the battery. The machine monitor dis-
play may temporarily disappear if it happens; it
is quite normal.
q Continuous operation of the machine monitor
may display blue bright spots on the screen
having a black background; it is quite normal.
The screen normally displayed on the monitor
has a blue or white background. For this rea-
son, blue spots will not cause any problem
(since the liquid crystal lights up red, blue, and
green spots when displaying white).
PC2000-8 59
Monitor items and display
Symbol Display item Display method
Swing holding brake

Swing lock switch Display of symbol
release switch
OFF OFF OFF
Swing lock
ON OFF ON
OFF ON Flashes
ON ON Flashes
Preheater operates at low temperature and

Automatic preheating symbol keeps lighting up for up to about 30
seconds and then goes off after engine starts.
Preheating Time after setting Display of symbol

0 – 30 sec ON
Manual preheating
30 – 40 sec Flashes
After 40 sec OFF
Engine coolant
temperature
Hydraulic oil
temperature
Fuel level See gauge display on next page.
PTO oil
temperature
Engine oil
Pressure
60 PC2000-8
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Gauge display: 1/2

Gauge Range Temperature or volume Indicator Buzzer sound
A1 105 Red Q
A2 102 Red
Engine coolant A3 100 Off
temperature
(°C) A4 85 Off
A5 60 Off
A6 30 White
B1 103 Red
B2 100 Red
Hydraulic oil B3 97 Off
temperature
(°C) B4 85 Off
B5 40 Off
B6 20 White
C1 2,800 Off
C2 2,100 Off
C3 1,250 Off
Fuel level (l)
C4 700 Off
C5 500 Off
C6 250 Red
PC2000-8 61
Gauge display: 2/2

Gauge Range Temperature or volume Indicator Buzzer sound
D1 125 Red Q
D2 122 Red
PTO oil temperature D3 120 Off
(°C) D4 100 Off
D5 50 Off
D6 0 White
E1 125 Red
E2 122 Red
Engine oil temperature E3 120 Off
(°C) E4 100 Off
E5 50 Off
E6 0 White
F1 7 Off
F2 6 Off
Engine oil pressure F3 4 Off
(kg/cm2) F4 2 Off
F5 0.6 Off
F6 0.2 Red
62 PC2000-8
Checks before starting (all symbols light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic
oil temperature gauge and the hydraulic oil temperature monitor disappear and the following symbols are
displayed.
Check before starting While engine is While engine is

Symbol Display item
item stopped running
Lights up and buzzer

Engine oil pressure q —
sounds when abnormal.
Lights up when
Battery charge q —
abnormal.
Lights up when Lights up and buzzer

Radiator coolant level q abnormal. sounds when abnormal.
Lights up when
Engine oil level q abnormal.
—
Lights up when
Air cleaner clogging q —
abnormal.
Notice lamp (yellow)/Warning lamp (red).

Maintenance Lights up for only 30 seconds after starting
switch is turned ON.
Symbols appear in the order in which they occur

from the upper left. When symbols are displayed, if
the hydraulic oil temperature is high or low, only its
symbol is displayed.
Condition of hydraulic oil Color of symbol
Low temperature Black on white
(below B6 or equivalent) background
Normal (B6 – B2) No display
White on red
High temperature (above B2)
background
PC2000-8 63
Items other than work check items

Method of Condition for occurrence
Check Condition for
Caution Symbol notifying
component Item Sub item reset
operator
Connection of sensor Monitor analog input
Normal
Fuel level gauge display 1
While engine judgment
is stopped Abnormal
Fuel level gauge display 0
judgment
Change of Normal Same as while engine is Above fuel
Fuel level
Monitor symbol color While engine judgment stopped level gauge
reduction
(Blue o Red) is operated Abnormal display 1
judgment
Moving average of values
Filter time input at intervals of 500
msec is obtained.
Remarks
Connection of sensor Engine controller
Normal Temperature equivalent to
While engine judgment 102°C or below
is stopped Abnormal Temperature equivalent to
Change of
symbol color judgment 102°C or above
Engine (Blue o Red) Normal Same as while engine is As per logic
Engine
coolant When above While engine judgment running in engine
controller
overheat 105°C, buzzer is operated Abnormal controller
sounds inter- judgment
mittently.
As per logic in pump con-
Filter time
troller
Alarm is masked in 100
Remarks
sec after engine is started.
Connection of sensor Engine controller
Normal Temperature equivalent to
While engine judgment 102°C or below
Change of is stopped Abnormal Temperature equivalent to
symbol color judgment 102°C or above
Hydraulic (Blue o Red) Normal Same as while engine is As per logic
Pump
oil over- When above While engine judgment running in engine
controller
heat 105°C, buzzer is operated Abnormal controller
sounds inter- judgment
mittently.
Filter time
troller
Alarm is masked in 100
Remarks
sec after engine is started.
Connection of sensor Pump controller
Normal As per logic in pump con-
While engine judgment troller
is stopped Abnormal As per logic in pump con-
Auto- judgment troller
grease As per logic
Display of Normal As per logic in pump con-
system in pump con-
symbol While engine judgment troller
abnormal- troller
ity is operated Abnormal As per logic in pump con-
judgment troller
Filter time
troller
Remarks Obtained by RTCDB2
64 PC2000-8
Method of Condition for occurrence

Check Condition for
Caution Symbol notifying
component Item Sub item reset
operator
Connection of sensor VHMS ON/OFF input
Normal
While engine judgment
is stopped Abnormal
Hydraulic judgment Other than
Display of
oil level Normal When sensor contact is conditions
symbol
reduction While engine judgment closed shown at left
is operated Abnormal When sensor contact is
judgment open
Filter time 3 sec
Remarks
Connection of sensor VHMS ON/OFF input
Normal When sensor contact is
While engine judgment closed
is stopped Abnormal When sensor contact is
judgment open
Normal
Hydraulic Other than
Display of While engine judgment
oil filter conditions
symbol is operated Abnormal
clogging shown at left
judgment
Filter time 10 sec
Detected only when
hydraulic oil temperature is
Remarks
above 25°C
Obtained by RPC
Check Screen page

before 1/2 2/2
starting Gauge Monitor Caution Gauge Monitor Caution
Engine coolant temperature q q q
Hydraulic oil temperature q q a q
Fuel level q q q
PTO oil temperature q q q
Engine oil temperature q q q a
Engine oil pressure q q q q
Charge level q q q
Radiator coolant level q q q
Engine oil level q q q
Air cleaner clogging q q q
Auto-grease system abnormality q q
Hydraulic oil level q q
Hydraulic oil filter clogging q q
Maintenance q q
a: If another caution is displayed, these items are displayed only when abnormal.
PC2000-8 65
Display
Symbol Display item Display range Display method
category
Windshield wiper Setting condition is displayed.
Working mode P, E Setting mode is displayed.
Operating condition is displayed.

(Auto-deceleration or auto-low
Auto-deceleration Operation Reset
idle is selected on user mode
menu)
Heavy lift ON OFF Setting condition is displayed.
Monitor Operating condition is displayed.

(Auto-deceleration or auto-low
Auto-low idle Operation Reset
idle is selected on user mode
menu)
Engine stop Displayed when engine stop is

Stop Operation
indicator judged
Display of auto- Displayed when grease level is

Alarm Normal
grease low level low
Auto-greasing Operation Stop Displayed during auto-greasing
Truck Truck counter 1

0 – 99 Number of counts
counter Truck counter 2
Green: Average of load in 1 minute is

ECO Work load is light – medium. displayed in 10 levels.
ECO indicator
indicator Orange: (Not displayed if ECO display is
Work load is heavy. turned “OFF” in service menu.)
Operating time is displayed.

Service Service meter
While service meter is operating (If F4 is pressed, clock is dis-
meter indicator
played instead.)
Clock is displayed.
12-hour display
Clock Clock (If F4 is pressed, service meter
24-hour display is displayed instead.)
66 PC2000-8
PC2000-8 67
Switches 1
1. Buzzer cancel switch Buzzer cancel switch

2. Auto-deceleration switch/auto low idle switch Pressing this switch when the alarm buzzer is mak-
3. Guidance icon ing sound stops the alarm buzzer.
4. Function switch If a new abnormality is detected, the alarm buzzer
5. Working mode selector switch sounds.
6. Heavy lift switch Depending on the alarm buzzer type, it does not
7. Window washer switch stop even if you press the buzzer cancel switch.
8. Wiper switch
Auto-deceleration switch/auto low idle switch
This switch toggles the auto-deceleration or auto
low idle function on and off. When the working
mode is switched, it is automatically set to ON.
When it is set to ON, the auto-deceleration monitor
appears.
68 PC2000-8
Guidance icon and function switch

The function switches differ depending on the
screen display. Each guidance icon shows the func-
tion of the switch below it.
Switches with no guidance icon are disabled.
The functions shown by the guidance icons are as
shown in the table below.
Symbol Switch Item Function
F6 Enter Enters selected/set item.
F5 Return Returns to previous screen.
F4 Select service meter/clock Selects service meter and clock alternately.
F5 Select maintenance screen Selects maintenance screen.
F6 Select user mode screen Selects user mode screen.
Selects item on left side (Selects right end item after left
F3 Select item
end item).
Selects item on right side (Selects left end item after right
F4 Select item
end item).
Selects item on lower side (Selects top item after bottom
F3 Select item
item)/Resets holding of monitoring.
Selects item on upper side (Selects bottom item after top
F4 Select item
item)/Holds monitoring.
Selects page on lower side (Selects top page after bottom
F1 Select item
page).
Selects page on upper side (Selects bottom page after top
F2 Select item
page).
F1 Display No. 1 camera screen Selects No. 1 camera screen.
Display No. 1 and No. 2

F4 Displays No. 1 and No. 2 camera screens simultaneously.
camera screens
F1 Ordinary work screen select Selects (1/2) or (2/2) screen.
Returns selected item to default setting.

F2 Return to default setting
(Used for adjustment of screen.)
Starts operation. (Used to start measurement of split fuel
F1 Start
consumption on fuel consumption display screen.)
Stops operation. (Used to stop measurement of split fuel
F1 Stop
consumption on fuel consumption display screen.)
F1/F2 Clear Clears selected/displayed item
F1 Set Executes setting.
PC2000-8 69
Working mode selector switch Camera screen display function 1

Pressing working mode selector switch switches q For an optional-camera-equipped machine,
among working modes. pressing the F3 on the normal screen switches
Check the working mode on the working mode to the camera image.
monitor. q For a machine with no camera equipped, the
guidance icon for switching to the camera
screen does not appear; even if you press the
switch, the screen does not switch to the cam-
era image.
q Up to three cameras are mountable.
Window washer switch

While the switch is being pressed, window washer
liquid is sprayed out. There is a time delay before
the wiper starts.
Wiper switch
F1 : Displays the image of No. 1 camera full-screen.
Each time you press the wiper switch, the wiper F2 : Displays the image of No. 2 camera full-screen.
settings switch as follows. F3 : Displays the image of No. 3 camera full-screen.
OFF o INT o ON (upper, lower) o ON (UPPER) F4 : Displays the images of No. 1 and No. 2 cam-
o OFF o …. eras at the same time.
The wiper operation setting is confirmable on the F5 : Returns to the normal screen.
wiper monitor.
The relationship between the wiper setting and the q Even when the camera screen is displayed,
monitor display is shown in the table below. the working mode selector switch, heavy lift
switch, auto-deceleration switch, buzzer can-
Setting Display Wiper actuation status cel switch, wiper switch, and window washer
Stowing stopped or switch are enabled.
OFF None q Changing the working mode returns to the nor-
now stowing
mal screen.
q If an abnormality corresponding to an alarm
INT Intermittent actuation item with the camera screen displayed, the
alarm monitor appears on the upper left of the
screen. If it appears, return to the normal
screen with F5 to check the alarm display.
q If an abnormality corresponding to an error
ON Upper, lower wiper
(LOWER) continuous actuation item with the camera screen displayed, the
error monitor appears on the upper left of the
screen. If it appears, you must move the
machine to safe posture immediately and
ON Upper wiper make inspections.
(UPPER) continuous actuation q If you do not operate the lever at least 10 sec.
after the error monitor starts to blink, the
screen switches to the normal screen.
70 PC2000-8
Service meter/time selector function 1

q Pressing F4 on the normal screen when the
service meter is displayed in the top center of
the screen switches the display to the time,
and doing so when the time is displayed
switches the display to the service meter.
PC2000-8 71
Maintenance function 1 q If the remaining time on the maintenance table

q Pressing F5 on the normal screen switches to screen is less than 30 hours, the relevant items
the maintenance screen. are highlighted in yellow, and if 0 hours, they
are done in red.
q On the maintenance time reset screen, reset
the remaining time for the selected item to
return to the default.
F5 : Cancels the reset to return to the maintenance

table screen.
F6 : Resets the remaining time to return to the nor-
mal screen.
No operation at least 30 sec. : Returns to the nor-
mal screen.
q The table below shows the maintenance items

and replacement intervals. The time remaining
to maintenance is reduced as the machine is
F1 : Displays the next page.
operated.
Displays the top page when the last page is
displayed. Replacement interval
No. Item
F2 : Displays the previous page. (Hours)
Displays the last page when the top page is 01 Engine oil 500
displayed. 02 Engine oil filter 500
F3 : Selects (highlights) an item one down. 03 Fuel main filter 1000
F4 : Selects (highlights) an item one up. 41 Fuel prefilter 500
F5 : Returns to the normal screen. 04 Hydraulic filter 1000
F6 : Switches to the maintenance time reset screen. 05 Hydraulic tank breather 1000
No operation at least 30 sec. : Returns to the nor- 06 Corrosion resistor 1000
mal screen. 07 PTO case oil 1000
08 Final case oil 2000
09 Machinery case oil 1000
10 Hydraulic oil 5000
30 Hydraulic oil pilot filter 500
31 Hydraulic oil drain filter 500
— Oil cooler accumulator 4000
72 PC2000-8
q The content of the caution display differs accord-

ing to the remaining time. The relationship is as
shown in the table below.
Display Condition
Remaining time for mainte-
None nance for all items is more
than 30 hours.
There is one or more items
Notice display
with less than 30-hour
(black symbol displayed
remaining time for mainte-
on yellow background)
nance.
There is one or more items
Warning display
with less than 0-hour
(white symbol displayed
remaining time for mainte-
on red background)
nance.
q You can lock the maintenance time by a pass-

word to prevent it from carelessly being reset.
q The default password is “000000”.

a For information on changing the maintenance
pa ss wo rd , se e “M ai nte nan c e pas sw or d
change function” in the Testing and adjusting
section.
PC2000-8 73
User mode 1 Screen adjustment

q Pressing F6 on the normal screen enters the q Selecting the “Screen adjustment” from the user
user mode, switching to the user menu screen. menu and pressing F6 switches to the screen
q In user mode, you can specify items relating to adjustment screen.
the machine monitor and machine shown below. q From this menu, you can adjust the brightness,
Screen adjustment contrast, and luminance of the machine moni-
ECO display selection tor screen.
Time adjustment q When the light switch is in Night mode ON, the
Language setting night mode screen is adjustable.
Economy mode adjustment q When the light switch is in Daytime mode ON or
Auto-low idle setting OFF, the daytime mode screen is adjustable.
Truck counter correction/clearing
Hydraulic fan reverse setting
F2 : Returns all adjusted values to the defaults.

F3 : Decreases the value indicated by the indicator
F3 : Selects (highlights) an item one down.
one graduation left.
F4 : Selects (highlights) an item one up.
F4 : Increases the value indicated by the indicator
F5 : Returns to the normal screen.
one graduation right.
F6 : Switches to the setting screen for the selected
F5 : Cancels changes you made before confirming
item.
them with F6 to return to the menu screen.
No operation at least 30 sec. : Returns to the nor-
F6 : Confirms the changes and moves to the next
mal screen.
item.
(In user mode, no switch operation at least 30 sec.
returns to the previous screen.) q For a camera-equipped machine, the bright-
ness, contrast, and illuminance of the camera
screen are also adjustable.
q For a camera-equipped machine, selecting
Sc reen adjustme nt from the us er me nu
switches to the screen for selecting a screen
you want to adjust.
74 PC2000-8
F3 : Selects (highlights) an item one down. Clock adjustment

F4 : Selects (highlights) an item one up. q Selecting the “Clock adjustment” from the user
F5 : Cancels changes you made before confirming menu and pressing F6 switches to the clock
them with F6 to return to the menu screen. adjustment screen.
F6 : Moves to the setup items of the selected (high- q On this screen, you can change the setting of
lighted) item. the time displayed on the normal screen.
q The adjustment methods for the camera screen
and normal screen are the same.
q The background when adjusting the camera
screen is the No. 1 camera image.
1) Time setting
Set the clock time. If the time setting item
is not highlighted, press F6 to highlight it.
The time display part is highlighted.

F3 : Selects (highlights) an item one down. F3 : Advances the clock one hour.
F4 : Selects (highlights) an item one up. F4 : Sets the clock back one hour.
F5 : Cancels changes you made before confirming F5 : Cancels changes you made before
them with F6 to return to the menu screen. confirming them with F6 to return to
F6 : Moves to the setup items of the selected (high- the user menu.
lighted) item. F6 : Confirms the changes and moves to
minute setting.
The minute display part is highlighted.

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

Specify time display to 12-hour display
(AM/PM) or 24-hour display. If the item of
12/24 display mode is not highlighted,
press F6 to highlight it.
F3 : Moves to the item one right.
F4 : Moves to the item one left.
F5 : Cancels the changes to return to the
user menu.
F6 : Confirms the changes and moves to
summer time.
PC2000-8 75
3) Summer time Economy mode adjustment

Selecting ON for this sets the time forward q Selecting the “Economy mode adjustment” from
one hour. Setting OFF returns to the ordi- the user menu and pressing F6 switches to the
nary time. Economy mode setting screen.
F3 : Moves to the item one right. q From this menu, you can adjust engine output
F4 : Moves to the item one left. to improve fuel consumption in E mode.
F5 : Cancels changes you made before q The fuel consumption level is specified to one
confirming them with F6 to return to of two levels from E0 to E1. The larger the
the user menu screen. value, the better the fuel consumption, but the
F6 : Confirms the changes and moves to smaller the work rate.
the time setting.
a Summer time (daylight saving time) is

a system to lead a life according to
the one-hour advanced time in order
to make efficient use of daylight time.
Language setting
q Selecting the “Language” from the user menu
screen and pressing F6 switches to the lan-
guage setting screen.
q From this menu, you can change the language
to be displayed on the monitor. Available lan-
guages are as follows.
English, Japanese, Chinese, French, Spanish, F3 : Selects (highlights) an item one down.
Portuguese, German, Russian, and Indone- F4 : Selects (highlights) an item one up.
sian F5 : Cancels the changes to return to the user menu.
F6 : Confirms the changes to return to the user menu.
F3 : Selects (highlights) an item one down.

F4 : Selects (highlights) an item one up.
F5 : Cancels the changes to return to the user menu.
F6 : Confirms the changes to return to the user menu.
76 PC2000-8
ECO display selection
q Select “Select ECO display” on the user menu

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

screen and press F6, and the screen changes
to the Auto-low idle setting screen.
q In this menu, you can select the auto-decelera-
tion speed or low idle speed to be set when the
auto-deceleration switch is pressed.
ON : Low idle speed
OFF: Auto-deceleration speed
PC2000-8 77
Truck counter correction/clearing q Select “Correct/Clear truck counter” on the

user menu screen and press F6, and the
screen changes to the “Correct/Clear truck
counter screen”.
q In this menu, you can correct/clear all the truck
counter values at a time or one by one.
q The contents of the menu are as follows from
the top.
A. Correct/Clear truck counter 1
B. Correct/Clear truck counter 2
C. Clear truck counters 1 and 2
On screen A or B, the counter value is increased or
decreased by 1 in the range between 0 and 99
each time the F3 or F4 switch is pressed. The cur-
rently adjusted value is displayed in the box on the
right side and entered by pressing F6.
If F5 is pressed, the screen is finished without
entering the currently adjusted value.
If F1 is pressed, the counter value is cleared.
On screen C, if F6 is pressed, the values of both
truck counters 1 and 2 are cleared to 0.
If F5 is pressed, the screen is finished without
clearing the counter values.
78 PC2000-8
Hydraulic fan reverse setting q While the fans are rotating in reverse, the
q Select “Reverse hydraulic fans” on the user screen shown below is displayed.
menu screen and press F6, and the screen q To return the hydraulic fans to the normal
changes to the screen to reverse the hydraulic direction, press F5 and change the screen to
fans. screen D.
q The hydraulic fans (2 units) can be reversed by
operating according to the guidance shown on
the screen.
q The user menu screen changes to screen A
shown below.
q While this screen is displayed, the fans are rotat-
ing in the normal direction. If F6 is pressed, the
fans are reversed and the screen changes to
screen B.
q To carry out the operation to return the hydrau-

lic fans to the normal direction, press F6, and
the screen changes to screen E.
q If F5 is pressed or no switch is operated for 5
seconds, the screen returns to screen C.
q While the fan rotation direction is being changed,

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

the screen shown below is displayed. After the
changing operation is finished and the hydraulic
fans rotate forward, the screen changes to the
normal screen automatically.
PC2000-8 79
q If the engine coolant temperature is above Idle stop guidance function

80°C and the hydraulic oil temperature is This function displays guidance to control unneces-
below 20°C or above 85°C, the screen shown sary fuel consumption. It is displayed only when all
below is displayed. In this case, the hydraulic the following conditions are met.
fans cannot be reversed. q “Energy saving guidance display” of the ser-
q If F5 is pressed, the screen changes to the vice menu is specified to ON.
user screen. q No operation is made at least 5 min. and the
engine is running at idle.
q No error or caution (excluding low hydraulic oil
temperature) is occurring.
This screen switches to the normal screen if one of

the following conditions occurs.
q When the lever is operated
q When F5 is pressed
q When an error or caution occurs
When you switch to the normal screen by pressing
F5, this screen does not appear even if the engine
continues to run at idle. If the engine continues to
run at least 5 min. after operating the lever, this
screen appears again.
80 PC2000-8
Service meter check function 1 Display LCD check function 1

q If you continuously press auto-deceleration q Continuously pressing the buzzer cancel
switch (1) and buzzer cancel switch (2) at the switch (1) and F2 at the same time on the nor-
same time when setting the starting switch to mal screen causes the entire LCD to light in
the OFF position, the service meter will appear white. Release F2 and buzzer cancel switch in
on the screen in 3 to 5 sec. order.
q The liquid crystal display panel may have black
spots (which do not light up) or bright spots
(which stay on).
Products having 10 or less black or bright
spots conform the product specification; such
the condition is quite normal.
q When these switches are released, the LCD

goes out.
a Continuous operation of the machine monitor
may display blue bright spots on this screen; it
is quite normal.
q Pressing any function switch returns to the pre-

vious screen.
PC2000-8 81
User code/failure code display function 1 q If the telephone number has been set in the
q If there is any problem in machine operation, service menu, the screen shows the telephone
the user code and failure code are displayed symbol and telephone number simultaneously
on the monitor to advise the operator of the with the user code/failure code. (For informa-
steps to take. tion on how to input and set the telephone
q These codes appear on the normal screen. number, see “Special functions of machine
q On the normal screen, user code (1) and fail- monitor” in the Testing and adjusting section.)
ure code (2) are displayed on the portion for
the hydraulic oil temperature gauge.
q If multiple user codes or failure codes are issued,

they are displayed alternately every 2 sec. The
drawing below shows the case two types of user
codes and failure codes are displayed.
82 PC2000-8
Sensor 1
q The signals from the sensors are input to the engine controller, pump controller, machine monitor, and
VHMS controller.
q The contact type sensors are always connected at one end to the chassis GND.
Name of sensor Type of sensor When normal When abnormal Input controller
Fuel level Resistance — — Monitor
Coolant level Contact ON (closed) OFF (open) Monitor
Air cleaner clogging Contact OFF (open) ON (closed) Monitor
Engine oil level Contact ON (closed) OFF (open) Monitor
Fuel level (low, mid, high) Contact — — Pump controller 1
Main pump pressure
Analog — — Pump controller 1
Fan pump pressure
Jet sensor differential pressure Analog — — Pump controller 1
Hydraulic oil temperature Resistance — — Pump controller 2
Travel PPC pressure switch Contact — — Pump controller 2
Work equipment PPC pressure sensor Analog — — Pump controller 2
Auto-greasing pressure Analog — — Pump controller 2
Hydraulic filter clogging Contact ON (open) OFF (closed) VHMS controller
Hydraulic oil level Contact ON (closed) OFF (open) VHMS controller
VHMS hydraulic oil temperature Resistance — — VHMS controller
PTO oil temperature Resistance — — VHMS controller
Ambient temperature Resistance — — VHMS controller
Blowby temperature Resistance — — VHMS controller
Exhaust temperature Analog — — VHMS controller
Exhaust temperature sensor AMP Analog — — VHMS controller
Coolant level sensor
1. Reservoir tank 2. sensor 3. Connector
PC2000-8 83
Detail of sensor
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
Fuel level sensor
1. Float
2. Switch
3. Connector
4. Variable resistor
84 PC2000-8
Air cleaner clogging sensor
Engine oil level sensor
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
Fuel level (low, mid, high) sensor
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
PC2000-8 85
Main pump oil pressure sensor
1. Sensor
2. Connector
Operation
q The oil pressure applied from the pressure q Relationship between pressure (P) and output
intake part presses the diaphragm of the oil voltage (E) is as follows.
pressure sensor, the diaphragm is deformed.
q The gauge layer facing the diaphragm mea-
sures the deformation of the diaphragm by the
change of its resistance, then converts the
change of the resistance into a voltage and
transmits it to the amplifier (voltage amplifier).
86 PC2000-8
Hydraulic oil temperature sensor, PTO oil temperature sensor
1. Thermistor 3. Wire 5. Tube

2. Tube 4. Body 6. Connector
Grease pump discharge pressure sensor
1. Sensor
2. Connector
Hydraulic filter clogging sensor
1. Block
2. Sensor
3. Wire
4. Connector
PC2000-8 87
Boom, arm, bucket, swing PPC oil pressure sensor
1. Sensor
2. Connector
Function q Relationship between pressure (P) and output

q The PPC oil pressure sensor is installed to 6 voltage (E) is as follows.
places of the junction block.
q This sensor senses the operating condition of
each actuator by the PPC pressure and sends
it to the pump controller.
Operation
q The oil pressure applied from the pressure
intake part presses the diaphragm of the oil
pressure sensor, the diaphragm is deformed.
q The gauge layer facing the diaphragm mea-
sures the deformation of the diaphragm by the
change of its resistance, then converts the
change of the resistance into a voltage and
transmits it to the amplifier (voltage amplifier).
88 PC2000-8
Hydraulic oil level sensor
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
VHMS hydraulic oil temperature sensor, Ambient temperature sensor
1. Thermistor 3. Wire 5. Tube

2. Tube 4. Body 6. Connector
PC2000-8 89
Engine blow-by pressure sensor
1. Sensor Specifications and function

2. Connector q Pressure range:
3. Ambient pressure intake tube 0 – 20 kPa {0 – 2,040 mmH2O}
q Pressure limit:
A: GND (Black) –20 – 100 kPa {–2,040 – 10,200 mmH2O}
B: Power source (Red) q Power supply voltage: 5 ± 0.25 V
C: Output (White) q Output characteristics: See graph.
q The blow-by pressure sensor is a relative pres-
sure sensor of low pressure type, which mea-
sures the difference between the pressure in
the crankcase and ambient pressure.
q The pressure in the crankcase is applied to the
end side of the sensor and the ambient pres-
sure is applied to the wiring harness side.
90 PC2000-8
Exhaust temperature sensor
Exhaust temperature sensor amplifier
Travel PPC pressure switch
PC2000-8 91
VHMS controller
92 PC2000-8
Location of pins
CN1 CN2
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
1 NC — A1 NC —
2 PWR_OUT_24V Output A2 AIS_PTO. OIL TMP. SENS Input
3 PWR_OUT_12V Output A3 NC —
4 NC — A4 AIS_ALTR_VOLT_VHMS Input
5 PWR_OUT_5V Output A5 AIS_EX. GAS. TMP. SENS. LBR Input
6 PWR_IN_BATT Input A6 AIS_EX. GAS. TMP. SENS. RBR Input
7 PWR_IN_BATT Input A7 AIS_EX. GAS. TMP. SENS. RBF Input
8 PWR_IN_BRY Input A8 NC —
9 PWR_IN_BRY Input A9 DIS_SEL0 (GND) Input
10 NC — A10 AIS_AIR. TMP. SENS Input
11 GND_PWR — A11 AIS_HYD_OIL_LOW_TMP. SENS Input
12 GND_PWR — A12 GND_SIG —
13 NC — A13 GND_SIG —
14 DOS_DUMP_COUNT_BUZZER Output A14 NC —
15 NC — A15 AIS_FUEL_REMAIN. SENS Input
16 NC — A16 AIS_EX. GAS. TMP. SENS. LBF Input
17 PWR_CTR_KEY Input A17 *DIS_WUL Input
18 NC — A18 AIS_BLOWBY. PRES. SENS Input
19 GND_PWR — B1 AIS_HYD_FILTER_CLOG. SENS Input
20 GND_PWR — B2 AIS_HYD_OIL_LEVEL. SENS Input
B3 NC —
B4 NC —
B5 NC —
B6 DIS_WUH (GND) Input
B7 NC —
B8 NC —
B9 GND_SIG —
B10 NC —
B11 NC —
B12 DIS_SEL1 (GND) Input
NC: Not connected
PC2000-8 93
CN3 CN4
A1 NC — A1 NC —
A2 DIS_CAB. OUT. DL. SW Input A2 NC —
A3 NC — A3 NC —
A4 NC — A4 COMM_CAN_H_1 (KOMNET) Input/Output
A5 DIS_ORB Input A5 NC —
A6 NC — A6 COMM_CAN_H_0 (MMS) Input/Output
A7 NC — A7 NC —
A8 NC — A8 NC —
A9 DIS_SEL2 (OPEN) Input A9 GND_COMM —
A10 Truck_COUNT_SW1 Input A10 COMM_232C_RXD_0 (PC Tool) Input
A11 Truck_COUNT_SW2 Input A11 COMM_232C_TXD_0 (PC Tool) Output
A12 NC — A12 COMM_CAN_L_1 (KOMNET) Input/Output
A13 GND_SIG — A13 NC —
A14 NC — A14 COMM_CAN_L_0 (MMS) Input/Output
A15 NC — B1 NC —
A16 NC — B2 NC —
A17 GND_SIG — B3 GND_COMM (Orbcomm) —
A18 NC — B4 COMM_232C_TXD_1 (Orbcomm) Output
B1 NC — B5 NC —
B2 NC — B6 NC —
B3 NC — B7 NC —
B4 NC — B8 NC —
B5 NC — B9 GND_COMM (Orbcomm) —
B6 NC — B10 COMM_232C_RXD_1 (Orbcomm) Input
B7 NC —
B8 NC —
NC: Not connected
B9 GND_SIG —
B10 NC —
B11 NC —
B12 DIS_SEL3 (OPEN) Input
94 PC2000-8
ORBCOMM terminal 1
1. Communication antenna connection

2. DRC connector (40-pole) connection
Outline
q The ORBCOMM terminal obtains various kinds of machine information recorded in the VHMS controller
and transmits them via the wireless communication antenna. It has a CPU (Central Processing Unit)
and wireless communication function.
q This terminal has an LED lamp and a 7-segment display lamp used for inspection and troubleshooting.
Input/Output signals
q DRC connector
1 NC Input 15 NC Output
4 Communication signal 232C_TxD Input 18 NC Output
5 Communication signal 232C_RxD Output 19 VHMS controller signal Output
6 NC — 20 NC Output
7 NC Input/Output 21 NC Input
9 NC — 23 NC Input
11 GND_232C — 25 NC Input
29 GND —
30 NC Output
31 NC Input
32 NC Input
33 NC Input
34 NC Input
35 NC Output
36 ACC input (analog) Input
37 Power supply GND —
38 Power supply GND —
39 Unswitched power supply (12/24 V) Input
40 Unswitched power supply (12/24 V) Input
PC2000-8 95
SEN01623-00
96
SEN02006-00
PC2000-8

PC2000-8 20001 and up
20 Standard value table 1

Standard service value table
Standard service value table ........................................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ............................................. 2
Standard service value table for chassis .............................................................................................. 3
PC2000-8 1
SEN02006-00 20 Standard value table
Standard service value table 1

Standard service value table for testing, adjusting, and
troubleshooting 1
Applicable model PC2000-8
Engine SAA12V140E-3
Category
Standard
Service limit
Item Measurement conditions Unit value for new
value
machine
Max. speed at no load rpm 1,980 ± 25 1,980 ± 25

Performance
Speed
Min. speed at no load rpm 825 ± 25 825 ± 25
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Air boost kPa Min. 125.70

At rated output —
pressure {mmHg} {Min. 950}
Air intake and exhaust system
Exhaust
Whole speed range (20°C ) °C Max. 700 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Blow-by At rated output kPa Max. 2.94 5.88

pressure Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {600}
At rated output SAE0W30E0S MPa 0.29 – 0.44 0.2
Lubrication system
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.06
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.6}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
a The above values are calculated when the engine is installed in the chassis.
2 PC2000-8
20 Standard value table SEN02006-00
Standard service value table for chassis 1

Category
Standard
Service limit
Item Measurement conditions Unit value for new
value
machine
• Engine coolant temperature:

Within operating range
• Hydraulic oil temperature: 45 – 55°C
All pumps at relief 1,780 ± 100 1,780 ± 100
• Engine at high idle
• Working mode: P
• Boom up relief
Engine speed
• Engine coolant temperature:

Within operating range rpm
Heavy lift ON
+ 1,780 ± 100 1,780 ± 100
All pumps at relief
• Working mode: P & heavy lift
• Boom up relief
Auto-deceleration
• Auto-deceleration switch ON 1,400 ± 100 1,400 ± 100
actuated
• All control levers at neutral
Boom Lo control valve • Engine stopped
Spool stroke of control valves
• Stroke (a) or (b) side

Boom Hi control valve
Arm Lo control valve
Arm Hi control valve
16 ± 0.5 16 ± 0.5
Bucket Lo control valve
Bucket Hi control valve
Swing control valve
Travel control valve
Boom control lever N o Raise, Lower mm 85 ± 10 85 ± 10
Arm control lever N o In, Out 85 ± 10 85 ± 10

Travel of control levers
• Center of lever knob

Bucket control lever • Read max. value to N o Curl, Dump 85 ± 10 85 ± 10
end of travel (Exclude
Swing control lever play at neutral.) N o R.H., L.H. 85 ± 10 85 ± 10
• Engine stopped
N o F, R
Travel control lever 115 ± 12 115 ± 12
(L.H., R.H.)
Work equipment,
Play of control levers Max. 10 Max. 15
swing, travel
PC2000-8 3

Category
Standard value Service limit

Item Measurement conditions Unit
for new machine value
15.7 ± 4.9 15.7 ± 4.9

Boom control lever
{1.6 ± 0.5} {1.6 ± 0.5}
Operating effort of control levers
• Hydraulic oil temperature: 45 – 55°C 15.7 ± 4.9 15.7 ± 4.9

Arm control lever
• Engine at high idle {1.6 ± 0.5} {1.6 ± 0.5}
• Center of lever knob 12.7 ± 3.9 12.7 ± 3.9
Bucket control lever • Measure max. value to end of travel {1.3 ± 0.4} {1.3 ± 0.4}
N {kg}
12.7 ± 3.9 12.7 ± 3.9
Swing control lever
{1.3 ± 0.4} {1.3 ± 0.4}
21.6 ± 5.4 21.6 ± 5.4
Lever
Travel control lever, {2.2 ± 0.6} {2.2 ± 0.6}
pedal 98.1 ± 25.4 98.1 ± 25.4
Pedal
{10 ± 2.5} {10 ± 2.5}
+1.0
29.4 ± 1.0 29.4
–2.0
Normal
{300 ± 10} +10
{300 }
RAISE
–20
+1.0
At heavy 32.1 ± 1.0 32.1
–2.0
Boom relief pressure lift {150 ± 20} +10
{327 –20
}
• Hydraulic oil tem-
perature: 45 – 55°C 14.7 ± 2.0 14.7 ± 2.0
Normal
LOWER
• Engine at high idle {150 ± 20} {150 ± 20}

• Working mode: P At machine 28.4 ± 2.0 28.4 ± 2.0
• Pump outlet push-up {290 ± 20} {290 ± 2.0}
pressure when
measured circuit is +1.0
29.4 ± 1.0 29.4
relieved –2.0
Arm relief pressure
{300 ± 10} +10
• Relieve either travel {300 –20
}
circuit.
Hydraulic pressure
+1.0
29.4 ± 1.0 29.4
–2.0
Bucket relief pressure Curl
MPa {300 ± 10} +10
{300 –20
}
{kg/cm2}
+1.0
29.4 ± 1.0 29.4
–2.0
Swing relief pressure
{300 ± 10} +10
{300 –20
}
+1.0
Relieve L. H. travel: L1/L2 (P1R/ P2R) 32.9/33.8 ± 1.0 32.9/33.8
–2.0
Travel relief pressure
Relieve R. H. travel: R1/R2 (P1F/ P2F) {335/345 ± 10} +10
{335/345 –20
}
• Hydraulic oil temperature: +0.49 +0.49

3.24 3.24
–0 –0.20
Control pressure 45 – 55°C
+5 +5
• Engine at high idle {33 0 } {33 –2 }
All control
Max. 0.59 Max. 0.59
• Hydraulic oil tem- levers at neu-
Pump EPC solenoid {Max. 6} {Max. 6}
perature: 45 – 55°C tral
valve output
• Engine at high idle Travel under no
pressure 1.11/2.04 ± 0.39 1.11/2.04 ± 0.39
• Working mode: P load (Lever full)
{11.3/20.8 ± 4.0} {11.3/20.8 ± 4.0}
(P1/P2)
4 PC2000-8

Category

All control
Min. 1.28 Min. 1.28
• Hydraulic oil tem- levers at neu-
{Min. 13.1} {Min. 13.1}
Jet sensor differential perature: 45 – 55°C tral
pressure • Engine at high idle
Hydraulic pressure
• Working mode: P Travel under no Max. 0.17 Max. 0.17

load (Lever full) {Max. 1.7} {Max. 1.7}
MPa
• Hydraulic oil temperature: 45 – 55°C {kg/cm2} +0.8 +0.8
PPC valve output 2.9 2.9
–0.2 –0.2
pressure +8 +8
• Control lever at stroke end {30 –2 } {30 –2 }

Max. 2.0 Max. 2.9
Oil pressure drop • Difference between relief pressure at
{Max. 20} {Max. 30}
high idle and that at low idle
All control
levers at neu- Min. 2.77 Min. 2.77
Output voltage of dif- tral
perature: 45 – 55°C
ferential pressure V
• Engine: High idle
sensor Travel under no
Electronic control
• Working mode: P
load Max. 1.40 Max. 1.40
(Lever full)
All control
levers at neu- 220 ± 60 220 ± 60
tral
perature: 45 – 55°C
Pump EPC current mA
• Engine: High idle
Travel under no
• Working mode: P
load 450/675 ± 60 450/675 ± 60
(Lever full)
Swing
Overrun when stop- deg. Max. 62 Max. 80

ping swing • Hydraulic oil temperature: 45 – 55°C (mm) (Max. 1,593) (Max. 2,056)
• Bucket: No load
• Working mode: P
• Stop after swinging one turn and mea-
sure distance that swing circle moves
PC2000-8 5

Category

90° 5.7 ± 0.6 Max. 6.8
Time taken to start • Hydraulic oil temperature: sec.

swing 45 – 55°C
• Bucket: No load
180° 9.0 ± 0.9 Max. 10.8
• Working mode: P
• Time taken to swing 90° and
180° from starting position
Time taken to swing sec. 57.5 – 67.5 Max. 70

• Bucket: No load
Swing
• Working mode: P
• Swing one turn, then measure time
taken to swing next 5 turns
Hydraulic drift of
• Hydraulic oil temperature: 45 – 55°C mm 0 0
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
• Swing lock switch: ON l/min Max. 5 Max. 10
motor
• Leakage in 1 minute during swing
relief
6 PC2000-8

Category

Travel speed
sec. 90.5 – 110.5 90.5 – 110.5
(Idle travel)
• 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.
Travel speed
sec. 24.2 – 29.6 24.2 – 29.6
(Actual travel) • Hydraulic oil temperature: 45 – 55°C
• Working mode: P
Travel
• On level ground
• Run up for at least 10 m, and mea-
sure time taken to travel next 20 m on
flat ground.

• Working mode: P
Travel deviation mm Max. 200 Max. 220
• Travel speed: Lo
• On hard and level ground
• Measure travel deviation (x) in travel
of 20 m after running up 10 m.
PC2000-8 7

Category

Hydraulic drift of travel mm 0 0

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

at uphill end of machine.
• Measure the distance the machine
moves in 5 minutes.
Leakage of travel
• Travel: Lock sprocket. l/min Max. 25 Max. 30
motor
• Measure leakage in 1 minute during
travel relief.
Total work equip-

ment
Max. 1,200 Max. 1,800
(hydraulic drift at
(Max. 650) (Max. 1,000)
tip of bucket
teeth)
• Measure extraction or retraction distance

Hydraulic drift of work equipment
of each cylinder and lowering distance of

Boom cylinder
bucket tooth tip from above posture. Max. 60 Max. 90
(amount of retrac-
Rated load on work equipment (Max. 35) (Max. 50)
tion of cylinder)
Work equipment
Backhoe specification: 21,600 kg

• Measure on level and flat ground.
• Set lever in neutral.
mm
• Stop engine.
Arm cylinder • Measure just after setting.
Max. 165 Max. 250
(amount of exten- • Measure lowering distance every 5 min-
utes. Judge by lowering distance in 15 (Max. 70) (Max. 105)
sion of cylinder)
minutes.
• Values in ( ) are standard values when
no load is applied to work equipment.
Bucket cylinder
Max. 50 Max. 75
(amount of retrac-
(Max. 15) (Max. 25)
tion of cylinder)
8 PC2000-8

Category
Standard value for

Item Measurement conditions Unit Service limit value
new machine
Backhoe Backhoe
specification specification
*RAISE
Boom
Lower bucket 7.5 ± 0.8 Max. 9.0
tooth to ground.
• Run engine at full throttle.

Extract cylinder to • Set in mode P
stroke end.
LOWER
• Hydraulic oil temperature:
45 – 55°C 5.3 ± 0.5 Max. 6.4
Work equipment speed
7.5 ± 0.8 Max. 9.0

IN
Work equipment
Arm
Retract cylinder to
stroke end. sec.
Extract cylinder to
stroke end. • Run engine at full throttle.
*OUT
• Set in mode P 5.2 ± 0.5 Max. 6.2

45 – 55°C
*CURL
5.0 ± 0.5 Max. 6.0

Bucket
Retract cylinder to
stroke end.
Extract cylinder to • Run engine at full throttle.

DUMP
stroke end. • Set in mode P 3.9 ± 0.4 Max. 4.7

45 – 55°C
PC2000-8 9

Category
Standard value for

new machine
Boom Max. 6 Max. 6
• Time required to raise chassis

after bucket reaches ground
• Run engine at slow speed.
45 – 55°
Time lag
sec.
Work equipment
Arm Max. 5 Max. 5
• Time from stop of arm to start.

45 – 55°C
Bucket Max. 4 Max. 4
• Time from stop of bucket to

start.
45 – 55°C
Oil leakage
Cylinders • Hydraulic oil temperature: Max. 5 Max. 20

45 – 55°C
cc/min
Center swivel • Hydraulic oil pressure:
29.4 ± 1.0 MPa {300 ±10 kg/cm2} Max. 10 Max. 100
joint
45 – 55°C STD: 840 ± 50 STD: 840 ± 50
Fan speed rpm
• Engine: High idle +55°C spec.: 1,100 ± 50 +55°C spec.: 1,100 ± 50
• Fan 100% speed mode
Fan (Radiator)
• Hydraulic oil temperature: STD: 1.69 ± 0.39 STD: 1.69 ± 0.39

Output pressure of fan
45 – 55°C MPa {17.2 ± 4.0} {17.2 ± 4.0}
pump EPC solenoid
• Engine: High idle {kg/cm2} +55°C spec.: 1.32 ± 0.39 +55°C spec.: 1.32 ± 0.39
valve
• Fan 100% speed mode {13.5 ± 4.0} {13.5 ± 4.0}
Fan pump EPC cur- 45 – 55°C STD: 625 ± 50 STD: 625 ± 50
mA
rent • Engine: High idle +55°C spec.: 555 ± 50 +55°C spec.: 555 ± 50
10 PC2000-8

Category
Standard value for

new machine

45 – 55°C STD: 760 ± 50 STD: 760 ± 50
Fan speed rpm
• Engine: High idle +55°C spec.: 1,100 ± 50 +55°C spec.: 1,100 ± 50
Fan (Oil cooler)
• Hydraulic oil temperature: STD: 1.81 ± 0.39 STD: 1.81 ± 0.39

Output pressure of fan
45 – 55°C MPa {18.5 ± 4.0} {18.5 ± 4.0}
pump EPC solenoid
• Engine: High idle {kg/cm2} +55°C spec.: 1.32 ± 0.39 +55°C spec.: 1.32 ± 0.39
valve
• Fan 100% speed mode {13.5 ± 4.0} {13.5 ± 4.0}
Fan pump EPC cur- 45 – 55°C STD: 650 ± 50 STD: 650 ± 50
mA
rent • Engine: High idle +55°C spec.: 555 ± 50 +55°C spec.: 555 ± 50
Pmup performance
Delivery ammount of
• See next page l/min See next page
hydraulic pump
PC2000-8 11
Category
Delivery amount of one hydraulic pump (P1 Pump, per one pump)
PC2000 No. 1 PUMP IQ standards at 100 kg/cm2
Upper limit standard (ref.)

Lower limit standard
Performance of hydraulic pump
• Pump speed: At 1,729 rpm

• Pump discharge pressure: 9.8 MPa {100 kg/cm2}
Standard value Judgement

Test pump
Check point for delivery amount Q standard lower limit Q
Test pump EPC current (mA)
(l/min) (l/min)
As desired I See graph See graph
12 PC2000-8
Category
Delivery amount of one hydraulic pump (P2 Pump, per one pump)
PC2000 No. 2 PUMP IQ standards at 100 kg/cm2
Upper limit standard (ref.)

Lower limit standard
Performance of hydraulic pump
• Pump speed: At 1,423 rpm

• Pump discharge pressure: 9.8 MPa {100 kg/cm2}
Standard value Judgement

Test pump
Check point for delivery amount Q standard lower limit Q
Test pump EPC current (mA)
(l/min) (l/min)
As desired I See graph See graph
PC2000-8 13
SEN02007-00
PC2000-8

PC2000-8 20001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Testing and adjusting, Part 1........................................................................................................................... 3
Tools for testing, adjusting, and troubleshooting .................................................................................. 3
Measuring engine speed...................................................................................................................... 6
Testing air boost pressure .................................................................................................................... 7
Testing exhaust temperature................................................................................................................ 8
Testing exhaust color ........................................................................................................................... 9
Adjusting valve clearance ...................................................................................................................11
Testing compression pressure ........................................................................................................... 13
Testing blow-by pressure ................................................................................................................... 15
Measuring blow-by pressure .............................................................................................................. 16
Testing engine oil pressure ................................................................................................................ 17
Handling fuel system parts ................................................................................................................. 18
Releasing residual pressure in fuel system........................................................................................ 18
Testing fuel pressure .......................................................................................................................... 19
Testing leakage from pressure limiter and return rate from injector ................................................... 20
Bleeding air from fuel circuit............................................................................................................... 23
PC2000-8 1
SEN02007-00 30 Testing and adjusting
Testing fuel system for leakage .......................................................................................................... 27

Testing and adjusting air conditioner compressor belt tension........................................................... 29
2 PC2000-8
30 Testing and adjusting SEN02007-00
Testing and adjusting, Part 1 1

Tools for testing, adjusting, and troubleshooting 1
symbol
Testing and adjusting
Q’ty
Part No. Part name Remarks
item
Measuring intake air

pressure (boost pres- A 799-201-2202 Boost gauge kit 1 –101 to 200 kPa {–760 to 1,500 mmHg}
sure)
Measuring exhaust 1 799-101-1502 Digital thermometer 1

B –99.9 to 1,299ºC
temperature 2 799-201-1150 Adapter connector 1
Measuring exhaust gas 1 799-201-9001 Handy smoke checker 1 Bosch index: 0 to 9 (With standard color)
J
color 2 Purchased Smoke meter 1
Adjusting valve clear-
C Purchased Clearance gauge 1 (Intake: 0.35 mm, Exhaust: 0.57 mm)
ance
1 795-502-1590 Compression gauge 1 0 to 6.9 MPa {0 to 70 kg/cm2}
Measuring compres-
D 795-471-1310 Adapter 1 For 140E-3, 5 engine
sion pressure 2
6261-71-6150 Gasket 1 For 140E-3, 5 engine
1 799-201-1590 Gauge 1 0 – 10 kPa {0 – 1,000 mmH2O}
Measuring blow-by 2 799-201-1450 Adapter 2

E
pressure 3 799-201-1511 Nozzle 2
4 799-201-1571 Tube 1
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil
F
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Testing fuel pressure G 2 795-471-1450 Adapter 1 8 x 1.25 mm (male) o R1/8 (female)

799-101-5220 Nipple 1
3 Size: 10 × 1.25 mm
07002-11023 O-ring 1
4 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 6151-51-8490 Spacer 1 Ø 14
2 6141-71-1710 Joint 1 Ø 10
3 Purchased Hose 1 Inside diameter: approx. 11 mm
Testing fuel return rate
of injector and leakage H 4 Purchased Hose 1 Inside diameter: approx. 17 mm
of pressure limiter
5 Purchased Measuring cylinder 1
6 Purchased Stopwatch 1
7 07376-70315 Plug 1 Size: 03
Measuring clearance of Dial gauge (with mag-
K Purchased 1 With magnet
swing circle bearing net)
Gas filling in HIC circuit Charge valve assem-
M 792-610-1700 1
accumulator bly
PC2000-8 3
symbol
Q’ty
item

1 {25, 60, 400, 600 kg/cm2}
control circuit oil pres- P 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
sure 799-101-5220 Nipple 1 Size: 10 × 1.25 mm
2
07002-11023 O-ring 1
1 {25, 60, 400, 600 kg/cm2}
control signal of Q 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
piston pump 799-101-5220 Nipple 2 Size: 10 × 1.25 mm
2
07002-11023 O-ring 2
Measuring fan speed R 799-203-8001 Multiple tachometer 1 L: 60 – 2000 rpm, H:60 – 19,999 rpm
1 {25, 60, 400, 600 kg/cm2}
Measuring fan pump
EPC solenoid output S 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
pressure 799-101-5220 Nipple 1 Size: 10 x 1.5 mm
2
07002-11023 O-ring 1
1 {25, 60, 400, 600 kg/cm2}
Measuring PPC valve 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
output pressure, sole- 799-401-3200 Adapter 1 Size: 03
T
noid valve outlet pres- 2
sure 02896-11009 O-ring 1
799-401-3300 Adapter assembly 1
3
02896-11012 O-ring 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Measuring outlet pres- 799-401-3200 Adapter 1 Size: 03
sure of solenoid valve, 2
swing PPC shuttle U 02896-11009 O-ring 1
valve, and swing prior- 799-401-3300 Adapter 1 Size: 04
ity selector valve 3
02896-11012 O-ring 1
799-101-5220 Nipple 2 Size: 10 × 1.25 mm
4
07002-11023 O-ring 2
799-608-3211 Diskette 1
VHMS controller initial 1
799-608-3220 Wiring harness 1
setting and replace- W
ment time setting Windows 98/2000/Me/XP,
2 Purchased Note type PC 1
with RS232C terminal
Measuring coolant tem-
perature and oil tem- X 799-101-1502 Digital thermometer 1 –99.9 to 1,299 ºC
perature
4 PC2000-8
symbol
Q’ty
item
Measuring operating 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}

effort and pressing Y
force 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
Measuring stroke and

Z Purchased Scale 1
hydraulic drift
Measuring work equip-
AA Purchased Stopwatch 1
ment speed
Measuring voltage and
AB Purchased Tester 1
resistance
799-601-7400 T-adapter assembly 1 SWP, X, M connector
799-601-7500 T-adapter assembly 1 AMP070 connector
799-601-9000 T-adapter assembly 1 DT, HD30 connector
799-601-9300 T-adapter assembly 1 DRC26 – 24, 40 pin
799-601-7360 Adapter 1 Relay (5 pins)
799-601-9420 T-adapter 1 Pressure sensor
799-601-3450 Adapter 1 VHMS download harness
799-601-4100 T-adapter assembly 1 Engine-related connectors
795-799-5530 Adapter 1 Engine coolant, oil, fuel temperature
795-799-5540 Adapter 1 Boost temperature sensor
Troubleshooting of sen-
sors and wiring har- — 799-601-4130 T-adapter 1 Ne sensor
ness
799-601-4150 T-adapter 1 Oil pressure sensor
799-601-4211 T-adapter 1 Controller (50 poles)
799-601-4240 Socket 1 Ambient pressure sensor
799-601-4250 Socket 1 Boost pressure sensor
799-601-9020 T-adapter 1 Injector
799-601-9420 T-adapter 1 Common rail pressure sensor
799-601-9430 Adapter 1 Supply pump PCV
799-601-9030 T-adapter 1 G sensor
PC2000-8 5
Measuring engine speed 1 4. Measuring all-pump relief speed

1) Start the engine and set the fuel control
dial in the high idle position (MAX).
a Measure the engine speed under the following 2) Set the working mode switch in the P-mode
condition. position.
q Engine coolant temperature: Within oper- 3) Turn the heavy lift switch OFF.
ating range 4) Relieve the boom circuit by raising the
q Hydraulic oil temperature: 45 – 55°C boom and measure the engine speed.
1. Preparation work 5. Measuring heavy-lift ON + all-pump relief

Turn the starting switch ON and set the speed
machine monitor to “Monitoring”. 1) Start the engine and set the fuel control
a For the operating method, see “Special dial in the high idle position (MAX).
functions of machine monitor”. 2) Set the working mode switch in the P-
a Monitoring code: 01002 Engine speed mode position.
01006 Engine speed 3) Turn the heavy lift switch ON.
a Code 01002 is information of the engine 4) Relieve the boom circuit by raising the
controller and code 01006 is information boom and measure the engine speed.
of the pump controller. The engine speed
can be measured with either of those 6. Measuring auto-deceleration ON speed
codes. 1) Start the engine and set the fuel control
a The engine speed is displayed in rpm. dial in the high idle position (MAX).
2) Turn the auto-deceleration switch ON.
3) Set the work equipment control, swing
control, and travel control levers in neutral.
When the auto-decelerator operates,
measure the engine speed.
a The engine speed lowers to a certain
level about 5 seconds after all the
levers are set in neutral. This level is
the auto-deceleration speed.
2. Measuring low idle speed

dial in the low idle position (MIN).
2) Set the work equipment control, swing con-
trol, and travel levers in neutral and measure
the engine speed.
3. Measuring high idle speed

dial in the high idle position (MAX).
2) Set the working mode switch to the P-mode
position.
3) Turn the auto-decelerator switch OFF.
6 PC2000-8
Testing air boost pressure 1
a Testing tools for air boost pressure

Symbol Part No. Part name
799-201-2202 Boost gauge kit
A
790-401-2220 Hose
k Be careful not to touch any hot part when

removing or installing the testing tools.
1. Remove air boost pressure pickup plug ((L1)

on left bank or (R1) on right bank) from the bot-
tom of the air intake connector.
a Example of the left bank
2. Install nipple [1] of boost gauge kit A and con-

nect it to gauge [2].
3. Run the engine at the rated output and test the

air boost pressure. (P mode and relieve boom-
raise)
4. After finishing testing, remove the testing tools

and return the removed parts.
PC2000-8 7
Testing exhaust temperature 1 2. Points for testing of the maximum temperature

in troubleshooting.
Test the maximum exhaust temperature when
a Testing tool for exhaust temperature
work is conducted.
Symbol Part No. Part name a Use a digital thermometer with PEAK
1 799-101-1502 Digital thermometer mode.
B
2 799-201-1150 Adapter connector
3. Points for periodical testing in preventive main-
k Remove and install the testing tools after tenance service (Pm clinic).
the exhaust manifold temperature has low- 1) Start the engine and set the work mode
ered. switch to the P mode.
a Subject section for measuring includes front 2) Turn ON the heavy-lift switch.
left, rear left, front right and rear right (4 points 3) Test exhaust temperature when the
in total). engine is at high idle and the boom raise
is relieved.
1. Connect adapter connector B2 to exhaust tem-
perature sensor (1) connector and then con-
nect digital thermometer B1.
a Installation example to the front left-hand
side (LF)

8 PC2000-8
Testing exhaust color 1 2. Measuring with Smoke Meter J2

1) Insert probe [1] of Smoke Meter J2 into
the outlet port of the exhaust pipe, and
a Tools for measuring exhaust color tighten the clip to secure it to the exhaust
Symbol Part No. Part name pipe.
1 799-201-9001 Handy Smoke Checker
J Commercially
2 Smoke Meter
available
k Be careful not to touch any hot parts when

removing or installing the testing tools.
a When measuring in the field where there is no
air or electric power supply, use Handy Smoke
Checker J1; when recording formal data, use
Smoke Meter J2.
a Measure the exhaust color under the following
conditions.
q Coolant temperature: Within operating range
1. Measuring with Handy Smoke Checker J1 2) Connect the air hose and the socket of the
1) Install filter paper to Handy Smoke Checker prove hose and accelerator switch to
J1. Smoke Meter J2.
2) Insert the exhaust gas suction port into the a Keep the pressure of the air supply
exhaust pipe. below 1.5 MPa {15 kg/cm2}.
3) Start the engine. 3) Connect the power cord to the AC100V
4) Accelerate the engine suddenly or run at socket.
high idle, and operate the handle of Handy a Before connecting the cord, check
Smoke Checker J1 at the same time to that the power switch of the Smoke
collect the exhaust gas on the filter paper. Meter is OFF.
4) Loosen the cap nut of the suction pump
and fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas cannot leak.
5) Turn the power switch of Smoke Meter J2
ON.
5) Remove the filter paper and compare it with

the scale supplied to judge the condition.
6) After completing the measurement, remove
the measuring equipment and set to the
original condition.
PC2000-8 9
6) Start the engine.

7) Accelerate the engine suddenly or run at
high idle, and depress the accelerator
pedal of Smoke Meter J2 at the same time
to collect the exhaust gas color on the fil-
ter.
8) Place the filter paper used to catch the
exhaust gas color on top of at least 10
sheets of unused filter paper inside the fil-
ter paper holder, and read the value
shown.
9) After completing the measurement, remove
the measuring equipment and set to the
original condition.
10 PC2000-8
Adjusting valve clearance 1 5. Hereafter crank the engine similar way in the
firing order. Match the stamped line of the
damper to the pointer and adjust the valve
a Adjusting tool for valve clearance clearance of each cylinder.
Symbol Part No. Part name a Firing order
R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 –
Commercially
C Clearance gauge R2 – L2 – R4 – L4
available
Valve clearance adjusting method

1. Remove cylinder head cover.
2. Rotate the crankshaft forward and match

stamped line of R1.6 TOP on vibration damper
(1) to pointer (2), by setting RH No. 1 cylinder
to the compression top dead center while
watching the movement of the intake valve of
RH No. 6 cylinder.
a Crank the engine using the barring tool (B)
mounted to the front right-hand side of the
flywheel housing.
a At near the compression top dead center
of the RH No. 1 cylinder, the intake valve
of RH No. 6 cylinder moves (opens).
q The radiation on the left side of the
drawing.
3. Loosen locknut (6) of RH No. 1 cylinder adjust

screw (5). Insert a clearance gauge C of speci-
fied clearance between the crosshead (4) and
rocker arm (3) and adjust the adjustment
screw to the degree that the clearance gauge
can be moved lightly.
a Valve clearance
Air Intake valve: 0.35 mm, Exhaust valve:
0.57 mm
4. Tighten locknut (6) to secure adjustment

screw.
3 Locknut:
52.9 – 64.7 Nm {5.4 – 6.6 kgm}
a After tightening the locknut, check the
valve clearance again.
PC2000-8 11
6. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
14.7 – 34.3 Nm {1.5 – 3.5 kgm}
12 PC2000-8
Testing compression pressure 1
a Testing tools for compression pressure

1 795-502-1590 Compression gauge
D 795-471-1310 Adapter
2
6261-71-6150 Gasket
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the
engine is warmed up. 4. Install adapter D2 to the mounting hole on the
(Engine oil temperature: 40 – 60°C). injector and compression gauge D1.
a Fit the gasket to the injector end without
1. Remove cylinder head cover (1) of the cylinder fail.
to be tested for compression pressure. a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
5. Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm assembly mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a See “Adjusting valve clearance”.
2. Bring the cylinder to be tested to the compres-

sion top dead center and remove rocker arm
assembly (2).
a See “Adjusting valve clearance”.
3. Disconnect fuel high-pressure tube (3) and

injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector wir-
ing harness on the injector side and the
bracket on the rocker housing side and
r e mo v e t he i n j ec to r w i r i ng h a r n es s
(Loosen the 2 terminal nuts alternately) 6. Set the engine in the no-injection cranking
from the injector. mode. For details, see “No-injection cranking”
a Pass injector under the fuel path projected in the Special function of machine monitor.
sideways and pull up the injector through k If the engine is not set in the no-injec-
wire (Do not pry the injector top up). tion cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
PC2000-8 13
7. Rotate the engine with the starting motor and a Install the injector wiring harness accord-
measure the compression pressure. ing to the following procedure.
a Read the pressure gauge pointer when it 1) Install the injector wiring harness to the
is stabilized. cylinder head and fix the connector side
with the plate. Install O-ring (16).
8. After finishing testing, remove the testing tools 2) Install cap (17) with clip on the injector
and return the removed parts. side of wiring harness.
a Install the injector and fuel high-pressure Press wiring harness (18) between the
tube according to the following procedure. injector top and cap to the injector main
1) Push in injector (11) with the hand to body without slack.
assemble holder (12) temporarily. 3) Tighten nut (19) on the injector side.
2) Tighten bolt (13) and washer (14) tempo- 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
rarily.
2 Spherical part of washer:
Engine oil
3) Tighten sleeve nut (15) of the fuel high-
pressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}
4) Tighten the clamp and spacer with the

bolt.
5) Install rocker arm assembly.
3 Rocker arm assembly mounting
bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust the valve clearance. For details,
see “Adjusting valve clearance”.
6) Install head cover.
3 Cylinder head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
14 PC2000-8
Testing blow-by pressure 1 3. Run the engine at the rated output (P mode
and relieve the boom raise) and test the blow-
by pressure.
a Testing tool for blow-by pressure
Symbol Part No. Part name Q'ty
1 799-201-1590 Gauge 1
2 799-201-1450 Adapter 2
E
3 799-201-1511 Nozzle 2
4 799-201-1571 Tube 1
a Measure blow-by pressure after the engine is

warmed up.
(Engine coolant temperature: Min. 70°C)
a Breather is provided to each RH and LH
banks. Test the breather on either one of the
banks.
1. Install adapter [2] and nozzle [3] to the tip of 4. After finishing testing, remove the testing tools
each breather hose on the RH and LH. and return the removed parts.
2. Connect tube [4] and gauge [1] to either one of

the nozzles. Close the tube connecting mate of
other nozzle with a piece of short cut tube, etc.
PC2000-8 15
Measuring blow-by pressure 1
Measuring method of blow-by pressure

k When measuring blow-by pressure, care
should be taken not to burn yourself on the
exhaust manifold or muffler or caught in a
rotating part.
a Measure blow-by pressure after the engine is
warmed up.
(Engine coolant temperature: Min. 70°C)
a Breather is provided to each RH and LH
banks. Test the breather on either one of the
banks.
1. Install adapter and tool main body of blow-by

checker to the tip of breather tube on one of
the banks.
2. Install adapter, tool main body of blow-by

checker, hose and gauge to the tip of breather
tube on one of the banks.
3. Run the engine at rated output (P mode and

boom raise relief) and read the pressure indi-
cated on the gauge.
a If rated output or full-stroke operation is not

possible, measure the blow-by in high-idle
operation.
In this case, approx. 80% of blow-by pressure
of the rated output can be obtained.
a Since blow-by pressure varies sharply depend-
ing on engine condition, if measured value is
judged abnormal, investigate phenomena
associated with defective blow-by such as
large oil consumption, abnormal exhaust color,
oil degradation and earlier contamination, etc.
a When measuring on the LH bank, close the
hose on RH bank.
16 PC2000-8
Testing engine oil pressure 1 3. Run the engine at the rated output (P mode
and boom raise relief) and low idle and test the
oil pressure.
a Testing tools for oil pressure
799-101-5002 Hydraulic tester
1
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
1. Remove oil temperature sensor (1) on the LH

side of the cylinder block.
Keep the removed oil temperature sensor and
the wiring harness connector connected to
each other.
a Don't remove the oil pressure sensor from
the block because the engine controller
detects abnormal low pressure error of the 4. After finishing testing, remove the testing tools
oil pressure sensor. and return the removed parts.
2. Install nipples [1] and [2] of hydraulic tester F1

and connect them to hydraulic tester F2.
a Since the screw size of the sensor mount
is 14 x P1.5, nipple (799-101-5230) may
be used.
PC2000-8 17
Handling fuel system parts 1 Releasing residual pressure in

fuel system 1
a Precautions for testing and maintaining fuel
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. sticks a The pressure in both low-pressure circuit and
to any part, wash that part thoroughly with high-pressure circuit lowers to a safety level
clean fuel. automatically 30 seconds after the engine is
a Precautions for replacement of fuel filter car- stopped.
tridge a Before the fuel circuit is tested and its parts are
The fuel filter cartridge used must be a genuine removed, the residual pressure in the fuel cir-
Komatsu part. cuit must be released completely. Accordingly,
The fuel injection pump and nozzle of the com- observe the following.
mon rail type fuel injection system (CRI) are k Before testing the fuel system or removing
consisted of more precision parts than those its parts, wait at least 30 seconds after stop-
used for the current pumps and nozzles. This ping the engine until the residual pressure
system, therefore, employs a special filter with in the fuel circuit is released. (Do not start
highly efficient filtering performance to prevent the work just after stopping the engine
mixing of foreign substances. Thus, substitut- since there is residual pressure.)
ing it with a non-genuine filter could cause
troubles in the fuel system. It is strictly prohib-
ited to use such part.
18 PC2000-8
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a If the fuel pressure is in the following
a Testing tools for fuel pressure range, it is normal.
Symbol Part No. Part name Engine speed Fuel pressure
799-101-5002 Hydraulic tester 0.15 – 0.3 MPa
1 High idle
790-261-1204 Digital hydraulic tester {1.5 – 3 kg/cm2}
2 795-471-1450 Adapter
G
799-101-5220 Nipple
3
07002-11023 O-ring
4 799-401-2320 Gauge
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 cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove air bleeder plug (1) on the top of fuel

filter. 4. Since the fuel circuits on the LH and RH banks
after the priming pump are independent, test
each circuit.

2. Install adapter [G2] and connect to gauge [G4].
PC2000-8 19
Testing leakage from pressure limiter and return rate from injector 1
Type of engine having intake manifold equipped with return block
a If the engine is of a type that returns the fuel a Prepare an oil pan of about 20 l to receive the
spilling from the injector from the return block fuel flowing out during the test.
installed to the front of intake manifold, check
the engine according to the following. 1. Preparatory work (case of the LH bank)
a Testing tools for pressure limiter leakage and 1) Remove tube (4) between common rail (3)
injector return rate and supply pump (5).
2) Insert spacer H1 on supply pump (5) side
and tighten the removed joint bolt again.
1 6151-51-8490 Spacer 3) Connect the return piping to the fuel tank
2 6141-71-1710 Joint side again.
Commercially Hose (Inside diameter: a Make sure to install gaskets on both
3 ends of spacer.
available Approx. 11 mm)
Commercially Hose (Inside diameter:
4
H available Approx. 17 mm)
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
7 07376-70315 Plug
20 PC2000-8
a If the leakage from the pressure lim-

iter is in the following range, it is nor-
mal.
Engine speed Leakage
(rpm) (cc/min)
1,600 Max. 10
4) Insert joint H2 on common rail (3) side and

tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the joint.
5) Connect test hose H3 to the end of joint
H2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off. 5) After finishing testing, stop the engine.
a The above is the preparation work for
testing the leakage from the pressure
limiter. 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 injec-
tor.
1) Disconnect return hose (2) of return block
(1) and connect test hose H4.
a Apply plug H7 to the return hose side
to stop oil, and fix it to the fuel tank.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
2) Lay test hose H4 so that it will not slacken
and put its end in the oil pan.
2. Testing leakage from pressure limiter

1) Lay test hose H3 so that it will not slacken
and put its end in the oil pan.
2) Operate the machine monitor and set it so
that it can check the engine speed.
3) Start the engine and keep its speed to
1,600 rpm with no load.
4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
PC2000-8 21
3) Operate the machine monitor and set it so

that it can check the engine speed.
4) Run the engine at the rated output (With P
mode and boom raise relieved).
5) After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Limit of return rate (spill)
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
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.
5. Check the RH bank following the identical pro-

cedure.
22 PC2000-8
Bleeding air from fuel circuit 1 2) Set a container to receive oil under the
fuel prefilter cartridge.
3) Remove the drain hose (4) of cup (3) of
a If fuel is used up or if a fuel circuit part is the water separator.
removed and installed, bleed air from the fuel 4) Using the filter wrench, turn filter cartridge
circuit according to the following procedure. (2) to the left to remove.
5) Turn cup (3) of the water separator
Reference installed to the bottom of the removed car-
q The Komatsu genuine fuel filter cartridge tridge to the left to remove. (This cup will
employs a high-efficiency special filter. Always be reused.)
use it. 6) Install removed cup (3) to the new fuel
q The common rail fuel injection system used on prefilter cartridge. (At this time, be sure to
this machine consists of more precise parts use a new O-ring.)
than the conventional fuel injection pump and 3 Cup: 10 Nm {1.0 kgm}
nozzle. If a filter cartridge other than the
Komatsu genuine one is used, foreign matter
may enter the fuel system and may cause a
trouble in the system. Accordingly, never use a
substitute.
q When checking or servicing the fuel system,
take care of entry of foreign matter more than
ever. If dirt sticks, wash it off with fuel.
1. Replacing prefilter cartridge or bleeding air

from it
1) Pull fuel shut-off lever (1) installed to the
front of the main pump in the pump room
to close the fuel supply circuit from the fuel
tank.
PC2000-8 23
7) Clean the filter stand. Fill the new or 12) Press down fuel cut lever (1) installed to
reused filter cartridge with clean fuel, the front of the main pump in the pump
apply oil to the packing surfaces thinly, room to supply the fuel.
and install the cartridge to the filter stand.
a Add fuel through 8 small holes (a) on
the dirty side without removing cap
(b) at the center.
a After adding fuel, remove cap (b) at
the center and install the fuel filter.
a Fill the fuel filter with clean fuel and
take care that dirt will not enter it.
Since the center is the clean side, do
not remove cap (b) when adding fuel,
and particularly take care that dirt will
not enter it.
8) When installing the filter cartridge, tighten

it 3/4 turns after its packing surface
13) Start the engine and check the filter seal
touches the seal surface of the filter stand.
surface and water separator mounting
a If the filter cartridge is tightened too
surface for fuel leakage and then run the
much, fuel will leak because of dam-
engine at low idle for about 10 minutes.
age of the packing. If the filter car-
tridge is not tightened sufficiently, fuel
will also leak through the clearance of
the packing. Accordingly, observe the
tightening angle.
q When tightening the filter car-
tridge with the filter wrench, take
care extremely not to scratch or
dent the filter.
9) Install the drain hose.
10) Check that the drain plug at the cup bot-
tom of the water separator is tightened
securely.
3 Drain plug:
0.2 – 0.45 Nm {0.02 – 0.046 kgm}
11) When replacing the standard fuel filter car-
tridge (every 1,000 hours) or bleed air
from it, see “Replacing main filter car-
tridge”.
24 PC2000-8
2. Replacing main filter cartridge or bleeding

air from it
1) Replacing main filter cartridge
1] Pull fuel shut-off lever (1) installed to
the front of the main pump in the
pump room to close the fuel supply
circuit from the fuel tank.
a Do not add fuel to the fuel filter car-

tridge.
a Remove cap (b) at the center and
install the fuel filter.
5] When installing the filter cartridge,

tighten it 3/4 turns after its packing
2] Set a container to receive oil under surface touches the seal surface of
the filter cartridge. the filter stand.
3] Using the filter wrench, turn filter car- If the filter cartridge is tightened too
tridge (5) to the left to remove. much, fuel will leak because of dam-
4] Clean the filter stand. Thinly apply oil age of the packing. If the filter car-
to the packing of the new filter cartridge is not tightened sufficiently, fuel
tridge and install the cartridge to the will also leak through the clearance of
filter stand. the packing. Accordingly, observe the
tightening angle.
q When tightening the filter car-
tridge with the filter wrench, take
care extremely not to scratch or
dent the filter.
6] After replacing filter cartridge (5),
loosen its air bleeding plug (6) and
press down fuel shut-off lever (1) to
open the fuel supply circuit from the
fuel tank.
a Open the circuit in the reverse
order to closing.
PC2000-8 25
2) To bleed air when fuel is used up, perform 3) Bleed air according to the following proce-
the following air bleeding procedure taken dure.
after replacement of the main filter car- 1] Fill the fuel tank with fuel (to the FULL
tridge. mark of the fuel level gauge).
2] After replacing filter cartridge (5),
loosen air bleeding plug (6).
3] Remove locknut (8) of priming pump
lever (7), operate priming pump lever
(7), and check that fuel and bubbles
flow out of air bleeding plug (6).
4] Tighten air bleeding plug (6).
3 Plug:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
5] Push in priming pump lever (7) and
tighten locknut (8) to lock it.
6] After replacing the filter cartridge,
start the engine and check the filter
seal surface for fuel leakage.
26 PC2000-8
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
its parts, test it for fuel leakage according a If no fuel leakage is detected, check is
to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.

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

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

a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
PC2000-8 27
Testing and adjusting Adjustment

a Adjust the belt according to the following pro-
alternator belt tension cedure when the belt deflection is not normal.
Testing 1. Loosen nuts and bolts (1), (2), (3) and (4) in
1. Remove V belt cover (7) on the rear side of the this order.
engine.
2. Turn nut (5) to move alternator (6), and adjust
the belt tension.
a Nut (5):
q It is moved to the side that belt is
loosened when fastening it clockwise.
q It is moved to the side that belt is ten-
sioned when loosening it counter-
clockwise.
a Test for breakage of each pulley, friction of
V-ditch, friction of belt, and contact
between belt and V-ditch.
a Replace it with new belt if it was too
stretched so that adjustability was lost, or
cut and crack occurred.
2. Measure the belt deflection (a) when pushing a
point midway between the alternator pulley 3. Tighten nuts and bolts (4), (3), (2) and (1) in
and the drive pulley with the finger. this order.
a Deflection (a) when pressing force is a When the belt was replaced, readjust it
approx. 58.8 N {approx. 6 kg}: 10 – 15 mm after one-hour operation.
28 PC2000-8
Testing and adjusting air Adjustment procedure

conditioner compressor belt a Adjust the belt according to the following pro-
tension 1 cedure when the amount of belt deflection is
not normal.
Testing procedure 1. Loosen nuts and bolts (1), (2), (3) and (4) in
1. Dismount belt covers (7), (8) and (9). this order.
2. Turn nut (5) to move air conditioner compres-

sor (6), and adjust the belt tension.
a Nut (5):
q It is moved to the side that belt is
loosen when fastening it clockwise.
q It is moved to the side that belt is ten-
sioned when loosening it counter-
clockwise.
a Test for breakage of each pulley, friction of
V-ditch, friction of belt, and contact
between belt and V-ditch.
a Replace it with new belt if it was too
stretched so that adjustability was lost, or
cut and crack occurred.
3. Tighten nuts and bolts (4), (3), (2) and (1) in

this order.
2. Measure the belt deflection (a) when pushing a

point midway between the air conditioner com-
pressor pulley and the drive pulley with the fin-
ger.
a Press force at approx. 58.8 N {Approx. 6
kg}, (a): 6 mm
4. Mount the belt cover.
PC2000-8 29
SEN02008-00
PC2000-8

PC2000-8 20001 and up

Testing swing circle bearing clearance................................................................................................. 3
Remaining pressure relief from HIC circuit .......................................................................................... 4
Gas filling in HIC circuit accumulator ................................................................................................... 4
Bleeding air from HIC circuit and supplying oil to it.............................................................................. 6
Testing and adjusting track shoe tension ............................................................................................. 8
Bleeding air from pilot selector valve circuit ........................................................................................11
Testing and adjusting work equipment, swing and travel circuit oil pressures ................................... 12
Testing and adjusting control circuit oil pressure (output pressure of self pressure reducing valve) . 16
Testing and adjusting main pump control signal ................................................................................ 18
Measuring fan speed.......................................................................................................................... 21
Measuring fan pump EPC solenoid current ....................................................................................... 22
Measuring fan pump EPC solenoid valve output pressure ................................................................ 23
Oil pressure measuring points for pump discharge pressure or jet sensor differential pressure ....... 25
Measuring PPC valve output pressure............................................................................................... 26
Measuring solenoid valve outlet pressure.......................................................................................... 30
PC2000-8 1
Adjusting work equipment and swing PPC valve ............................................................................... 32

Testing and adjusting travel deviation ................................................................................................ 33
Testing work equipment hydraulic drift cause portion......................................................................... 35
Testing oil leakage.............................................................................................................................. 36
Remaining pressure relief from hydraulic circuit ................................................................................ 39
Air bleeding from each component..................................................................................................... 40
Testing and adjusting auto grease system ......................................................................................... 46
Adjusting mirrors ................................................................................................................................ 49
2 PC2000-8

Testing swing circle bearing 3. Set the dial gauge K to the zero point.
clearance 1
4. Arrange the arm almost at right angles to the
ground and lower the boom until the front leg
a Inspection device of swing circle bearing clear- of the machine body rises.
ance a At the time, the front of the upper structure
Symbol Part Number Part Name rises and its rear lowers.
Dial gauge
K Commercial item
(with magnet)
a When measuring swing circle bearing clear-

ance on a machine, follow the procedures
below:
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 undercar-
riage.
6. Return the work equipment to the state in

Paragraph 2 and make sure that the dial gauge
K has returned to the zero point. If not, repeat
Steps 3 to 5.
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.
PC2000-8 3
Remaining pressure relief from Gas filling in HIC circuit

HIC circuit 1 accumulator 1
a If the HIC equipment is to be removed or the a Device for filling gas in HIC circuit accumulator
piping are to be disconnected, release the
Symbol Part Number Part Name
release the remaining pressure from the HIC
circuit as follows. Charge valve
M 792-610-1700
k
assembly
Lower the work equipment completely to
the ground, stop the engine and use the
control lever several times to relieve pres- a If the gas was discharged from the HIC circuit
sure remaining in the pipe. Then, loosen accumulator or the accumulator was replaced,
the oil filler cap of the hydraulic tank gradu- charge the accumulator with gas according to
ally to relieve pressure in the tank. the following procedure.
1. Loosen stop valves (1) and (2) slowly and 1. Relieve pressure remaining in the HIC circuit.
relieve pressure remaining in the circuit. a Refer to the Paragraph of “Remaining
k Quick loosening will cause a high pres- pressure relief from HIC circuit” and leave
sure in the tank circuit, so be sure to 2 pieces of the stop valve loosened.
loosen the stop valves slowly.
a After 1 minute elapsed, the remaining gas 2. Attach the plug (1) to the accumulator.
will have been relieved completely.
3. Attach the valve kit [1] of the charge valve

assembly M to accumulator (2) and attach the
nipple [2] to nitrogen bomb (3). Then, connect
the valve kit [1] and the nipple [2] with the hose
[3].
a Before attaching the valve kit [1], turn the
valve [4] fully to the left and turn the valve
[5] to the left and keep it opened.
2. When the remaining pressure is relieved com-

pletely, retighten stop valves (1) and (2).
4 PC2000-8
4. Open the valve [7] of the nitrogen bomb (3)

slowly, keep the pressure to the pressure
gauge [6] at 0.2 – 0.3 MPa {2 – 3 kg/cm2} and
tighten the valve [5].
k Quick filling high pressure gas will
expand the plug suddenly and may
break it, so be sure to fill nitrogen gas
slowly.
5. Screw in the valve [4] until it touches some-

thing lightly.
6. Open the valve [7] further slowly and fill the

accumulator (4) with nitrogen gas.
a Close the valve [7] gradually until the
pressure gauge becomes stable, and then
read the value shown on the pressure
gauge.
7. After filling nitrogen gas to the specified pres-

sure, tighten the valve [7] firmly.
a Specified pressure :
13.2 ± 0.3 MPa {135 ± 3 kg/cm2}
(Atmospheric temperature: 20 ± 3°C)
a If more pressure than the specified one
was filled in, tighten the valve [7] and turn
the valve [4] slowly to the left to relieve the
gas gradually to the specified pressure.
8. Turn the valve [4] to the left until it stops, turn

the valve [5] to open it and discharge gas
remaining in the valve kit [1] and the hose [3].
9. Remove the valve kit [1] from accumulator (2)

and attach plug (3) to the valve kit.
10. After filling gas, bleed air from the HIC circuit
and fill pressurized oil in the circuit.
a Refer to the paragraph of “Bleeding air
from HIC circuit and supplying oil to it”.
PC2000-8 5
Bleeding air from HIC circuit and 3. Fully open stop valve (3) at the left inside of the
supplying oil to it 1 axle.
Before bleeding air from the HIC circuit and supply-

ing grease to the hydraulic grease supply cylinder,
be sure to bleed air.
1. Loosen plug (1) of the grease cylinder by 1

turn (2 places on the right and left).
2. Fully open stop valve (2) at the right inside of

the axle.
4. Loosen air bleeding plug (4) of the cushion cyl-

inder about 1 turn (2 places on the right and
left).
6 PC2000-8
5. Remove plug (6) under the block on the side of

the relief valve and loosen air bleeding plug (5)
about 1 turn.
8. Tighten plugs (1) (at 2 places on the right and

left).
9. Tighten plug (6).

3 Plug: 81.3 ± 6.9 Nm {8.3 ± 0.7 kgm}
a Be sure to tighten plug (1) last.
a Fully close the stop valves and air bleed-
ing plugs.
a After bleeding air, test and adjust the track
shoe tension. For details, see “Testing and
adjusting track shoe tension”.
6. Run the engine at low idle for 2 – 3 minutes.
7. When clear oil flows out of air bleeding plugs

(4) (at 2 places on the right and left) and the
hole for plug (6) under the block on the side of
the relief valve, fully tighten valves (2) and (3)
and plugs (4) and (5).
PC2000-8 7
Testing and adjusting track shoe Adjusting

tension 1 a If the track shoe tension is abnormal, adjust it
according to the following procedure.
Testing 1. Adjusting HIC cylinder

1. Run the engine at low idle and drive the 1) Check that stop valve (4) at the right
machine forward by the length of track on inside of the axle is fully closed.
ground, and then stop slowly.
2. Place steel bar (b) on the track shoe between

2nd carrier roller (1) and 3rd carrier roller (2).
3. Measure the maximum clearance between the

track shoe top and the steel bar.
q Maximum clearance (a): 10 – 30 mm
8 PC2000-8
2) Open stop valve (5) at the left inside of the

axle.
7) Fully close stop valve (1).
2. Adjusting grease cylinder
When tension is low

1) Add grease through plug (8).
2) To check that the tension is normal, move
the machine forward slowly.
3) Check the track shoe tension again. If it is
not proper, adjust it again.
3) Turn the fuel control dial to the medium

position and run the engine at medium
speed.
4) Operate the right travel lever in the for-
ward and reverse directions intermittently
(2 – 3 seconds) 5 – 6 times.
a Do not perform this operation on a
slippery place (steel plate etc.)
a Even if projection (a) of the hydraulic
cushion cylinder is normal, the
hydraulic cushion charge pressure
may be low. Accordingly, perform the
operation in 4) securely.
5) Check that projection (a) of the plunger of
hydraulic cushion cylinder (7) is 135 ± 5
mm on each side.
6) If projection (a) is not 135 ± 5 mm, perform
the operation in 4) again to set projection
(a) in the specified range.
If projection (a) cannot be set to 135 ± 5
mm, too much grease may be in grease
cylinder (6). In this case, discharge the
grease according to “2. Adjusting grease
cylinder”.
PC2000-8 9
4) You may adjust the track shoe tension by

adding grease until projection (b) of
grease cylinder (9) becomes 35 – 190
mm.
a If the tension is still low, the pins and
bushings may be worn much.
When tension is too high

1) Loosen plug (8) gradually to discharge
grease.
k Do not loosen the valve more than
1 turn. If it is loosened more, it may
jump out because of the high-pres-
sure grease in it.
k If the grease is not discharged
well, move the machine forward
and in reverse and then check the
track shoe tension.
2) Tighten plug (8).
3) To check that the tension is normal, move
the machine forward and in reverse.
4) Check the track shoe tension again. If it is
not proper, adjust it again.
10 PC2000-8
Bleeding air from pilot selector 2. While running the engine at low idle, move the
valve circuit 1 arm in and curl or dump the bucket simulta-
neously. When oil containing no bubbles flows
out of bleeder (1), tighten bleeder (1).
a If the pilot selector valve circuit was discon- 3 Bleeder: 8.8 – 9.8 Nm {0.9 – 1.0 kgm}
nected and connected, bleed air from it k Operate each lever slightly to a degree
according to the following procedure. that each oil pressure switch is turned
k If the air bleeding operation is not per- ON.
formed or all air is not bled, the work equip-
ment speed may decrease during 3. Turn swing lock switch ON.
compound operation. Therefore, be sure to
bleed air according to the specified proce- 4. While running the engine at low idle, raise the
dure. boom and swing the upper structure simulta-
neously. When oil containing no bubbles flows
1. Start the engine and loosen bleeders (1) and out of bleeder (2), tighten bleeder (2).
(2). 3 Bleeder: 8.8 – 9.8 Nm {0.9 – 1.0 kgm}
a Pilot selector valves PV1 and PV2 have 1 k Operate each lever slightly to a degree
bleeder each. that each oil pressure switch is turned
q Pilot selector valve PV1 ON.
BPP15696
q Pilot service valve PV2
PC2000-8 11
Testing and adjusting work 2) Measurement of relief oil pressure at the

equipment, swing and travel time of heavy lift operation
a
circuit oil pressures 1 i) Start the engine and turn on the
heavy lift switch.
Measurement ii) Measure the oil pressure when the
a Measure the work equipment, swing and travel boom cylinder is raised and is
circuit oil pressures under the following condi- relieved individually at the stroke end
tions: at high idle.
q Hydraulic oil temperature : 45 – 55ºC a The heavy lift function works only
when the boom is individually raised.
1. Preparatory work a The main relief valve of each control
Turn on the starting switch and display the valve is relieved on the high pressure
screen for measuring the work equipment, set side.
swing and travel circuit oil pressures on the 3) Measurement of relief oil pressure at the
machine monitor. time of machine push operation
a For the control method, refer to the para- i) Start the engine and turn on the
graph of “Special function of machine machine push-up switch.
monitor”. ii) Measure the oil pressure when the
a Screen display on the machine monitor boom cylinder is lowered and is
(Display unit : MPa, kg/cm2) relieved individually at the stroke end
q P1F system (Monitoring code: 01124) at high idle.
q P1R system (Monitoring code: 01125) a When the boom cylinder is lowered
q P2F system (Monitoring code: 01126) and relieved at the stroke end, the
q P2R system (Monitoring code: 01127) safety valve with suction on the boom
lower side of the control valves VL1
and VR2 is relieved (because the set
pressure is lower than that of the
main relief valve).
3. Measurement of swing oil pressure

1) Start the engine and turn on the swing lock
switch.
2) Measure the oil pressure when the swing
motor is relived at engine high idle.
a The safety valve of the swing motor is
relieved.
4. Measurement of travel oil pressure

1) Start the engine and place a pin or a block
2. Measurement of work equipment oil pres- between the sprocket and the track frame
sure or the track link to lock traveling.
1) Measurement of normal relief oil pressure k Make sure that travel is certainly
Start the engine and measure the oil pres- locked.
sure when each cylinder is relieved individ- 2) Measure the oil pressure when the travel
ually at the stroke end at high idle. motor is relieved at engine high idle.
a The main relief valve of each control a The main relief valve of each control
valve is relieved on the low pressure valve is relieved on the high pressure
set side. set side.
a When the boom cylinder is lowered
and relieved at the stroke end, the
safety valve with suction on the boom
lower side of the control valves VL1
and VR2 is relieved (because the set
pressure is lower than that of the
main relief valve).
12 PC2000-8
Adjustment 1) Loosen the locknut (5) and make the

1. Adjustment of main relief valve (High pres- elbow (6) free.
sure set) of control valves VL1, VL2, VR1 2) Loosen the locknut (7) and turn the holder
and VR2 (8) for adjustment.
a When the work equipment oil pressure q Turn the holder to the right, and the
(when the machine push-up is working) is pressure will rise.
abnormal or when the travel oil pressure is q Turn the holder to the left, and the
abnormal, adjust the high pressure set pressure will lower.
side of the main relief valves (1), (2), (3) a Pressure adjusted by a turn of the
and (4) of each control valve according to holder: about 21.8 MPa {222 kg/cm2}
the following procedures: 3 Locknut (7) :
q (1) : VL1 control valve (P1R pump) 93 – 123 Nm {9.5 – 12.5 kgm}
q (2) : VL2 control valve (P2R pump) a Since the low pressure set changes
q (3) : VR1 control valve (P1F pump) when the high pressure set is
q (4) : VR2 control valve (P2F pump) adjusted, the low pressure set should
be adjusted.
q VL valve
3) Fix the elbow (6) and tighten the locknut
(5).
q VR valve
4) After the adjustment, check the oil pres-

sure again according to the above mea-
surement procedures.
a High pressure set is the state that the 2-

stage relief solenoid valve is ON and that
a pilot pressure is applied to the
changeover port.
PC2000-8 13
2. Adjustment of main relief valve (Low pres- 3. Adjustment of swing motor safety valve
sure set) of control valves VL1, VL2, VR1 a When the swing oil pressure is abnormal,
and VR2 adjust the swing motor safety valves (11)
a When the work equipment relief oil pres- and (12) according to the following proce-
sure (normal relief) is abnormal, adjust the dures:
low pressure set side of the main relief q (11) : For the front swing motor
valves (1), (2), (3) and (4) of each control q (12) : For the rear swing motor
valve according to the following proce-
dures:
a Low pressure set is the state that the 2-
stage relief solenoid valve is OFF and that
a pilot pressure is not applied to the
changeover port.
1) Loosen the locknut (5) and make the
elbow (6) free.
2) Loosen the locknut (9) and turn the holder
(10) for adjustment.
q Turn the holder to the right, and the
pressure will rise.
q Turn the holder to the left, and the
pressure will lower.
a Pressure adjusted by a turn of the
holder: about 21.8 MPa {222 kg/cm2}
3 Locknut (9) :
78 – 93 Nm {8.0 – 9.5 kgm}
3) Fix the elbow (6) and tighten the locknut

(5). 15523
a The front and rear swing motors are

divided from one spool. Adjust the valves
in the following procedures.
a If swing starting power is not powerful, or if
swing speed is not fast:
1) Put match marks on the body and on
adjustment screw (14) for safety valves
(11) and (12) of each motor.
4) After the adjustment, check the oil pres- a The match marks are for returning the
sure again according to the above mea- screw and body to the original posi-
surement procedures. tions after no fault is found.
2) Loosen locknut (14) of safety valve on one
side and tighten adjustment screw (13).
q Turn the adjustment screw to the
right, and the pressure will rise.
q Turn the adjustment screw to the left,
and the pressure will lower.
a Pressure adjusted by one turn of the
adjustment screw :
about 4.70 MPa {47.9 kg/cm2}
3 Locknut :
147 – 196 Nm {15 – 20 kgm}
14 PC2000-8
3) Start the engine, relieve the swing lock,

and measure the relief oil pressure.
4) Rise of the oil pressure shows lowering of
the valve set pressure. Adjust the pres-
sure according to the criteria.
5) If the oil pressure is not changed, return
the valves to the original positions in
accordance with the match marks.
6) Adjust the relief valves on the other side in
the same steps 2) – 4) above.
7) After the adjustment, check the oil pres-

sure again according to the above mea-
surement procedures.
PC2000-8 15
Testing and adjusting control 3. Run the engine at high idle, set the work equip-
circuit oil pressure (output ment/swing lever and travel lever in neutral,
and measure the oil pressure.
pressure of self pressure
reducing valve) 1
a Instruments for testing and adjusting control

circuit oil pressure
1
790-261-1204 Digital hydraulic tester
P
799-101-5220 Nipple (10 x 1.5 mm)
2
07002-11023 O-ring
Measuring
a Measure the control circuit oil pressure under
the following condition. Adjusting
q Hydraulic oil temperature: 45 – 55°C a If output pressure of self pressure reducing
k Lower the work equipment to the
valve is not normal, adjust self pressure reduc-
ground and stop the engine. Operate ing valve (2) in the following procedure.
the control levers several times to
release the residual pressure in the
piping, and then loosen the oil filler cap
of the hydraulic tank slowly to release
the internal pressure of the hydraulic
tank.
1. Remove pressure measurement plug (1) of the

main pump.
a The plugs are installed in the same places
for P1 and P2 pumps.
2. Install nipple P2 and connect oil pressure

gauge [1] of hydraulic tester P1.
1) Fix adjustment screw (3) and then loosen

locknut (4).
2) Adjust the pressure by turning adjustment
screw (3).
a Target values: 3.2 – 3.5 MPa {33 – 36
kg/cm2}
a Adjustment screw:
q Turning it clockwise increases
the pressure.
q Turning it counterclockwise
decreases the pressure.
a Pressure adjusted by one turn of the
adjustment screw: 1.16 MPa {11.9 kg/
cm2}
16 PC2000-8
3) Fix adjustment screw (3) and then tighten

locknut (4).
3 Locknut :
59 – 78 Nm {6 – 8 kgm}
PC2000-8 17
Testing and adjusting main pump 2) Install nipple Q2 and connect oil pressure
control signal 1 gauge [1] of hydraulic tester Q1.
a Use the oil pressure gauges of 5.9
MPa {60 kg/cm2}.
a Devices for inspecting and measuring main
pump control signal
1
Q
799-101-5220 Nipple (10 × 1.5 mm)
2
07002-11023 O-ring
Measurement
a Measure the piston pump control oil pressure
under the following conditions:
q Hydraulic oil temperature: 45 – 55°C
k Lower the work equipment to the ground
and stop the engine. Operate the control 3) Start the engine and set the working mode
levers several times to release the residual switch in the P-mode position.
pressure in the piping, and then loosen the 4) Set all the control levers in neutral and
oil filler cap of the hydraulic tank slowly to measure the EPC solenoid valve output
release the internal pressure of the hydrau- pressure under the following condition.
lic tank. i) Set all the control levers in neutral.
ii) Run the engine at high idle and
1. Measuring EPC solenoid valve output pres- measure the output pressure.
sure 5) Drive the travel motor idle and measure
a Since the basic pressure of the EPC sole- the EPC solenoid valve output pressure
noid valve is the control circuit pressure, under the following condition.
check that the control circuit pressure (self i) Raise the track shoe to be measured
pressure reducing valve) is normal before by using the boom and arm
measuring the EPC solenoid valve output ii) Run the engine at high idle, drive the
pressure. travel motor idle and measure the
a The EPC solenoid valve is controlled with output pressure.
the command current from the pump con- a For measurement posture, see “Stan-
troller. (For details, see Structure, function dard service value table”.
and maintenance standard.)
1) Remove oil pressure pickup plug (1) or 2. Measuring EPC solenoid valve current
(2). a The EPC current can be checked with the
a Plug (1) is on the front pump side and monitoring function of the machine moni-
plug (2) is on the rear pump side. tor, too.
a The plugs are installed in the same (For the operating method, see “Special
places for P1 and P2 pumps. functions of machine monitor”.)
q Monitoring code:
01306 P1F pump EPC current
01308 P1R pump EPC current
01310 P2F pump EPC current
01312 P2R pump EPC current
1) Start the engine and set the working mode
switch in the P-mode position.
2) Set all the control levers in neutral and
measure the EPC current under the fol-
lowing condition.
i) Set all the control levers in neutral.
ii) Run the engine at high idle and
measure the current.
18 PC2000-8
3) Drive the travel motor idle and measure 3) Drive the travel motor idle and measure
the EPC current under the following condi- the jet sensor output differential pressure
tion. under the following condition.
i) Raise the track shoe to be measured i) Raise the track shoe to be measured
by using the boom and arm. by using the boom and arm.
ii) Run the engine at high idle, drive the ii) Run the engine at high idle, drive the
travel motor idle and measure the travel motor idle, and measure the out-
current. put differential pressure.
15746 15747
3. Measuring output differential pressure of 4. Measuring output voltage of jet sensor dif-
jet sensor differential pressure sensor ferential pressure sensor
a The jet sensor output differential pressure a The differential pressure sensor output
can be checked with the monitoring func- voltage can be checked with the monitor-
tion of the machine monitor, too. ing function of the machine monitor.
(For the operating method, see “Special (For the operating method, see “Special
functions of machine monitor”.) functions of machine monitor”.)
a Monitoring code: a Monitoring code:
13804 VR1 J/S differential pressure 13808 VR1 J/S differential pressure sensor
13805 VL1 J/S differential pressure voltage
13806 VR2 J/S differential pressure 13809 VL1 J/S differential pressure sensor
13807 VL2 J/S differential pressure voltage
13810 VR2 J/S differential pressure sensor
1) Start the engine and set the working mode voltage
switch in the P-mode position. 13811 VL2 J/S differential pressure sensor
2) Set all the control levers in neutral and voltage
measure the jet sensor output differential 1) Start the engine and set the working mode
pressure under the following condition. switch in the P-mode position.
i) Set all the control levers in neutral. 2) Set all the control levers in neutral and
ii) Run the engine at high idle and meas- measure the voltage under the following
ure the output differential pressure. condition.
i) Set all the control levers in neutral.
ii) Run the engine at high idle and meas-
ure the voltage.
PC2000-8 19
3) Drive the travel motor idle and measure

the voltage under the following condition.
i) Raise the track shoe to be measured
by using the boom and arm.
ii) Run the engine at high idle, drive the
travel motor idle, and measure the
voltage.
15748
1) Fix adjustment screw (21) and loosen

locknut (22).
2) Turn adjustment screw (21) to adjust the
pressure.
a If the adjustment screw is
q turned to the right, the pressure
rises.
q turned to the left, the pressure
Adjusting lowers.
1. Adjusting jet sensors of VR1, VL1, VR2 and a Pressure changed by 1 turn of adjust-
VL2 control valves ment screw: 0.288 MPa {2.94 kg/cm2}
a If the jet sensor output differential pres- 3) Fix adjustment screw (21) and tighten
sure is abnormal, adjust jet sensor relief locknut (22).
valves according to the following proce- 3 Locknut: 59 – 78 Nm {6 – 8 kgm}
dure.
q (17): jet sensor relief valve of VL1 control
valve
q (18): jet sensor relief valve of VL2 control
valve
q (19): jet sensor relief valve of VR1 control
valve
q (20): jet sensor relief valve of VR2 control
valve
4) After finishing adjustment, check the oil

pressure again according to the above
described measurement procedure.
20 PC2000-8
Measuring fan speed 1 2. Measuring fan speed (oil cooler)

1) Open the inspection cover of the engine
hood and remove the fan guard and stick
1. Measuring fan speed (radiator) a reflection tape to the fan (1).
a Tools for measuring fan speed 2) Install the fan guard.
Symbol Part Number Part Name 3) Set probe [1] of multitachometer R with
stand [2], match it to the reflection tape,
R 799-203-8001 Multitachometer
and connect it to meter [3].
a Set the probe with the fan away 100
1) Remove the fan guard and put a sheet of mm from it.
reflection tape (a) on fan (1).
2) Install the fan guard.
3) Set probe [1] of multitachometer R with
stand [2], match it to the reflection tape,
and connect it to meter [3].
a Set the probe with the fan away 100
mm from it.
4) Start the engine, set the fan to 100%

mode, and measure the fan speed with
the engine at high idle.
a Stabilization of the tachometer num-
bers shows correct measurement.
a If the fan is rotated in reverse, the
measuring instruments can be
4) Start the engine, set the fan to 100% sucked in. Accordingly, be sure to
mode, and measure the fan speed with rotate the fan forward when measur-
the engine at high idle. ing.
a Stabilization of the tachometer num-
bers shows correct measurement.
a If the fan is rotated in reverse, the
measuring instruments can be
sucked in. Accordingly, be sure to
rotate the fan forward when measur-
ing.
5) After finishing measurement, remove the

measuring instruments and return the
removed parts.

removed parts.
PC2000-8 21
Measuring fan pump EPC 1) Run the engine at high idle and measure
solenoid current 1 the EPC current with the fan 100% speed
mode.
1. Measuring fan (radiator) pump EPC sole-

noid current
a The fan (radiator) pump EPC solenoid current
can be checked with the monitoring function of
the machine monitor.
(For the operating method, see “Special func-
tions of machine monitor”.)
q Monitoring code:
31624 RAD fan pump EPC current
q The current is displayed in mA.
a Measure the fan (radiator) pump EPC current

under the following condition.
1) Run the engine at high idle and measure
the EPC current with the fan 100% speed
mode.

noid current
a The fan (oil cooler) pump EPC solenoid current
can be checked with the monitoring function of
(For the operating method, see “Special func-
tions of machine monitor”.)
q Monitoring code:
31634 O/C fan pump current
q The current is displayed in mA.
a Measure the fan (oil cooler) pump EPC current
under the following condition.
22 PC2000-8
Measuring fan pump EPC solenoid 2) Install nipple S2 and connect it to oil pres-
valve output pressure 1 sure gauge [1] of hydraulic tester S1.
q Use the oil pressure gauge of 5.9
MPa {60 kg/cm2}.
a Measuring instruments for fan pump EPC sole- 3) Run the engine at high idle and measure
noid valve output pressure the solenoid output pressure.
Symbol Part Number Part Name 4) After finishing measurement, remove the
799-101-5002 Hydraulic tester removed parts.
1
S
799-101-5220 Nipple (Max. 1.5 mm)
2
07002-11023 O-ring
a Measure the fan pump EPC solenoid valve

output pressure
a Since the basic pressure of the EPC solenoid
valve output pressure is the control circuit
pressure, check that the control circuit pres-
sure is normal before measuring the EPC sole-
noid valve output pressure.
k Lower the work equipment to the ground
and stop the engine. Then, operate the con-
trol levers several times to release the 2. Measuring fan (oil cooler) pump EPC sole-
residual pressure in the piping and loosen noid valve output pressure
the hydraulic tank cap gradually to release 1) Remove oil pressure pickup plug (1) from
the internal pressure of the hydraulic tank. the top of the fan (oil cooler) pump.

noid valve output pressure
1) Remove oil pressure pickup plug (1) from
the top of the fan (radiator) pump.
2) Install nipple S2 and connect it to oil pres-

sure gauge [1] of hydraulic tester S1.
q Use the oil pressure gauge of 5.9
MPa {60 kg/cm2}.
3) Run the engine at high idle and measure
the solenoid output pressure.
PC2000-8 23

removed parts.
24 PC2000-8
Oil pressure measuring points for (3) Fan (Radiator) pump discharge pressure
pump discharge pressure or jet pickup plug
(4) Fan (Oil cooler) pump discharge pressure
sensor differential pressure 1 pickup plug
a Measuring tools for fan pump discharge
q The oil pressures checked with the monitoring pressure
function can be measured at the following
points with “oil pressure gauges”.
1
1. Measuring main pump discharge pressure 790-261-1204 Digital hydraulic tester
—
(Common to pumps P1 and P2) 799-101-5220 Nipple (M10 x 1.25 mm)
2
07002-11023 O-ring
3. Measuring jet sensor differential pressure

(Common to control valves VL and VR)
(1) Main pump discharge pressure pickup

plug (F pump)
(2) Main pump discharge pressure pickup
plug (R pump)
a Measuring tools for main pump discharge
pressure (5) Jet sensor output pressure (High pressure
Symbol Part Number Part Name side) [Valve 1 side]
(6) Jet sensor output pressure (Low pressure
1 side) [Valve 1 side]
— (7) Jet sensor output pressure (High pressure
799-101-5220 Nipple (M10 x 1.25 mm) side) [Valve 2 side]
2
07002-11023 O-ring (8) Jet sensor output pressure (Low pressure
side) [Valve 2 side]
2. Measuring fan pump discharge pressure a Measuring tools for jet sensor differential pres-
sure
1
Differential pressure
— 2 799-401-2701
gauge
799-101-5220 Nipple (M10 x 1.25 mm)
3
07002-11023 O-ring
PC2000-8 25
Measuring PPC valve output 4. Start the engine, operate the control lever of
pressure 1 the measuring PPC circuit at high idle and
measure the oil pressure.
a When the oil pressure is 0 while the con-
a Devices for measuring PPC valve output pres- trol lever is set at the neutral position,
sure operate the lever to the full stroke. If the oil
pressure comes almost to the oil pressure
of the control circuit, the valve is normal.
1 Digital type hydraulic 5. After the measurement, remove the measuring
790-261-1203
tester devices and return the valve to the original
T 799-401-3200 Adapter assembly #3 state.
2
02896-11009 O-ring
799-401-3300 Adapter assembly #4
3
02896-11012 O-ring
a Measure the PPC valve output pressure under

the following conditions:
q Hydraulic oil temperature : 45 – 55°C
1. Disconnect the hoses (1) – (12) from the PPC

circuit. Check the cab base.
a See the connection drawing in the next
page.
a Disconnect these hoses at the PPC junc-
tion block part.
2. Attach the adapter T2 or T3 and connect the

disconnected hoses again.
a #3 size for the travel and swing circuits.
#4 size for the work equipment circuits.
3. Attach the nipple [1] of the hydraulic tester T1

and connect it to the oil pressure gauge [2].
26 PC2000-8
Measure the pressures inside the cab base first.
15542
No. PPC Circuit Colored band No. PPC Circuit Colored band
1 Boom RAISE Green 7 Swing left Red
2 Boom LOWER Brown 8 Swing right None
3 Bucket CURL White 9 R.H. travel REVERSE Black, black
4 Bucket DUMP Black 10 R.H. travel FORWARD Blue, black
5 Arm OUT Yellow 11 L.H. travel REVERSE Red, black
6 Arm IN Blue 12 L.H. travel FORWARD Green, black
PC2000-8 27
15751
28 PC2000-8
15752
PC2000-8 29
Measuring solenoid valve outlet

pressure 1
a Devices for measuring solenoid valve outlet

pressure
Symbol Part Number Part Name 15546
1 Digital type hydraulic
790-261-1203
tester
U 799-401-3200 Adapter assembly
2
02896-11009 O-ring
799-401-3300 Adapter assembly
3
02896-11012 O-ring
a Measure the solenoid valve outlet pressure

under the following conditions:
1. Disconnect the hoses (1) – (11) from the sole-

noid valve circuit to be measured.
2. Attach the adapter U2 and connect the discon-

nected hoses again.
3. Attach the nipple [1] of the hydraulic tester U2

and connect it to the oil pressure gauge [2].
4. Start the engine, idle it at a high speed under

the measuring conditions and measure the oil
pressure.
5. After the measurement, remove the measuring

devices and return the valve to the original
state.
30 PC2000-8
Solenoid Oil pressure

No. Solenoid valve Measuring conditions Machine operation
operation (MPa {kg/cm2})
The back pressure valve
Swing or travel (Back pressure ON) is OFF 0 {0}
Variable back released
1
pressure The back pressure valve
Min. 2.74
All levers at neutral (Back pressure OFF) is ON
{Min. 28}
operated
All levers at neutral — OFF 0 {0}
2 Swing priority Swing priority function is Min. 2.74
Swing and arm or bucket ON
operated. {Min. 28}
When the heavy lift switch is turned The main relief valve is set
OFF 0 {0}
off to low pressure.
3 2-stage relief When the heavy lift switch is turned
The main relief valve is set Min. 2.74
on and boom RAISE is operated ON
to high pressure. {Min. 28}
independently
4 Arm throttle (L1) The arm throttle valve of

Min. 2.74
Boom RAISE and arm IN or OUT control valve (L1) is oper- ON
{Min. 28}
ated.
Arm throttle The arm throttle valve of
5 Min. 2.74
(R2) Boom RAISE and arm IN or OUT control valve (R2) is oper- ON
{Min. 28}
ated.
Boom throttle The boom throttle valve of
6 Boom and swing are operated at Min. 2.74
(R1) control valve (R1) is oper- ON
the same time {Min. 28}
ated.
The travel pump and work
When the travel lever is operated
equipment/swing pump are OFF 0 {0}
independently
merged.
7 Straight-travel
When the travel lever and the work The travel pump and work
Min. 2.74
equipment/swing lever are oper- equipment/swing pump are ON
{Min. 28}
ated at the same time separated.
The boom LOWER safety
When the machine push-up switch
valve is set to high pres- OFF 0 {0}
Machine push- is turned on
8 sure.
up
When the machine push-up switch The boom LOWER safety Min. 2.74
ON
is turned off valve is set to low pressure. {Min. 28}
When the swing lock switch is
The swing brake operates. OFF 0 {0}
turned on or all levers are at neutral
Swing holding
9 When the swing lock switch is
brake The swing holding brake is Min. 2.74
turned off and the swing operation ON
released. {Min. 28}
starts
The basic pressure circuit to
When the lock lever is locked OFF 0 {0}
PPC oil pres- the PPC valve is blocked.
10
sure lock The basic pressure circuit to Min. 2.74
When the lock lever is released ON
the PPC valve is opened. {Min. 28}
The bucket PPC circuit of
All levers at neutral control valve (R2) is OFF 0 {0}
Bucket Hi can- opened.
11
cel The bucket PPC circuit of
Min. 2.74
Arm IN and bucket CURL control valve (R2) is ON
{Min. 28}
blocked.
PC2000-8 31
Adjusting work equipment and

swing PPC valve 1
a When the work equipment and swing lever tip

plays much, adjust according to the following
procedures.
k Lower the work equipment completely to
the ground, stop the engine and operate
the work equipment control lever several
times to relieve pressure remaining in the
pipe. Then, loosen the hydraulic tank oil
filler cap slowly and bring the safety lock
lever to the lock position.
a Lever play : 0.5 to 3 mm at the position of
200 mm from the center of the lever
mounting pin.
1. Remove bellows (1).
2. Loosen the locknut (2), turn the disc (3) to

adjust the lever play.
a At the time, do not move the piston.
3. Fix the disc (3) and tighten the locknut (2) by

applying the specified torque.
3 Locknut : 69 – 78 Nm {7 – 9 kgm}
32 PC2000-8
Testing and adjusting travel

deviation 1
Measurement
a Measure travel deviations under the following
conditions:
q Measuring position : Horizontal hard flat
ground
1. Start the engine and bring the work equipment

to the travel posture.
2. Set the working mode to the P Mode.
3. Run the machine 10 m with the engine at full

throttle and run it further 20 m as it is, then
measure the deviation (A).
PC2000-8 33
Adjusting
a Carry out troubleshooting for “H-16 Machine
deviates by itself during travel” to find out the
causal part in advance.
a Adjust the deviation with the motor idle run-
ning.
a If the main pump is adjusted for measures,
adjust the servo piston.
a Increase and decrease the maximum delivery
amount of the pump.
1. Fix adjustment screw (1) and loosen locknut

(2).
2. Adjust the maximum delivery amount by turn-

ing adjustment screw (1).
a If the adjustment screw:
q is turned clockwise, the delivery is
d ec r e as ed ( T h e tr a v el s p ee d i s
decreased)
q is turned counterclockwise, the deliv-
ery is increased (The travel speed is
increased)
a Amount adjusted by 45° angle turn of the
adjustment screw: 4.9 cm3/rev (equivalent
to the pump delivery amount)
a Criterion delivery amount of the pump
when shipped (For reference):
375 ± 2 cm3/rev
3. Fix adjustment screw (1) and tighten locknut

(2).
3 Locknut: 539 – 647 Nm {55 – 66 kgm}
BJP14844
34 PC2000-8
Testing work equipment hydraulic 2. Testing arm cylinder

drift cause portion 1 1) Stop the arm cylinder about 100 mm
before the IN stroke end and stop the
engine.
a When a hydraulic drift occurred to the work
equipment, follow the procedures below to
check if the cause has come from the cylinder
piston ring side or from the control valve side.
1. Testing boom cylinder and bucket cylinder

1) Take the same posture as that for measur-
ing hydraulic drift and stop the engine.
a Place the rated load or sand in the
bucket.
2) Operate the arm control lever to the “IN

side”.
q If the drift speed becomes faster, the
cylinder piston ring is defective.
q If the speed does not change, the
control valve is defective.
a Operate the control lever when the
starting switch is ON.
a When the accumulator pressure is 0,
run the engine for about 10 seconds
2) In case of boom, bring the boom control to accumulate pressure.
lever to the “RAISE side”, or in case of
bucket, bring the bucket control lever to [Reference] The reason why the above operation
the “CURL side”. makes the drift speed faster when the
q If the drift speed becomes faster, the cause of hydraulic drift is the cylinder
cylinder piston ring is defective. piston ring:
q If the speed does not change, the 1) In case of the above work equipment posture
control valve is defective. (the holding pressure rises on the bottom side),
a Operate the control lever when the oil leaks from the bottom side to the head side
starting switch is ON. but the head side volume is smaller than the
a When the accumulator pressure is 0, bottom side one by the rod. So, oil flowing in
run the engine for about 10 seconds from the bottom side increases the internal
to accumulate pressure. pressure on the head side.
2) As the internal pressure on the head side
increases, both pressures come to balance at a
certain pressure (depending on leakage), and
the drift speed becomes slow.
3) If the head side circuit opens to the drain circuit
at the time (the bottom side is closed with the
check valve) by the above lever operation, oil
will flow from the head side to the drain circuit.
Pressure will come not to balance, and the drift
speed will become faster.
PC2000-8 35
Testing oil leakage 1 2. Measurement of leakage from arm cylinder

1) Extend the cylinder fully and stop the
engine.
a Measure oil leakage under the following condi-
tions:
q Hydraulic oil temperature : within operating
temperature range
1. Measurement of leakage from boom cylin-

der
1) Extend the cylinder fully and stop the
engine.
2) Disconnect the pipes (2) from the head

side and block the pipe on the control
valve side with flange.
k Be careful not to disconnect the
pipe on the bottom side.
2) Disconnect the pipes (1) from the head

side and block the pipe on the control
valve side with flange.
k Be careful not to disconnect the
pipe on the bottom side.
3) Start the engine, operate the right control

lever to the “Arm IN” side at high idling
and apply the relief oil pressure to the cyl-
inder bottom side.
k Be careful not to operate the con-
trol lever to the “Arm OUT” side.
4) After 30 seconds elapsed, measure oil
leakage for 1 minute.
3) Start the engine, operate the left control

lever to the “Boom RAISE” side at high
idle and apply the relief oil pressure to the
cylinder bottom side.
trol lever to the “Boom LOWER”
side.
36 PC2000-8
3. Measurement of leakage from bucket cylin- 4. Measurement of leakage from swing motor
der k After the engine stopped, loosen the oil
1) Extend the cylinder fully and stop the filler cap of the hydraulic tank slowly to
engine. relieve pressure from the tank.
1) Disconnect the drain hose (4) from the
swing motor and block the hose side with
plug.
2) Disconnect the pipe (3) from the head side

and block the pipe on the control valve
side with flange.
k Be careful not to disconnect the 2) Start the engine and turn the swing lock
pipe on the bottom side. switch to the lock position.
3) Run the engine at high idle speed and
relieve the swing motor.
a Measure oil leakages several times while
moving the swing motor little by little (by
sliding the valve plate and the cylinder
block).
3) Start the engine, operate the left control

lever to the “Bucket CURL” side at high
idling and apply the relief oil pressure to
the cylinder bottom side.
trol lever to the “Bucket DUMP”
side.
PC2000-8 37
5. Measurement of leakage from travel motor 6. Measurement of leakage from center swivel
1) Start the engine and place a pin or a block joint
between the sprocket and the track frame 1) Start the engine and place a pin or a block
or the track link to lock the travel. between the sprocket and the track frame
k Make sure that the travel is locked or the track link to lock the travel.
certainly. k Make sure that the travel is locked
k After the engine stopped, loosen certainly.
the oil filler cap of the hydraulic k After the engine stopped, loosen
tank slowly to relieve pressure the oil filler cap of the hydraulic
from the tank. tank slowly to relieve pressure
2) Disconnect the drain hose (5) from the from the tank.
travel motor and block the hose side with 2) Disconnect the upper and lower measur-
plug. ing port hoses of the inspection port with
the upper and lower swivels and block the
hose side with plug or flange.
Inspection Measuring
Circuit
port port
A Right travel FORWARD T, A
B Right travel REVERSE A, C
15557
C Left travel FORWARD P, D
D Left travel REVERSE D, T
3) Start the engine and operate the travel on

the measuring side at high idle to relieve
the travel motor. BJP11309
a Measure oil leakages several times
while moving the travel motor little by
little (by sliding the valve plate and
the cylinder block).
3) Start the engine and operate the travel of

the measuring port at high idle to relieve
the travel motor.
k Check the inspection port and con-
duct the travel operation carefully.
a Measure oil leakages from the two
measuring ports of the lower swivel.
38 PC2000-8
Remaining pressure relief from

hydraulic circuit 1
k When disconnecting the pipe between the

control valve and the cylinder or the motor,
relieve pressure remaining in the circuit
according to the following procedures.
a No pressure remains in the travel motor circuit,
but the internal pressure of the hydraulic tank
influences the relief. So, open the cap of the
hydraulic tank.
1. Stop the engine and loosen the oil filler cap of

the hydraulic tank slowly to relieve pressure in
the tank.
2. Free the lock lever and operate the control

lever several times.
a When the control lever is operated 2 or 3
times, the pressure accumulated in the
accumulator is relieved completely.
3. Start the engine, idle it at low speed for about

10 seconds to accumulate pressure in the
accumulator, then stop the engine.
4. Repeat Steps 2 and 3 several times.
PC2000-8 39
Air bleeding from each component 1
1. Air bleeding from hydraulic pump
a After removing and installing the hydraulic 5) Loosen plug (5) for suction tube and
pump or changing hydraulic oil, bleed air check that oil flows out. Then, tighten the
from the hydraulic pump according to the plug temporarily.
following procedures.
k If air was not bled or air was bled insuf-
ficiently, the pump may be broken. So,
be sure to bleed air strictly according
to the procedures.
1) Loosen bleeders (1) – (3) of all hydraulic 15559

pump 1 or 2 turns at the same time.
a Connect a tube [1] to each bleeder to
prevent oil from being scattered and
to receive oil in oil pan.
2) Feed hydraulic oil up to the specified level.
a Even after feeding oil to the hydraulic
tank, keep the oil filler cap removed.
3) After oil flew out from bleeder (3) of the
fan pump PF, tighten bleeder (3) tempo-
rarily.
4) After bleeders (1) and (2) of the main
pumps P1 and P2 stop bleeding air,
tighten only bleeder (2) of the main pump
P2 temporarily.
a Keep bleeder (1) of the main pump
P1 loose.
40 PC2000-8
6) Crank the engine and make sure that oil 2. Air bleeding from work equipment cylinder
flows out from bleeder (1) of the main circuit
pump P1. Then, tighten the bleeder tem-
porarily.
a For cranking, idle the engine at low
speed for 15 seconds twice.
7) Loosen the bleeder (2) of the main pump
P2.
8) Crank the rear engine and make sure that
oil flows out of the bleeder (2) of the main
pump P2. Then, tighten the bleeder tem-
porarily.
a For cranking, idle the engine at low
speed for 15 seconds twice.
9) Start the engine and keep it idle at low
speed.
10) Loosen the bleeders (1) – (3) of all
hydraulic pumps and make sure that bub- a When removing and installing the work
ble-free oil flows out of them. Then, equipment cylinder or when disconnecting
tighten these bleeders temporarily. and connecting the cylinder circuit piping,
11) Close the oil filler caps of the hydraulic bleed air from the work equipment cylinder
tank. according to the following procedures.
12) Keep the engine idling at low speed, raise k If air was not bled or air was bled insuf-
the work equipment from the ground and ficiently, the cylinder piston ring may
swing the upper structure 180°. be broken. So, be sure to bleed air
a After the swing, lower the work equip- strictly according to the procedures.
ment completely to the ground. 1) Start the engine and idle it at low speed for
13) Loosen plug (5) for the suction tube and about 5 minutes.
make sure that bubble-free oil flows out of 2) Repeat raising and lowering the boom 4 or
it. Then, tighten the plug. 5 times at the low idle.
3 Plug : 58.8 – 78.4Nm {6 – 8kgm} a Stop the piston rod about 100mm
14) Loosen the bleeders (1) – (3) of all before the stroke end and be careful
hydraulic pumps and make sure that bub- not to relieve it.
ble-free oil flows out of them. Then, 3) Execute Step 2) at high idle.
tighten these bleeders temporarily. 4) Bring the piston rod to the stroke end at
a This work is the same as in the above low idle and relieve it.
Step 10. 5) Execute Steps 2) – 4) for the arm and the
15) Keep the engine idling at low speed, raise bucket.
the work equipment from the ground and a When the cylinder was replaced, execute
swing the upper structure 180°. the procedures before connecting the
a Swing the upper structure in the work equipment. Especially, when the
reverse direction from the one in the boom cylinder was installed to the work
above Step 12. After the swing, lower equipment, the lowering side does not
the work equipment completely to the move to the stroke end.
ground.
16) Loosen the bleeders (1) – (3) of all
hydraulic pumps and make sure that bub-
ble-free oil flows out of them. Then,
tighten these bleeders.
3 Bleeder :
8.8 – 9.8Nm {0.9 – 1.0kgm}
17) Stop the engine.
18) Loosen the oil filler cap of the hydraulic
tank slowly and remove it. Relieve pres-
sure from the hydraulic tank and feed
hydraulic oil up to the specified level.
PC2000-8 41
3. Air bleeding from swing motor circuit 4. Air bleeding from swing motor circuit
(Swing motor) (Parking brake circuit)
a When removing and installing the swing a When removing and installing the swing
motor or when disconnecting and con- motor or when disconnecting and con-
necting the swing motor main circuit pipes, necting the swing holding brake circuit pip-
bleed air from the swing motor according ing, bleed air from the brake circuit
to the following procedures. according to the following procedures.
k If air was not bled or air was bled insuf- k If air was not bled or air was bled insuf-
ficiently, the swing motor may be dam- ficiently, the swing holding brake may
aged. So, be sure to bleed air strictly be dragged. So, be sure to bleed air
according to the procedures. strictly according to the procedures.
1) Start the engine and operate it while the 1) Start the engine and loosen bleeder (11).
engine is idling at low speed. a The bleeder is mounted on the front
2) Repeat operations of swing, start, and and rear swing motors.
stop 5 or 6 times. 2) Turn off the swing lock switch.
3) Swing the motor while the engine is idling
at low speed and make sure that bubble-
free oil flows out of bleeder (11). Then,
tighten the bleeders.
3 Bleeder :
8.8 – 9.8Nm {0.9 – 1.0kgm}
a The swing operation may be as faintly
as the swing oil pressure switch turns
on.
42 PC2000-8
5. Air Bleeding from travel motor circuit

(Travel motor)
BWP15572
a When removing and installing the travel

motor or when disconnecting and con-
necting the travel motor main circuit pipes,
bleed air from the travel motor according
to the following procedures.
k If air was not bled or air was bled insuf-
ficiently, the travel motor may be dam-
aged. So, be sure to bleed air strictly
according to the procedures.
1) Start the engine and loosen bleeder (12).
a The bleeder is mounted on the LH
and RH travel motors.
2) Make sure that bubble-free oil flows out of
the bleeders (12). Then, tighten the
bleeder.
3 Bleeder :
8.8 – 9.8Nm {0.9 – 1.0kgm}
PC2000-8 43
Air bleeding from PPC circuit 1
a When removing and installing the control valve

or when disconnecting and connecting PPC
hose, bleed air from the PPC circuit according
to the following procedures.
If air was not bled or air was bled insufficiently,
time lag or abnormal sound may occur. So, be
sure to bleed air strictly according to the proce-
dures.
1. Start the engine and loosen the bleeder (13).

a The bleeders are installed on the wiring
harness spring case elbow of the control
valve spool (28 places in total).
2. Control each actuator while the engine is idle

at low speed.
3. Make sure that bubble-free oil flows out of

bleeder (13). Then, tighten bleeder.
3 Bleeder: 8.8 – 9.8 Nm {0.9 – 1.0 kgm}
k The operation of each lever should be

enough to the extent that each hydrau-
lic switch turns on.
4. The circuits and places to be bled are as fol-

lows.
A : Arm IN circuit (3 places),
Q : Boom RAISE circuit (3 places),
T : Bucket CURL circuit (4 places),
U : Travel REVERSE circuit (4 places),
a : Arm OUT circuit (4 places),
q : Boom LOWER circuit (2 places),
t : Bucket DUMP circuit (4 places),
u : Travel FORWARD circuit (4 places)
44 PC2000-8
q Front side of control valve
q Rear side of control valve
PC2000-8 45
Testing and adjusting auto grease system 1
1. Indication of abnormality by auto grease

controller
If the auto grease system has abnormality, the
auto grease caution lamp lights up red and the
auto grease caution mark is indicated in the
machine monitor.
Indication by machine
Lamp Abnormality Cause
monitor
• Pump trouble
• No grease
Lighting Pump is running but pressure in
15562 • Breakage of grease piping
up grease piping does not rise.
or leakage
2. Adjusting delivery from injector

a The delivery from the injector is adjusted
when shipped. If necessary, increase or
decrease the delivery according to the fol-
lowing procedure.
q Delivery set when shipped:
1.3 cc/st (Dimension (a): 10 mm)
1) Remove the cap from the adjustment
screw and loosen locknut (3).
2) Turn adjustment screw (2) to adjust the
delivery.
a If the adjustment screw
q is turned clockwise, the delivery
is reduced.
q is turned counterclockwise, the
delivery is increased.
a Delivery increase or decrease by 1
turn of adjustment screw: 0.17 cc/st
a Limit dimension (a) of the adjustment
screw to 10 mm.
a If the adjustment screw is tightened
fully to reduce dimension (a) to 0 mm,
the delivery is 0.13 cc/st.
3) Tighten locknut (3) and install the cap of
the adjustment screw.
46 PC2000-8
3. Bleeding air from grease pump line 5. Bleeding air from injector line
a When a new machine is delivered or a When a new machine is delivered or
transported disassembled or when the transported disassembled or when the
grease can becomes empty or when the grease can becomes empty or when the
hose, pump, or injector is replaced, bleed hose, pump, or injector is replaced, bleed
air from the grease pump line according to air from the grease pump line according to
the following procedure. the following procedure.
1) Set the grease mode selector switch to a Perform this work after “Bleeding air from
the MANUAL position. distributor line” is finished.
2) Operate the grease gun to bleed air from a Perform this work on the all distributor
the grease pump line. lines.
a Check that the grease discharged 1) Set the grease mode selector switch to
from the grease gun does not contain the MANUAL position.
air. 2) Remove plug (5) of the injector.
3) Using the grease gun, supply grease
4. Bleeding air from distributor line through service nipple (6) to the injector
a When a new machine is delivered or line.
transported disassembled or when the
grease can becomes empty or when the
hose, pump, or injector is replaced, bleed
air from the grease pump line according to
the following procedure.
a Perform this work after “Bleeding air from
grease pump line” is finished.
a Perform this work on the all distributor
lines in order from the one nearest to the
grease pump (Swing circle → Boom cylin-
der bottom → Boom → Arm).
1) Set the grease mode selector switch to
the MANUAL position.
2) Remove plug (4) of the distributor.
4) Install plug (5).

3 Plug:
3.92 – 5.88 Nm {0.4 – 0.6 kgm}
3) Check that the grease discharged from

the plug hole does not contain air.
3 Plug:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
PC2000-8 47
6. Check of completion of air bleeding

Check that the indicator (7) of each injector is
operating normally with the auto grease sys-
tem operating.
a If the indicator reciprocates vertically, it is
normal.
a If the indicator does not operate normally,

air has not been bled completely. In this
case, perform procedures 3 – 5 again.
7. Method of supplying grease manually

a If the auto grease system has a trouble
and cannot supply grease automatically.
In this case, supply grease manually
according to the following procedure.
1) Set the grease mode selector switch to
the MANUAL position.
2) Remove plug (5) of the injector.
3) Using the grease gun, supply grease
through service nipple (6) to the injector
line.

3 Plug:
3.92 – 5.88 Nm {0.4 – 0.6 kgm}
48 PC2000-8
Adjusting mirrors 1 3. Adjusting mirrors (a1) and (a2)

Adjust these mirrors so that the operator can
see the left side and left rear of the machine.
q The mirrors are installed to the following 4
positions.
a: Cab at left front of machine
b: Floor around cab at left front of machine
c: Handrail at left rear of machine
d: Handrail at right center of machine
4. Adjusting mirror (b)

Adjust this mirror so that the operator can see
the catwalk.
5. Adjusting mirrors (c1) and (c2)

q c1: Adjust so that the operator can see
1. Loose nut (1), bolt (2) and screw (3) of each
the left rear part of the machine.
mirror and adjust the mirrors so that they will
q c2: Adjust so that the operator can see
be seen best from the operator's seat.
the left rear part of the counterweight.
a Adjust the mirrors so that the operator can
particularly see persons at the right and
left rear ends of the machine.
2. Adjust the mirrors so that the operator can see

persons (or things 1 m high and about 30 cm in
diameter) at the right and left rear ends of the
machine.
PC2000-8 49
6. Adjusting mirrors (d1) and (d2)

q d1: Adjust so that the operator can see
the right lower part of the fuel tank.
q d2: Adjust so that the operator can see
t h e r i g h t r e a r l o w e r pa r t o f t h e
machine.
50 PC2000-8
PC2000-8 51
SEN02009-00
PC2000-8

PC2000-8 20001 and up

Special functions of machine monitor................................................................................................... 2
Handling controller voltage circuit ...................................................................................................... 58
PC2000-8 1

Special functions of machine monitor 1
For all specifications
2 PC2000-8
Upper section of machine monitor (Display sec-

tion)
(a): Multi-display
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambi-
ent temperature and the condition of the bat-
tery. In this case, the machine monitor goes off
for a moment. This phenomenon is not a fail-
ure, however.
Upper section of machine monitor (Switch sec-

tion)
[F1]: F1 function switch
a The function of each function switch is indi-
cated by graphic mark in the multi-display (a)
above that function switch.
a If the graphic mark of a function switch is not
displayed, that function switch is not working.
Lower section of machine monitor (Switch sec-

tion)
[1]: Numeral 1 input switch/Auto-decelerator
switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Heavy lift shifting
switch
[4]: Numeral 4 input switch/Alarm buzzer cancel
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Windshield washer
switch
[7]: Numeral 7 input switch
Switch having no numerals: No function
a Each switch has the function indicated by
graphic mark and the function of inputting a
numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of multi-
display.
PC2000-8 3
t Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary function and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
Page Page
t Operator mode (Outline) Service mode
6p 18p
A Display of KOMATSU logo 6p Monitoring 19p
A Display of check before starting 6p Abnormality Mechanical Systems 27p
A Display of warning after check before starting 7p Record Electrical Systems 28p
A Display of ending of maintenance interval 7p Maintenance Record 36p
A Display of check of working mode 7p Maintenance Mode Change 37p
A Display of ordinary screen 7p Phone Number Entry 39p
B Change of ordinary screen 7p Key-on Mode 40p
A Display of end screen 8p Unit 41p
B Selection of auto-deceleration and auto low idle 8p Default Maintenance Password 42p
B Selection of working mode 8p Camera 43p
B Selection of heavy lift 9p ECO Display 44p
O (Special operation)
B Operation to stop alarm buzzer 9p Pump Absorption Torque 45p

B Operation of windshield wiper 10p Adjustment of auto grease pump dis-
46p
charge pressure
B Operation of window washer 10p
Interval adjustment of auto grease 46p
B Display of auto grease monitor 10p
Operating time adjustment of auto
B Display of truck counter 11p 46p
grease pump
Operation to display camera mode
B
(if camera is installed)
11p Adjustment Setting of grease start time after oper- 46p
ation
B Operation to display clock and service meter 12p Selection of fan speed mode 47p
B Check of maintenance information 12p Adjustment of RAD fan 100% speed 47p
B Setting and display of user mode 12p Adjustment of O/C fan 100% speed 47p
C Display of energy-saving guidance 13p Adjustment of RAD fan 70% speed 48p
C Display of caution monitor 13p Adjustment of O/C fan 70% speed 48p
C Display of action code and failure code 13p Cylinder Cut-Out 49p
O (Special operation) No Injection 52p
Function of checking display of LCD Fuel Consumption 53p
D 15p
(Liquid Crystal Display)
D Function of checking service meter 15p
D Function of changing maintenance password 16p
4 PC2000-8
a Classification of operator mode

A: Display/Function from time when starting switch is turned ON to time when screen changes to ordi-
nary screen and display after starting switch is turned OFF
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch
PC2000-8 5
t Operator mode (Outline) a Display pattern of operator mode

a Only outline of the operator mode is described The contents of display from the time when
in this section. For details of contents/opera- starting switch is turned ON to time when
tion of each function/display, see the “Struc- screen changes to ordinary screen depends on
ture, function and maintenance standard”, or the setting and condition of the machine.
“Operation and Maintenance Manual”. Other than D and B
a The following are the displays or functions of D : When there is abnormal item in check-
the operator mode explained in this section before-starting items
(including some items which need special E : When there is maintenance item which is
operations). not maintained after specified interval
Display Display of KOMATSU logo

pattern
When the s tarting switch is turned ON, the
B D E
KOMATSU logo is displayed for 2 seconds.
A Display of KOMATSU logo 1 1 1 a After the KOMATSU logo is displayed for 2
A Display of check before starting 2 2 2 seconds, the screen changes to “Display of
Display of warning after check before check before starting”.
A — 3 —
starting
A Display of ending of maintenance interval — — 3
A Display of check of working mode 3 — —
A Display of ordinary screen 4 4 4
B Change of ordinary screen
A Display of end screen
B Selection of auto-deceleration and auto low idle
B Selection of working mode
B Selection of heavy lift
B Operation to stop alarm buzzer
B Operation of windshield wiper
B Operation of wind washer
B Display of auto grease monitor
Display of check before starting
B Display of truck counter
When the screen changes to the check-before-
Operation to display camera mode starting screen, the check before starting is carried
B
(if camera is installed)
out for 2 seconds.
B Operation to display clock and service meter a If any abnormality is detected by the check
B Check of maintenance information before starting, the screen changes to “Display
B Setting and display of user mode of warning after check before starting” or “Dis-
C Display of energy-saving guidance play of ending of maintenance interval”.
a If no abnormality is detected by the check
C Display of caution monitor
before starting, the screen changes to “Display
C Display of action code and failure code
of check of working mode and travel speed”.
O (Special operation) a The monitors (6 pieces) displayed on the screen
Function of checking display of LCD are the items under the check before starting.
D
(Liquid Crystal Display)
D Function of checking service meter
D Function of changing maintenance password
6 PC2000-8
Display of warning after check before starting Display of check of working mode
If any abnormality is detected by the check before If the check before starting is finished normally, the
starting, the warning monitor is displayed on the screen to check the working mode is displayed for
screen. 2 seconds.
a The following figure shows that the engine oil a After display of check of the working mode is
level monitor (a) is warning of low of engine oil finished, the screen changes to “Display of
level. ordinary screen”.
15701
Display of ending of maintenance interval Display of ordinary screen

When the check before starting is carried out, if a If the machine monitor starts normally, the ordinary
maintenance item is near or after the end of the set screen is displayed.
interval, the maintenance monitor is displayed for a Service meter (a) or a clock is displayed at the
30 seconds to urge the operator to maintenance. center upper section of the screen (The ser-
a This screen is displayed only when the mainte- vice meter or clock is selected with [F4]).
nance function is effective. The color of the a ECO gauge (b) is displayed at the right end of
maintenance monitor (yellow or red) indicates the screen (It is turned ON and OFF in the ser-
the length of the time after the maintenance vice mode).
interval.
a Set or change the maintenance function in the
service mode.
a After display of this screen is finished, the
screen changes to “Display of check of work-
ing mode and travel speed”.
Change of ordinary screen

In the ordinary screen, 2 screens of 1/2 and 2/2 can
be selected. When the machine monitor is started,
1/2 screen is displayed.
a Press F1 once to change the 1/2 or 2/2
screens alternately.
PC2000-8 7
Display of end screen a If the auto low idle setting is turned “ON” from
When the starting switch is turned OFF, the end the user menu, the auto low idle function is
screen is displayed for 5 seconds. shifted between effective and ineffective in the
a Another message may be displayed on the order of “ON” — “OFF” — “ON” each time the
end screen, depending on the message dis- auto-deceleration switch is pressed.
play function of KOMTRAX.
Selection of working mode

Selection of auto-deceleration and auto low idle Select a working mode according to the following
While the ordinary screen is displayed, if the auto- procedure.
deceleration switch is pressed, large auto-deceler- 1. While the ordinary screen is displayed, press
ation monitor (a) is displayed for 2 seconds and the the working mode selector switch, and the
setting of the auto-deceleration is changed. working mode selection screen is displayed.
a Each time the auto-deceleration switch is
pressed, the auto-deceleration is turned ON
and OFF alternately.
a If the auto-deceleration is turned ON, large
monitor (a) and auto-deceleration monitor (b)
are displayed simultaneously.
a If the auto-deceleration is turned OFF, auto- 15702
deceleration monitor (b) goes off.
2. Operate the function switches or working mode

selector switch to select and confirm the work-
ing mode which you will use.
Function switches
q [F3]: Move to lower working mode
q [F4]: Move to upper working mode
q [F5]: Cancel selection and return to ordi-
nary screen
q [F6]: Confirm selection and return to ordi-
nary screen
Working mode selector switch
q Press: Move to lower working mode
q Hold down:Confirm selection and return to
ordinary screen
8 PC2000-8
a If you do not touch any of the function Selection of heavy lift

switches and working mode selector If the heavy lift switch is pressed with the ordinary
switch for 5 seconds, the selection is con- screen displayed, large monitor (a) of heavy lift is
firmed and the screen changes to the ordi- displayed for 2 seconds and the heavy lift setting is
nary screen. changed.
a Each time the heavy lift switch is pressed, the
heavy lift is turned ON and OFF alternately.
a If the heavy lift is turned ON, large monitor (a)
and heavy lift monitor (b) are displayed simul-
taneously.
a If the heavy lift is turned OFF, heavy lift monitor
15703 (b) goes off.
3. When the ordinary screen is displayed again,

large working mode monitor (a) is displayed for
2 seconds, and then the setting of the working
mode is changed.
a When large monitor (a) is displayed, the
display of working mode monitor (b) is
changed, too.
Operation to stop alarm buzzer

While the alarm buzzer is sounding, if the alarm
buzzer cancel switch is pressed, the alarm buzzer
stops.
a Even if the alarm buzzer cancel switch is
15704 pressed, the screen does not change.
PC2000-8 9
Operation of windshield wiper If the grease level lowers below the specified level
While the ordinary screen is displayed, if the wiper while the normal screen is displayed, grease level
switch is pressed, large wiper monitor (a) is dis- caution lamp (b) lights.
played for 2 seconds and the windshield wiper
starts or stops.
a Each time the wiper switch is pressed, the
windshield wiper setting is changed to INT, ON
(continuos, upper/lower), ON (continuos,
upper) OFF, and INT again in order.
a When large monitor (a) is displayed, the dis-
play of wiper monitor (b) is changed or turned
OFF, too.
a If the windshield wiper is turned OFF, large
monitor (a) is not displayed.
If the manual grease switch on the console is

pressed while the normal screen is displayed, man-
ual grease monitor (c) is displayed at the center of
the monitor and grease is supplied.
When greasing is completed, manual grease moni-
tor (c) goes off.
Operation of window washer 15705

While the ordinary screen is displayed, if the win-
dow washer switch is pressed, the washing liquid is
splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen does not change.
Display of auto grease monitor

If grease is supplied by the auto grease function If the auto grease system has abnormality, large
while the normal screen is displayed, auto grease auto grease caution mark (d) is displayed at the
monitor (a) lights. center of the monitor for 2 seconds and then small
When greasing is completed, auto grease monitor caution mark (e) is displayed.
(a) goes off.
10 PC2000-8
Display of truck counter a Up to 3 cameras can be connected. If the cam-

While the normal screen is displayed, the number era mode is selected, however, only the image
of times of pressing the truck counter switch on the of camera 1 is always displayed.
work equipment control lever can be displayed.
There are truck counter 1 switch and truck counter
2 switch on the work equipment control lever. Each
time truck counter 1 switch is pressed, the number
in “a” increases by 1. Each time truck counter 2
switch is pressed, the number in “b” increases by 1.
15706
a If a caution is generated in the camera mode,

the caution monitor is displayed at the left
upper of the screen (The low hydraulic oil tem-
perature caution is not displayed there, how-
ever).
a When an error that there is a user code occurs
Operation to display camera mode (if camera is in the camera mode, if you do not touch any
control lever for 10 seconds, the screen
installed)
changes to the ordinary screen and displays
When a camera is installed, if [F3] is pressed, the the error information.
multi-display changes to the camera image (Set the a When two or more cameras are connected, the
connection of the camera in the service mode). image of one of them or the images of two of
them can be displayed.
a If 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side
of the screen and the image of camera 2 is dis-
played on the right side. The image of camera
3 is displayed only singly.
a If the images of 2 cameras are displayed
simultaneously, images are displayed at inter-
vals of 1 second on the right and left screen.
PC2000-8 11
Operation to display clock and service meter Setting and display of user mode
While the ordinary screen is displayed, press [F4], While the ordinary screen is displayed, press [F6],
and section (a) changes to the service meter and and the user menu screen is displayed.
clock alternately.
a When the clock is selected, adjust the time, set
12-hour or 24-hour display, and set the sum-
mer time with the user mode function.
a There are following items in the user menu.

Screen Adjustment
ECO Display
Clock Adjustment
Check of maintenance information Language
Economy Mode Adjustment
While the maintenance monitor or ordinary screen
is displayed, press [F5], and the maintenance table Auto Low Idle
screen is displayed. Truck Counter Modification/Clear
Hydraulic Fan Reserve
15707
a To reset the time left after finishing mainte-

nance, more operations are necessary.
12 PC2000-8
Display of energy-saving guidance Display of action code and failure code

When the machine is set in a certain operating con- If an abnormality which displays an action code and
dition, the energy-saving guidance screen is dis- a failure code occurs on the ordinary screen or
played automatically to urge the operator to the camera mode screen, all the information of the
energy-saving operation. abnormality is displayed.
a The energy-saving guidance is displayed when (a): Action code (3 digits)
the following condition is satisfied while the (b): Failure code (5 or 6 digits)
display setting is set effective in the service (c): Telephone mark
mode. (d): Telephone No.
a Condition for display: a This screen is displayed only when an abnor-
Engine is running + All levers have been in mality (failure code) for which an action code is
neutral for 5 minutes + Caution (Note) or user set occurs.
code is not generated (Note) a The telephone mark and telephone No. are
Note: Excluding hydraulic oil low temperature displayed only when the telephone No. is reg-
caution istered in the service mode.
a If any lever or pedal is operated, or [F5] is a If multiple abnormalities occur simultaneously,
pressed, the screen returns to the ordinary all the codes are displayed repeatedly in order.
screen. a Since the information of the displayed failure
code is recorded in the abnormality record in
the service mode, check the details in the ser-
vice mode.
Display of caution monitor

If an abnormality which displays a caution monitor
occurs on the ordinary screen or camera mode
screen, the caution monitor is displayed large for a a When the caution monitor is also displayed,
moment and then displayed at (a) in the screen. the telephone mark is not displayed.
a On the camera mode screen, the caution mon-
itor flashes at the left upper of the screen when
the caution is generated.
PC2000-8 13
a Remedies given by displayed action codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
Action
Failure mode Action
code
E02 Sensor power supply error
Move the swing brake cancel switch up to release the brake.
When applying the swing brake, operate the swing lock switch
E03 Swing brake system error manually. Depending on the cause of the problem, it may not
be possible to release it. In any case, have inspection carried
out immediately.
An error occurs in the electronic control system of the pump.
Emergency avoidance function is underway.
E07 Pump control system error Some functions of the machine are disabled.
Operations are possible, but nave inspection carried out
immediately.
Engine controller power source error
E10 Engine controller drive system circuit error Have inspection carried out immediately.
(engine stopped)
Engine controller system error
Operate machine to a safe posture and have inspection carried
E11 Output reduced to protect engine
out immediately.
Fan drive system error
Operate machine to a safe posture and have inspection carried
E14 Abnormality in throttle system
out immediately.
Engine sensor (coolant temperature, fuel Operations are possible, but have inspection carried out
E15
pressure, oil pressure) system error immediately.
Network error Operate machine to a safe posture and have inspection carried
E0E
Solenoid power supply system error out immediately.
14 PC2000-8
Function of checking display of LCD (Liquid Function of checking service meter

Crystal Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are as follows. At this time, only the service meter sec-
operated as follows, all the LCD (Liquid Crystal Dis- tion displays.
play) lights up in white. q Operation of switches (simultaneous): [4] + [1]
q Operation of switches (simultaneous): [4] + [F2] a Since there is some time lag in start of the
a When finishing the operation of the switches, LCD, hold down the switches until the LCD dis-
release [F2] first. plays normally.
a If there is a display error in the LCD, only that a After the machine monitor is used continu-
part is indicated in black. ously, blue points (points which do not go off)
a The LCD panel sometimes has black points may be seen on this screen. This phenomenon
(points which are not lighted) and bright points does not indicate a failure or a defect.
(points which do not go off) for the reason of its
characteristics. If the number of the bright
points and black points does not exceed 10,
those points are not a failure or a defect.
a To return to the former screen, press the func-
tion switch.
PC2000-8 15
Function of changing maintenance password 3. After the New password input screen is dis-
When changing the maintenance password used played, input a new password with the numeral
for the maintenance setting function, follow these input switches and confirm it with the function
procedures. switch.
1. While the ordinary screen is displayed, perform a Set a new password of 4 – 6 digits (If it
the following operation with the numeral input has only 3 or less digits or has 7 or more
switches. digits, it is not accepted).
q Operation of switches (While pressing [4], q [F5]: Reset input numeral/Return to ordi-
perform the operation in order): nary screen
[4] + [5] o [5] o [5] q [F6]: Confirm input numeral
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.
4. After the New password input screen is dis-

played again, input a new password again with
the numeral input switches and confirm it with
2. After the Maintenance PASSWORD screen is the function switch.
displayed, input the current password with the q [F5]: Reset input numeral/Return to ordi-
numeral input switches and confirm it with the nary screen
function switch. q [F6]: Confirm input numeral
q [F5]: Reset input numeral/Return to ordi- a If a password different from the password
nary screen input before is input, the message to input
q [F6]: Confirm input numeral again is displayed.
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to input the password again is dis-
played.
16 PC2000-8
5. If the screen to notify completion of setting is

displayed and then the ordinary screen is dis-
played, the password is changed successfully.
PC2000-8 17
t Service mode a The items which can be selected in the

To change the operator mode to the service mode, service menu are as follows (including
perform the following operation. some items which need special opera-
This operation is always required when you use the tions).
service mode. 01 Monitoring
1. Check of display of screen and operation of Abnormality Mechanical Systems

02
switches Record Electrical Systems
While the ordinary screen is displayed, perform 03 Maintenance Record
the following operation with the numeral input
switches. 04 Maintenance Mode Change
q Operation of switches (While pressing [4], 05 Phone Number Entry
perform the operation in order): Key-on Mode
[4] + [1] o [2] o [3]
a This operation of the switches is accepted Unit
only while the ordinary screen is displayed. 06 Default Maintenance Password
Camera
ECO Display
Pump Absorption Torque
Adjustment of auto grease pump
discharge pressure
Interval adjustment of auto grease
Operation time adjustment of auto
grease pump
Setting of grease start time after
operation
07 Adjustment
Selection of fan speed mode
Adjustment of RAD fan 100%
speed
2. Selection of service menu Adjustment of O/C fan 100%
When the Service menu screen is displayed, speed
the service mode is selected. Select a service Adjustment of RAD fan 70%
menu you use with the function switches or speed
numeral input switches.
Adjustment of O/C fan 70% speed
q [F3]: Move to lower menu
q [F4]: Move to upper menu 08 Cylinder Cut-Out
q [F5]: Return to ordinary screen (operator 09 No Injection
mode)
10 Snap shot
q [F6]: Confirm selection
a You may enter a 2-digit code with the 11 Fuel Consumption
numeral input switches to select the menu 12 PM clinic
of that code and confirm it with [F6].
18 PC2000-8
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc. 15708
1. Selecting menu
Select “Monitoring” on the service menu
screen.
3. Deciding monitoring items

After selecting monitoring items, execute moni-
toring with the function switch or numeral input
switch.
a Execution with function switch: Double-
click or hold down [F6] (about 2 seconds).
a Execution with numeral input switch: Input
[99999] and press [F6].
a When monitoring only 2 items, for exam-
ple, select them and confirm with [F6]. If
[F6] is pressed once more at this time,
2. Selecting monitoring items monitoring is executed.
After the “Monitoring selection menu screen” is a If monitoring items are selected up to the
displayed, select items to be monitored with limit number, monitoring is executed auto-
t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t matically.
switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Reset input numeral/Return to ser-
vice menu screen 15709
a Selection with function switches: Select an
item with [F3] or [F4] and confirm it with
[F6].
a Selection with numeral input switches:
Enter a 5-digit code, and the item of that
code is selected directly. Confirm that item
with [F6].
a If the color of the selected box changes
from yellow to red, selection of the item of
that box is confirmed.
a Up to 6 monitoring items can be selected
at a time. You may not able to set up to 6
items, however, depending on the display
form of those items.
PC2000-8 19
4. Executing monitoring 6. Changing machine setting mode

After the “Executing monitoring screen” is dis- To change the setting of the working mode,
played, perform the necessary operation of the travel speed, or auto-deceleration during moni-
machine and check the monitoring information. toring, operate the corresponding switch under
a Monitoring information is indicated by the current condition, and the mode setting
value, ON/OFF, or special display. screen is displayed.
a The unit of display can be set to “SI unit”, While this screen is displayed, if the corre-
“metric unit”, or “inch unit” with the Initial- sponding switch is operated further, the corre-
ization function in the service mode. sponding mode is changed.
a After finishing changing the setting, press
[F6] to return to the monitoring information
screen.
a If the setting is changed during monitoring,
the new setting is held even after the
screen returns to the ordinary screen after
15710 monitoring is finished.
15712
5. Holding monitoring information

The monitoring information can be held and
reset with the function switches.
q [F3]: Reset holding
q [F4]: Hold information (displayed data)
q [F5]: Return to monitoring selection menu
screen
15711
20 PC2000-8
Monitoring items table

Code Component in Unit (Initial setting: ISO)
Monitoring item
No. charge ISO meter inch
00200 Controller Model Select PUMP —
00201 Machine ID ENG (1st) —
00203 Machine ID ENG (2nd) —
01601 2nd Engine Speed Command PUMP (1st) r/min rpm rpm
12100 1st Engine Speed Command PUMP (1st) r/min rpm rpm
01002 Engine speed ENG (1st), PUMP r/min rpm rpm
01006 Engine speed PUMP r/min rpm rpm
10001 RAD Fan Speed PUMP (1st) r/min rpm rpm
10004 O/C Fan Target Speed PUMP (1st) r/min rpm rpm
04206 Fuel Level PUMP (1st) % % %
01124 P1F Pump Pressure PUMP (1st) MPa kg/cm2 psi
01125 P1R Pump Pressure PUMP (1st) MPa kg/cm2 psi
2
01126 P2F Pump Pressure PUMP (1st) MPa kg/cm psi
01127 P2R Pump Pressure PUMP (1st) MPa kg/cm2 psi
01132 RAD Fan Pump Pressure PUMP (1st) MPa kg/cm2 psi
01134 O/C Fan Pump Pressure PUMP (1st) MPa kg/cm2 psi
2
07400 Boom Raise PPC Pressure PUMP (2nd) MPa kg/cm psi
07500 Boom Lower PPC Pressure PUMP (2nd) MPa kg/cm2 psi
07200 Arm Curl PPC Pressure PUMP (2nd) MPa kg/cm2 psi
07600 Arm Dump PPC Pressure PUMP (2nd) MPa kg/cm2 psi
2
07300 Bucket Curl PPC Pressure PUMP (2nd) MPa kg/cm psi
07301 Bucket Dump PPC Pressure PUMP (2nd) MPa kg/cm2 psi
09001 Swing Left PPC Pressure PUMP (2nd) MPa kg/cm2 psi
09002 Swing Right PPC Pressure PUMP (2nd) MPa kg/cm2 psi
2
13804 VR1 J/S Diff Pressure PUMP (1st) MPa kg/cm psi
13805 VL1 J/S Diff Pressure PUMP (1st) MPa kg/cm2 psi
13806 VR2 J/S Diff Pressure PUMP (1st) MPa kg/cm2 psi
13807 VL2 J/S Diff Pressure PUMP (1st) MPa kg/cm2 psi
2
13900 Auto Grease Disc Pressure PUMP (2nd) MPa kg/cm psi
36400 L/B Rail Pressure ENG (1st) MPa kg/cm2 psi
36403 R/B Rail Pressure ENG (2nd) MPa kg/cm2 psi
36500 L/B Charge Pressure ENG (1st) kPa kg/cm2 psi
2
37200 Engine Oil Pressure ENG (1st) kPa kg/cm psi
37400 Ambient Pressure ENG (1st) kPa kg/cm2 psi
42800 Blowby Pressure VHMS kPa kg/cm2 psi
04401 Hydr. Oil Temperature PUMP (2nd) °C °C °F
04405 VHMS Hydr. Oil Temperature VHMS °C °C °F
37501 Ambient Temperature VHMS °C °C °F
04107 Coolant Temperature ENG (1st) °C °C °F
14200 L/B Fuel Temperature ENG (1st) °C °C °F
14203 R/B Fuel Temperature ENG (2nd) °C °C °F
18400 Intake Temperature ENG (1st) °C °C °F
18500 Charge Temperature ENG (1st) °C °C °F
42700 Engine Oil Temperature ENG (1st) °C °C °F
30000 PTO Oil Temperature VHMS °C °C °F
42600 L/B1-3 Exhaust Temperature VHMS °C °C °F
42601 L/B4-6 Exhaust Temperature VHMS °C °C °F
42608 R/B1-3 Exhaust Temperature VHMS °C °C °F
42609 R/B4-6 Exhaust Temperature VHMS °C °C °F
01307 P1F Pump EPC Act Current PUMP (1st) mA mA mA
PC2000-8 21

Monitoring item
01309 P1R Pump EPC Act Current PUMP (1st) mA mA mA
01311 P2F Pump EPC Act Current PUMP (1st) mA mA mA
01313 P2R Pump EPC Act Current PUMP (1st) mA mA mA
31624 RAD Fan Pump EPC Current PUMP (1st) mA mA mA
31634 O/C Fan Pump EPC Current PUMP (1st) mA mA mA
01128 P1F Pump Press Volt PUMP (1st) V V V
01129 P1R Pump Press Volt PUMP (1st) V V V
01130 P2F Pump Press Volt PUMP (1st) V V V
01131 P2R Pump Press Volt PUMP (1st) V V V
04403 Hydr. Oil Temp Sensor Volt PUMP (2nd) V V V
04406 VHMS Hydr. Oil Temp Sens Volt VHMS V V V
01133 RAD Fan Pump Press Sensor Volt PUMP (1st) V V V
01135 O/C Fan Pump Press Sensor Volt PUMP (1st) V V V
03200 Battery Volt PUMP V V V
04300 Battery Charge Volt MON V V V
07201 Arm Curl PPC Press Volt PUMP (2nd) V V V
07302 Bucket Curl PPC Press Volt PUMP (2nd) V V V
07303 Bucket Dump PPC Press Volt PUMP (2nd) V V V
07401 Boom Raise PPC Press Volt PUMP (2nd) V V V
07501 Boom Lower PPC Press Volt PUMP (2nd) V V V
07601 Arm Dump PPC Press Volt PUMP (2nd) V V V
09003 Swing Left PPC Press Volt PUMP (2nd) V V V
09004 Swing Right PPC Press Volt PUMP (2nd) V V V
13808 VR1 J/S Diff Press Volt PUMP (1st) V V V
13809 VL1 J/S Diff Press Volt PUMP (1st) V V V
13810 VR2 J/S Diff Press Volt PUMP (1st) V V V
13811 VL2 J/S Diff Press Volt PUMP (1st) V V V
13901 Auto Grease Disc Press Volt PUMP (2nd) V V V
37505 Ambient Air Temp Sens Volt VHMS V V V
03000 Fuel Dial Pos Sens Volt ENG (1st) V V V
03203 L/B Battery Power Supply ENG (1st) V V V
03206 R/B Battery Power Supply ENG (2nd) V V V
04105 Coolant Temp Sens Volt ENG (1st) V V V
04200 Fuel Level Sensor Volt MON V V V
14201 L/B Fuel Temp Sens Volt ENG (1st) V V V
14202 R/B Fuel Temp Sens Volt ENG (2nd) V V V
17201 L/B PCV Close Timing ENG (1st) CA CA CA
17202 R/B PCV Close Timing ENG (2nd) CA CA CA
18401 Intake Temp Sens Volt ENG (1st) V V V
18501 Charge Temp Sens Volt ENG (1st) V V V
36401 L/B Rail Pressure Sens Volt ENG (1st) V V V
36404 R/B Rail Pressure Sens Volt ENG (2nd) V V V
36501 Charge Press Sens Volt ENG (1st) V V V
37201 Eng Oil Press Sens Volt ENG (1st) V V V
37401 Ambient Press Sens Volt ENG (1st) V V V
42701 Eng Oil Temp Sens Volt ENG (1st) V V V
30001 PTO Oil Temp Sens Volt VHMS V V V
42603 L/B1-3 Exhaust Temp Sens Volt VHMS V V V
42604 L/B4-6 Exhaust Temp Sens Volt VHMS V V V
42605 R/B1-3 Exhaust Temp Sens Volt VHMS V V V
42607 R/B4-6 Exhaust Temp Sens Volt VHMS V V V
22 PC2000-8

Monitoring item
42802 Blowby Pressure Sens Volt VHMS V V V
01306 P1F Pump EPC Current PUMP (1st) mA mA mA
01308 P1R Pump EPC Current PUMP (1st) mA mA mA
01310 P2F Pump EPC Current PUMP (1st) mA mA mA
01312 P2R Pump EPC Current PUMP (1st) mA mA mA
10002 RAD Fan Target Speed (70%) PUMP (1st) r/min rpm rpm
10003 RAD Fan Target Speed (Max) PUMP (1st) r/min rpm rpm
10005 O/C Fan Target Speed (70%) PUMP (1st) r/min rpm rpm
10006 O/C Fan Target Speed (Max) PUMP (1st) r/min rpm rpm
31623 RAD Fan Pump EPC Current PUMP (1st) mA mA mA
31633 O/C Fan Pump EPC Current PUMP (1st) mA mA mA
17500 Engine Power Mode ENG (1st) — — —
18600 Inject Fueling Command ENG (1st) mg/st mg/st mg/st
18700 Engine Output Torque ENG (1st) Nm kgm lbft
31701 Throttle Position ENG (1st) % % %
31706 Final Throttle Position ENG (1st) % % %
36200 Rail Press Command ENG (1st) MPa kg/cm2 psi
36300 Injection Timing Command ENG (1st) CA CA CA
36700 Engine Torque Ratio ENG (1st) % % %
13113 Pump Total Torque PUMP (1st) Nm kgm lbft
13114 RAD Fan Pump Torque PUMP (1st) Nm kgm lbft
13115 O/C Fan Pump Torque PUMP (1st) Nm kgm lbft
13116 P1F Pump Target Torque PUMP (1st) Nm kgm lbft
13117 P1F Pump Actual Torque PUMP (1st) Nm kgm lbft
13118 P1R Pump Target Torque PUMP (1st) Nm kgm lbft
13119 P1R Pump Actual Torque PUMP (1st) Nm kgm lbft
13120 P2F Pump Target Torque PUMP (1st) Nm kgm lbft
13121 P2F Pump Actual Torque PUMP (1st) Nm kgm lbft
13122 P2R Pump Target Torque PUMP (1st) Nm kgm lbft
13123 P2R Pump Actual Torque ENG (1st) Nm kgm lbft
37300 Fuel Rate ENG (1st) l/h l/h gal/h
Pressure Switch 1 PUMP (2nd)
Boom Lower PUMP (2nd)
01900 Boom Raise PUMP (2nd) ON or OFF
Arm Curl PUMP (2nd)
Arm Dump PUMP (2nd)
Pressure Switch 2 PUMP (2nd)
Bucket Curl PUMP (2nd)
01901 ON or OFF
Bucket Dump PUMP (2nd)
Service PUMP (2nd)
Pressure Switch 3 PUMP
Swing Left PUMP (2nd)
01902 Swing Right PUMP (2nd) ON or OFF
Travel Left PUMP (2nd)
Travel Right PUMP (2nd)
Solenoid Valve 1 PUMP (2nd)
Travel Straight PUMP (2nd)
02300 ON or OFF
Swing Brake PUMP (2nd)
2-Stage Relief PUMP (2nd)
PC2000-8 23

Monitoring item
Swing Priority PUMP (2nd)
02301 ON or OFF
Bucket Hi Cancel PUMP (2nd)
Boom Throttle PUMP (2nd)
Back Press Competing/L PUMP (2nd)
02302 ON or OFF
Arm Throttle/L PUMP (2nd)
Arm Throttle/R PUMP (2nd)
Solenoid Valve 4 PUMP (1st)
RAD Fan Reverse PUMP (1st)
02303 ON or OFF
O/C Fan Reverse PUMP (1st)
Auto Grease PUMP (1st)
Switch Input 1 PUMP (2nd)
02200 Swing Release Sw PUMP (2nd) ON or OFF
Swing Brake Sw PUMP (2nd)
Pump 2 Model Select 1 PUMP (2nd)
02205 ON or OFF
Switch Input 3 PUMP (1st)
02206 Key Switch (ACC) PUMP (1st) ON or OFF
Key Switch (C) PUMP (1st)
Manual Grease PUMP (1st)
Fuel Level Hi PUMP (1st)
02307 ON or OFF
Fuel Level Mid PUMP (1st)
Fuel Level Low PUMP (1st)
Grease Lo Level PUMP (1st)
Key Switch (ACC) PUMP (2nd)
Key Switch (C) PUMP (2nd)
02308 ON or OFF
Wiper Upper Sw PUMP (2nd)
Wiper Upper Limit Sw PUMP (2nd)
Wiper Lower Limit Sw PUMP (2nd)
Pump 1 Model Select 1 PUMP (1st)
02209 ON or OFF
Step Light Switch PUMP (2nd)
02210 ON or OFF
Horn Switch PUMP (2nd)
Ladder Down Signal PUMP (2nd)
24 PC2000-8

Monitoring item
Controller Output 1 PUMP (2nd)
Wiper Upper On PUMP (2nd)
03700 Wiper Upper Brake PUMP (2nd) ON or OFF
Wiper Lower On PUMP (2nd)
Wiper Lower Brake PUMP (2nd)
Controller Output 2 PUMP (2nd)
Step L. Relay PUMP (2nd)
03701 Flash L. Relay PUMP (2nd) ON or OFF
Travel Alarm PUMP (2nd)
Washer Relay PUMP (2nd)
Controller Output 3 PUMP (1st)
03702 Auto Grease Caution PUMP (1st) ON or OFF
Fan Reverse PUMP (1st)
Controller Output 4 PUMP (1st)
03703 ON or OFF
Battery Relay Output PUMP (1st)
Monitor input 1 MON
Key Switch MON
Start MON
04500 ON or OFF
Preheat MON
Light MON
Rad. Level MON
Monitor Input 2 MON
Aircleaner MON
04501 ON or OFF
Engine Oil Level MON
Battery Charge MON
Monitor Input 3 MON
04502 ON or OFF
Swing Brake Sw MON
VHMS Input 1 VHMS
Hyd Oil Level Sw VHMS
Hyd Oil Level Filter Clog Sw VHMS
40966 ON or OFF
Truck Counter Sw1 VHMS
Truck Counter Sw2 VHMS
PTO Oil Lv Sw/Opt VHMS
Orbcomm Communication Status VHMS
Controller Power VHMS
99003 ON or OFF
Satellite Condition VHMS
Data Transmission VHMS
20216 ECM Build Version ENG (1st) —
20217 L/B ECM Calibration Data Ver ENG (1st) —
20218 R/B ECM Calibration Data Ver ENG (2nd) —
18900 L/B ECM Internal Temp ENG (1st) °C °C °F
18902 R/B ECM Internal Temp ENG (2nd) °C °C °F
20400 L/B ECM S/N ENG (1st) —
20401 R/B ECM S/N ENG (2nd) —
20227 Monitor Ass'y P/N MON —
20402 Monitor Serial No MON —
20228 Monitor Prog. P/N MON —
20200 Monitor Program Version MON —
20229 Pump Con1 Ass'y P/N PUMP —
20403 Pump Con1 Serial No PUMP —
PC2000-8 25

Monitoring item
20230 Pump Con1 Prog. P/N PUMP —
20212 Pump Controller 1 Program Ver PUMP —
20249 Pump Con2 Ass'y P/N PUMP —
20407 Pump Con2 Serial No PUMP —
20220 Pump Con2 Prog. P/N PUMP —
20250 Pump Controller 2 Program Ver PUMP —
a Entry order of items in table

The items are entered in the order of display on the monitoring selection menu screen.
a Unit
The display unit can be set to “ISO”, “meter”, or “inch” freely (Set it with “Unit selecting” in Initialization of
the service menu).
“CA” in the display unit is an abbreviation for crankshaft angle.
“mg/st” in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of monitoring information.
ENG: The engine controller is in charge of detection of monitoring information.
PUMP: The pump controller is in charge of detection of monitoring information.
VHMS: The VHMS controller is in charge of detection of monitoring information.
26 PC2000-8
Abnormality Record (Mechanical Systems)

The machine monitor classifies and records the
abnormalities which occurred in the past or which
are occurring at present into the mechanical sys-
tems, electrical systems, and air-conditioning sys-
tem or heater system.
To check the mechanical system abnormality 15713
record, perform the following procedures.
1. Selecting menu
Select “Abnormality Record” on the “Service
Menu” screen.
3. Information displayed on “abnormality record”

screen
On the “Mechanical Systems” screen, the fol-
lowing information is displayed.
(a) : Occurrence order of abnormalities from
latest one/Total number of records
(b) : Failure code
(c) : Contents of trouble
(d) : Number of occurrence time (Displayable
range: 0 – 65,535 times)
(e) : Service meter reading at first occurrence
(f) : Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
2. Selecting sub menu played)
After the “Abnormality Record” screen is dis- q [F2]: Move to previous page (screen) (if
played, select “Mechanical Systems” with the displayed)
function switches or numeral input switches. q [F5]: Return to abnormality record screen
q [F3]: Move to lower item a If no abnormality record is recorded, “No
q [F4]: Move to upper item abnormality record” is displayed.
q [F5]: Return to service menu screen a If the number of occurrence time is 1 (first
q [F6]: Confirm selection occurrence), the service meter reading at
a You may enter a 2-digit code with the the first occurrence and that at the last
numeral input switches to select the record occurrence are the same.
of that code and confirm it with [F6]. a If [E] is displayed on the left of a failure
a The following figure shows the display of code, the abnormality is still occurring or
the air conditioner specification. The resetting of it has not been confirmed.
heater specification and heaterless speci- a For all the failure codes that the machine
fication are different from each other in the monitor can record, see the failure codes
display of “03 Air-conditioning System”, table in “Abnormality Record (Electrical
which may not be displayed in the heater- Systems)”.
less specification.
PC2000-8 27
4. Resetting abnormality record

The contents of the mechanical system
abnormality record cannot be reset.
Abnormality Record (Electrical Systems)

The machine monitor classifies and records the 15713
abnormalities which occurred in the past or which
are occurring at present into the mechanical sys-
tems and electrical systems.
To check the electrical system abnormality record,
perform the following procedures.
1. Selecting menu
Select “Abnormality Record” on the “Service 3. Information displayed on “abnormality record”
Menu” Screen. screen
On the “Electrical Systems” screen, the follow-
ing information is displayed.
(a) : Occurrence order of abnormalities from
latest one/Total number of records
(b) : Failure code
(c) : Contents of trouble
(d) : Number of occurrence time (Displayable
range: 0 – 65,535 times)
(e) : Service meter reading at first occurrence
(f) : Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if
displayed)
2. Selecting sub menu q [F4]: Move to upper item
After the “Abnormality Record” screen is dis- q [F5]: Return to “abnormality record” screen
played, select “Electrical Systems” with the a If no abnormality record is recorded, “No
function switches or numeral input switches. abnormality record” is displayed.
q [F3]: Move to lower item a If the number of occurrence time is 1 (first
q [F4]: Move to upper item occurrence), the service meter reading at
q [F5]: Return to service menu screen the first occurrence and that at the last
q [F6]: Confirm selection occurrence are the same.
a You may enter a 2-digit code with the a If [E] is displayed on the left of a failure
numeral input switches to select the code, the abnormality is still occurring or
record of that code and confirm it with resetting of it has not been confirmed.
[F6]. a For all the failure codes that the machine
a The following figure shows the display of monitor can record, see the failure codes
the air conditioner specification. The table.
heater specification and heaterless speci-
fication are different from each other in the
display of “03 Air-conditioning System”,
which may not be displayed in the heater-
less specification.
15714
28 PC2000-8
4. Resetting abnormality record 3) After the “Electrical Sys. Error Reset”

1) While the “Electrical Systems” screen is screen is displayed, operate the function
displayed, perform the following operation switches.
with the numeral input switches. q [F5]: Return to “Electrical systems”
q Operation of switches (While pressing screen (Reset mode)
[4], perform the operation in order): q [F6]: Execute reset
[4] + [1] o [2] o [3] a The following figure shows the screen
displayed when the items are reset
one by one (which is a little different
from the screen displayed when all
the items are reset together).
15715
2) Check that the screen is set in the reset

mode, and then reset the items one by
one or together with the function switches.
a If the screen is set in the reset mode,
[CLEAR] graphic mark is indicated at 4) If the screen to notify completion of reset
[F2]. is displayed and then the “Electrical Sys-
q [F2]: Reset all items tems” (reset mode) screen is displayed,
q [F3]: Move to lower item the reset of the abnormality record is com-
q [F4]: Move to upper item pleted.
q [F5]: Return to abnormality record a After a while, the screen returns to
screen the “Electrical Systems” screen.
q [F6]: Reset selected item
a To reset items one by one: Select the
item to be reset with [F3] or [F4] and
press [F6].
a To reset all items together: Press [F2],
and all the items are reset, regardless
of selection of the items.
a If [E] is displayed on the left of a fail-
ure code, the resetting operation is
accepted but the information is not
reset.
15716
PC2000-8 29
Failure code table
Action Applicable History

Failure code Failure contents
code equipment classification
0410KA
Fuel LV. Sensor Failure — VHMS Mechanical system
[n4o04]
0410KB
Fuel LV. Sensor Failure — VHMS Mechanical system
[n4o05]
6014NX
Hydraulic Oil Filter Clogging — VHMS Mechanical system
[n5o51]
8800ZG Auto grease abnormally — PUMP Mechanical system
7@HAZL VR1/P1F Relief Press Abnormality — PUMP Mechanical system
7@HBZL VL1/P1R Relief Press Abnormality — PUMP Mechanical system
7@HCZL VR2/P2F Relief Press Abnormality — PUMP Mechanical system
7@HDZL VL2/P2R Relief Press Abnormality — PUMP Mechanical system
AA10NX Aircleaner Clogging — MON Mechanical system
AB00KE Change Voltage Low — MON Mechanical system
aB00KE
Low Upper ALR Charge Voltage — VHMS Mechanical system
[n9o11]
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@CBNS
High PTO Temperature — VHMS Mechanical system
[n9o11]
B@HANS Hydr. Oil Overheat — MON Mechanical system
B@HAZK
Low Hydraulic Oil Level — VHMS Mechanical system
[n5o52]
CA111 ECM Critical Internal Failure E10 ENG Electrical system
CB111 ECM Critical Internal Failure E10 ENG Electrical system
CA115 Eng. Ne and Bkup Speed Sens Error E10 ENG Electrical system
CB115 Eng. Ne and Bkup Speed Sens Error E10 ENG Electrical system
CA122 Chg Air Press Sensor High Error E11 ENG Electrical system
CA123 Chg Air Press Sensor Low Error E11 ENG Electrical system
CA131 Throttle Sensor High Error E14 ENG Electrical system
CA132 Throttle Sensor Low Error E14 ENG Electrical system
CA135 Eng Oil Press Sensor High Error E15 ENG Electrical system
CA141 Eng Oil Press Sensor Low Error E15 ENG Electrical system
CA144 Coolant Temp Sens High Error E15 ENG Electrical system
CA145 Coolant Temp Sens Low Error E15 ENG Electrical system
CA153 Chg Air Temp Sensor High Error E15 ENG Electrical system
CA154 Chg Air Temp Sensor Low Error E15 ENG Electrical system
CA187 Sens Supply 2 Volt Low Error E15 ENG Electrical system
CB187 Sens Supply 2 Volt Low Error E15 ENG Electrical system
CA212 Eng Oil Temp Sensor High Error E15 ENG Electrical system
CA213 Eng Oil Temp Sensor Low Error E15 ENG Electrical system
CA221 Ambient Press Sens High Error E15 ENG Electrical system
CA222 Ambient Press Sens Low Error E15 ENG Electrical system
CA227 Sens Supply 2 Volt High Error E15 ENG Electrical system
30 PC2000-8

CB227 Sens Supply 2 Volt High Error E15 ENG Electrical system
CA234 Eng Over Speed E15 ENG Electrical system
CA238 Ne Speed Sens Supply Volt Error E15 ENG Electrical system
CB238 Ne Speed Sens Supply Volt Error E15 ENG Electrical system
CA263 Fuel Temp Sensor High Error E15 ENG Electrical system
CB263 Fuel Temp Sensor High Error E15 ENG Electrical system
CA265 Fuel Temp Sensor Low Error E15 ENG Electrical system
CB265 Fuel Temp Sensor Low Error E15 ENG Electrical system
CA271 IMV/PCV1 Short Error E10 ENG Electrical system
CB271 IMV/PCV1 Short Error E10 ENG Electrical system
CA272 IMV/PCV1 Open Error E10 ENG Electrical system
CB272 IMV/PCV1 Open Error E10 ENG Electrical system
CA273 PCV2 Short Error E10 ENG Electrical system
CB273 PCV2 Short Error E10 ENG Electrical system
CA274 PCV2 Open Error E10 ENG Electrical system
CB274 PCV2 Open Error E10 ENG Electrical system
CA322 Inj #1(L#1) Open/Short Error E11 ENG Electrical system
CA342 Calibration Code Incompatibility E10 ENG Electrical system
CB342 Calibration Code Incompatibility E10 ENG Electrical system
CA351 Injectors Drive Circuit Error E10 ENG Electrical system
CB351 Injectors Drive Circuit Error E10 ENG Electrical system
CA352 Sens Supply 1 Volt Low Error E15 ENG Electrical system
CB352 Sens Supply 1 Volt Low Error E15 ENG Electrical system
CA386 Sens Supply 1 Volt High Error E15 ENG Electrical system
CB386 Sens Supply 1 Volt High Error E15 ENG Electrical system
CA441 Battery Voltage Low Error E10 ENG Electrical system
CB441 Battery Voltage Low Error E10 ENG Electrical system
CA442 Battery Voltage High Error E10 ENG Electrical system
CB442 Battery Voltage High Error E10 ENG Electrical system
CA449 Rail Press Very High Error E11 ENG Electrical system
CB449 Rail Press Very High Error E11 ENG Electrical system
CA451 Rail Press Sensor High Error E11 ENG Electrical system
CB451 Rail Press Sensor High Error E11 ENG Electrical system
CA452 Rail Press Sensor Low Error E11 ENG Electrical system
CB452 Rail Press Sensor Low Error E11 ENG Electrical system
CA553 Rail Press High Error E15 ENG Electrical system
CB553 Rail Press High Error E15 ENG Electrical system
CA554 Rail Press Sensor In Range Error E11 ENG Electrical system
CB554 Rail Press Sensor In Range Error E11 ENG Electrical system
PC2000-8 31

CA559 Rail Press Low Error E15 ENG Electrical system
CB559 Rail Press Low Error E15 ENG Electrical system
CA689 Eng Ne Speed Sensor Error E15 ENG Electrical system
CB689 Eng Ne Speed Sensor Error E15 ENG Electrical system
CA691 Intake Air Temp Sens High Error E15 ENG Electrical system
CA692 Intake Air Temp Sens Low Error E15 ENG Electrical system
CA731 Eng Bkup Speed Sens Phase Error E15 ENG Electrical system
CB731 Eng Bkup Speed Sens Phase Error E15 ENG Electrical system
CA757 All Persistent Data Lost Error E10 ENG Electrical system
CB757 All Persistent Data Lost Error E10 ENG Electrical system
CA778 Eng Bkup Speed Sensor Error E15 ENG Electrical system
CB778 Eng Bkup Speed Sensor Error E15 ENG Electrical system
CA781 CEN Communication Error E0E ENG Electrical system
CB781 CEN Communication Error E0E ENG Electrical system
CA1117 Persistent Data Lost Error E10 ENG Electrical system
CB1117 Persistent Data Lost Error E10 ENG Electrical system
CA1257 Harness Key Error E0E ENG Electrical system
CB1257 Harness Key Error E0E ENG Electrical system
CB1548 Inj #7(R#1) Open/Short Error E11 ENG Electrical system
CA1633 KOMNET Data link Time out Error E0E ENG Electrical system
CA2185 Throt Sens Sup Volt High Error E14 ENG Electrical system
CA2186 Throt Sens Sup Volt Low Error E14 ENG Electrical system
CA2249 Rail Press Very Low Error E11 ENG Electrical system
CB2249 Rail Press Very Low Error E11 ENG Electrical system
CA2555 Grid Heater Relay Volt Low Error E15 ENG Electrical system
CA2556 Grid Heater Relay Volt High Error E15 ENG Electrical system
D110KB Battery Relay Drive S/C — MON Electrical system
D163KB Flash Light Relay S/C — MON Electrical system
D195KA Step Light Relay Disc — MON Electrical system
D195KY Step Light Relay S/C — MON Electrical system
D1E9KB Wiper Drive Relay 1 S/C — MON Electrical system
D1EAKB Wiper Drive Relay 2 S/C — MON Electrical system
D1EBKB Low Wiper Brake Relay Short Circuit — MON Electrical system
D1ECKB Upper Wiper Brake Relay Short Circuit — MON Electrical system
DA22KK Pump 1 Solenoid Power Low Error E0E PUMP Electrical system
dA22KK Pump 2 Solenoid Power Low Error E0E PUMP Electrical system
DA25KP Pump 1 Sens Supply Vol Low Error E07 PUMP Electrical system
dA25KP Pump 2 Sens Supply Vol Low Error — PUMP Electrical system
DA26KP 5V Sensor 2 Power Abnormality E07 PUMP Electrical system
32 PC2000-8

DA29KQ Pump 1 Model Select Abnormality — PUMP Electrical system
dA29KQ Pump 2 Model Select Abnormality — PUMP Electrical system
DA2RMC CAN Discon (Pump 1 Con Detected) E0E PUMP Electrical system
dA2RMC CAN Discon (Pump 2 Con Detected) E0E PUMP Electrical system
DA2SKQ Model Selection Abnormality — PUMP Electrical system
DA2TMC Pump Comm. ECM Child Abnormality — PUMP Electrical system
DAFRMC Monitor Comm. Abnormality E0E MON Electrical system
DBB0KK
VHMS Source Voltage Error — VHMS
[n9o01]
DBB0KQ
VHMS Connector Mismatch — VHMS
[nFo11]
DBB5KP
VHMS 5V source sys Error — VHMS
[n9o04]
DBB6KP
[n9o02]
DBB7KP
[n9o03]
DBBQKR
KOM-NET/c error — VHMS
[n8o02]
DGE5KK
Ambient Air Temp Sensor Failure — VHMS
[n4o01]
DGH2KB Hydr. Oil Temp. Sensor S/C — PUMP Electrical system
DGT3KZ
PTO Temp Sensor Failure — VHMS Electrical system
[n5o01]
DGT5KA
Exhaust Temp. Sensor LBF Failure — VHMS Electrical system
[n3o12]
dGT5KA
Exhaust Temp. Sensor LBR Failure — VHMS Electrical system
[n3o22]
DGT5KB
Exhaust Temp. Sensor LBF Failure — VHMS
[n3o11]
dGT5KB
Exhaust Temp. Sensor LBR Failure — VHMS
[n3o21]
DGT6KA
Exhaust Temp. Sensor RBF Failure — VHMS
[n3o24]
dGT6KA
Exhaust Temp. Sensor RBR Failure — VHMS
[n3o25]
DGT6KB
Exhaust Temp. Sensor RBF Failure — VHMS
[n3o23]
dGT6KB
Exhaust Temp. Sensor RBR Failure — VHMS
[n3o26]
DH25KX VR1/P1F J/S Dif Press Sensor Abnormality E07 PUMP Electrical system
DH26KX VL1/P1R J/S Dif Press Sensor Abnormality E07 PUMP Electrical system
DH27KX VR2/P2F J/S Dif Press Sensor Abnormality E07 PUMP Electrical system
DH28KX VL2/P2R J/S Dif Press Sensor Abnormality E07 PUMP Electrical system
DHE5KB
Blowby Pres. Sensor Failure
[n3o32]
DHE5KY
Blowby Pres. Sensor Failure
[n3o31]
DHH2KA
Hydraulic oil filter Sensor Failure
[n3o53]
PC2000-8 33

DHPEKX VR1/P1F Pump P. Sensor Abnormality E07 PUMP Electrical system
DHPFKX VL1/P1R Pump P. Sensor Abnormality E07 PUMP Electrical system
DHPGKX VR2/P2F Pump P. Sensor Abnormality E07 PUMP Electrical system
DHPHKX VL2/P2R Pump P. Sensor Abnormality E07 PUMP Electrical system
DHPSKX Auto Grease Press Sensor Abnormality — PUMP Electrical system
DHPTKX Fan(RAD) Pump P. Sensor Open Circuit — PUMP Electrical system
DHPUKX Fan(O/C) Pump P. Sensor Open Circuit — PUMP Electrical system
DHS3KX Arm Dig PPC Press Sensor Abnormality — PUMP Electrical system
DHS4KX Bucket Curl PPC Press Sensor Abnormality — PUMP Electrical system
DHS8KX Boom Raise PPC Press Sensor Abnormality — PUMP Electrical system
DHS9KX Boom Lower PPC Press Sensor Abnormality — PUMP Electrical system
DHSAKX Swing Right PPC Press Sensor Abnormality — PUMP Electrical system
DHSBKX Swing Left PPC Press Sensor Abnormality — PUMP Electrical system
DHSCKX Arm Dump PPC Press Sensor Abnormality — PUMP Electrical system
DHSDKX Bucket Dump PPC Press Sensor Abnormality — PUMP Electrical system
DUM3KB Auto Grease Caution LED Short Circuit — PUMP Electrical system
DUM4KB FAN Reverse LED Short Circuit — PUMP Electrical system
DV20KB Travel Alarm S/C — PUMP Electrical system
DW41KA Swing Priority Sol Open Circuit — PUMP Electrical system
DW41KB Swing Priority Sol Short Circuit — PUMP Electrical system
DW45KA Swing Brake Sol. Disc. E03 PUMP Electrical system
DW45KB Swing Brake Sol. S/C E03 PUMP Electrical system
DW91KA Straight-Travel Sol. Disc. PUMP Electrical system
DW91KB Straight-Travel Sol. S/C — PUMP Electrical system
DW4XKA Bucket Curl Hi Cancel Sol. Disc. — PUMP Electrical system
DW4XKB Bucket Curl Hi Cancel Sol. S/C — PUMP Electrical system
DW7BKA Fan Motor(RAD) Reverse Sol Open Circuit — PUMP Electrical system
DW7BKB Fan Reverse Sol S/C — PUMP Electrical system
DW7HKA Fan Motor(O/C) Reverse Sol Open Circuit — PUMP Electrical system
DW7HKB Fan Motor(O/C) Reverse Sol Short Circuit — PUMP Electrical system
DWA3KA Arm throttle Valve/L Sol Open Circuit — PUMP Electrical system
DWA3KB Arm throttle Valve/L Sol Short Circuit — PUMP Electrical system
DWA4KA Arm throttle Valve/R Sol Open Circuit — PUMP Electrical system
DWA4KB Arm throttle Valve/R Sol Short Circuit — PUMP Electrical system
DWA5KA Auto Grease Sol Open Circuit — PUMP Electrical system
DWA5KB Auto Grease Sol Short Circuit — PUMP Electrical system
DWA6KA Boom throttle Valve Sol Open Circuit — PUMP Electrical system
DWA6KB Boom throttle Valve Sol Short Circuit — PUMP Electrical system
DWK0KA 2-stage Relief Sol. Disc. — PUMP Electrical system
DWK0KB 2-stage Relief Sol. S/C — PUMP Electrical system
DWK2KA Back Press Comp Valve Sol Open Circuit — PUMP Electrical system
DWK2KB Back Press Comp Valve Sol Short Circuit — PUMP Electrical system
DWN5KA Fan(RAD) Pump Epc Sol Open Circuit E11 PUMP Electrical system
DWN5KB Fan(RAD) Pump Epc Sol Short Circuit E11 PUMP Electrical system
34 PC2000-8

DWNCKA Fan(O/C) Pump Epc Sol Open Circuit E11 PUMP Electrical system
DWNCKB Fan(O/C) Pump Epc Sol Short Circuit E11 PUMP Electrical system
DXAAKA P1F EPC Sol Disc E07 PUMP Electrical system
DXAAKB P1F EPC Sol S/C E07 PUMP Electrical system
DXABKA P1R EPC Sol Disc E07 PUMP Electrical system
DXABKB P1R EPC Sol S/C E07 PUMP Electrical system
DXACKA P2F EPC Sol Disc E07 PUMP Electrical system
DXACKB P2F EPC Sol S/C E07 PUMP Electrical system
DXADKA P2R EPC Sol Disc E07 PUMP Electrical system
DXADKB P2R EPC Sol S/C E07 PUMP Electrical system
DY2CKB Washer Drive S/C — PUMP Electrical system
DY20MA Low Wiper Working Abnormality — PUMP Electrical system
DY2FMA Upper Wiper Working Abnormality — PUMP Electrical system
F@BBZL
High Blowby Pressure — VHMS Electrical system
[n3o38]
F@BYNR
Very High LBF CYL Exhaust Temp — VHMS Electrical system
[n3o62]
f@BYNR
Very High LBR CYL Exhaust Temp — VHMS Electrical system
[n3o72]
F@BYNS
High LBF CYL Exhaust Temp — VHMS Electrical system
[n3o61]
f@BYNS
High LBR CYL Exhaust Temp — VHMS Electrical system
[n3o71]
F@BZNR
Very High RBF CYL Exhaust Temp — VHMS Electrical system
[n3o82]
f@BZNR
Very High RBR CYL Exhaust Temp — VHMS Electrical system
[n3o92]
F@BZNS
High RBF CYL Exhaust Temp — VHMS Electrical system
[n3o81]
f@BZNS
High RBR CYL Exhaust Temp — VHMS Electrical system
[n3o91]
PC2000-8 35
Maintenance Record a The following items can be selected in the

The machine monitor records the maintenance maintenance record.
information of the filters, oils, etc., which the opera- 01 Engine oil change
tor can display and check by the following opera- 02 Engine oil filter change
tions. When maintenance is carried out, if the data
03 Fuel main filter change
are reset in the operator mode, the number of the
41 Fuel pre-filter change
times of maintenance is recorded in this section.
04 Hydraulic oil filter change
05 Hydraulic tank breather change
1. Selecting menu 06 Corrosion resistor change
Select “Maintenance Record” on the “Service 07 PTO case oil change
Menu” screen. 08 Final drive case oil change
09 Machinery case oil change
10 Hydraulic oil change
30 Hydraulic oil pilot filter change
31 Hydraulic oil drain filter change
42 Oil cooler accumulator change
3. Items displayed on maintenance record screen

The following items are displayed.
(a) : Maintenance items
(b) : Number of times of replacement up to now
(c) : Service meter reading (SMR) at previous
replacement
2. Selecting maintenance record item

After the “Maintenance Record” screen is dis-
played, select an item to be checked with the
function switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F5]: Return to service menu screen
a You may enter a 2-digit code with the
numeral input switches to select the item
of that code.
36 PC2000-8
Maintenance Mode Change a The following items can be selected on

The operating condition for maintenance function in the Change of maintenance mode screen.
the operation mode can be set and changed with 01 Engine oil change
this menu. 02 Engine oil filter change
q Set function effective or ineffective
03 Fuel main filter change
q Change set replacement interval (by items)
41 Fuel pre-filter change
q Initialize all set replacement intervals
04 Hydraulic oil filter change
1. Selecting menu 05 Hydraulic tank breather change
Select of “Maintenance Mode Change” on the 06 Corrosion resistor change
“Service Menu” screen. 07 PTO case oil change
08 Final drive case oil change
09 Machinery case oil change
10 Hydraulic oil change
30 Hydraulic oil pilot filter change
31 Hydraulic oil drain filter change
42 Oil cooler accumulator change
3. Contents of setting of Maintenance mode on/

off
After selecting “Maintenance Mode On/Off”, if
the screen is displayed, set ON or OFF with
the function switches.
q ON: Functions of all maintenance items
are set effective in operator mode
2. Selecting sub menu q OFF: Functions of all maintenance items
After the “Maintenance Mode Change” screen are set ineffective in operator mode
is displayed, select an item to change the set- q [F3]: Move to lower item
ting with the function switches or numeral input q [F4]: Move to upper item
switches. q [F5]: Cancel selection and return to Main-
q [F1]: Move to next page (screen) tenance mode change screen
q [F2]: Move to previous page (screen) q [F6]: Confirm selection and return to
q [F3]: Move to lower item Maintenance mode change screen
q [F4]: Move to upper item a Even if ON/OFF of each item has been
q [F5]: Return to service menu screen set, if the above setting is changed, it is
a You may enter a 2-digit code with the applied.
numeral input switches to select the item
of that code and confirm it with [F6].
PC2000-8 37
4. Contents of setting of each maintenance item 5. Function of initializing all items

After selecting each maintenance item, if the After selecting “All Default Value”, if the screen
screen is displayed, set the item with the func- is displayed, set with the function switches.
tion switches. q If this operation is executed, the set val-
q Initial value: Maintenance interval set in ues of all the maintenance items are ini-
machine monitor (Recommended by man- tialized.
ufacturer and not changeable). q [F5]: Return to Maintenance mode change
q Set value: Maintenance interval which can screen
be set freely. Maintenance functions in q [F6]: Execute initialization
operator mode operate on basis of this set a A while after [F6] is pressed, the initializa-
time (which is increased or decreased by tion completion screen is displayed. Then,
50 hours). if the “Maintenance Mode Change” screen
q ON: Maintenance function of this item is is displayed, initialization is completed.
set effective in operator mode.
q OFF: Maintenance function of this item is
set ineffective in operator mode.
q [F3]: Select Reduce set value (Upper) or
OFF (Lower).
q [F4]: Select Increase set value (Upper) or
ON (Lower).
q [F5]: Cancel setting before confirmation
and return to Maintenance mode
change screen.
q [F6]: Confirm setting of upper or lower line.
a After the setting of the upper and lower
lines is confirmed with [F6] and the screen
changes to the Maintenance mode
change screen with [F5], the setting is
effective.
a If the set value of an item set to “ON” is
changed after 1 or more operating hours
since the start of setting, the change is
recognized as a resetting operation.
38 PC2000-8
Phone Number Entry a If [F6] is pressed without inputting a digit,

The telephone No. displayed when the user code/ there is not information of telephone No.
failure code is displayed in the operator mode can Accordingly, no telephone No. is displayed
be input and changed according to the following in the operator mode.
procedure.
If a telephone No. is not input with this function, no
telephone No. is displayed in the operator mode.
1. Selecting menu
Select “Phone Number Entry” on the “Service
Menu” screen.
2. Registering and changing telephone No.

After the “Phone Number Entry” screen is dis-
played, register or change the telephone No.
q [F2]: Reset all input No.
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Reset input digit/Return to service
menu
q [F6]: Confirm input
a Up to 14 digits can be input from the left.

Input nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (orange background) and over-
write it with the correct digit.
PC2000-8 39
Default (Key-on Mode) 3. Selecting mode

Check or change various settings related to the After the “Key-on Mode” screen is displayed,
machine monitor and machine by “Default”. select the mode to be set with the function
The function of working mode with key ON is used switches.
to set the working mode displayed on the machine q Power Mode: [P] is displayed when key is
monitor when the starting switch is turned ON. ON
q Economy Mode: [E] is displayed when key
1. Selecting menu is ON
Select “Default” on the “Service Menu” screen. q Mode at Previous Key-off: Final mode in
previous operation is displayed when key
is ON
q [F5]: Cancel selection and return to
“Default” screen
q [F6]: Confirm selection and return to
a When the machine is delivered, Mode at
previous key-OFF is set.
2. Selecting sub menu

After the “Default” screen is displayed, select 15718
“Key-on Mode” with the function switches or
a Select this item similarly to an item on the
“Service Menu” screen.
15717
40 PC2000-8
Default (Unit) 3. Selecting unit

Check or change various settings related to the After the “Unit” screen is displayed, select the
machine monitor and machine by “Default”. unit to be set with the function switches.
The unit selecting function is used to select the unit q [F3]: Move to lower unit
of the data displayed for monitoring, etc. q [F4]: Move to upper unit
q [F5]: Cancel selection and return to
1. Selecting menu “Default” screen
Select “Default” on the “Service Menu” screen. q [F6]: Confirm selection and return to
a When the machine is delivered, the SI unit
system is set.

After the “Default” screen is displayed, select
“Unit” with the function switches or numeral
input switches.
15717
PC2000-8 41
Default (Maintenance Password) 3. Selecting Disable/Enable

Check or change various settings related to the After the Maintenance Password screen is dis-
machine monitor and machine by “Default”. played, select the setting with the function
The function of setting maintenance password is switches.
used to set the display of the password screen q Disable : Password screen is not dis-
when the functions related to the maintenance are played
used in the operator mode. q Enable : Password screen is displayed
q [F3] : Move to lower item
1. Selecting menu q [F4] : Move to upper item
Select “Default” on the “Service Menu” screen. q [F5] : Cancel selection and return to
q [F6] : Confirm selection and return to
15719

“Maintenance Password” with the function
switches or numeral input switches. 4. Displaying maintenance password screen
a Select this item similarly to an item on the When the following operation is performed, the
“Service Menu” screen. password screen is displayed in the operator
mode.
q Maintenance mode: The Maintenance
table screen is changed to the Mainte-
nance interval reset screen.
5. Changing maintenance password

15717 The password can be changed by operating
the switches specially in the operator mode.
a See Maintenance password changing
function in the operator mode.
a Default password: [000000]
a If the password setting is changed from
“Enable” to “Disable”, the password is
reset to the default. When “Enable” is set
again, be sure to set a new password.
a The maintenance password is different
from the engine start lock password.
42 PC2000-8
Default (Camera) 3. Selecting camera setting

Check or change various settings related to the After the “Camera” setting screen is displayed,
machine monitor and machine by “Default”. select the setting with the function switches.
The camera setting function is used to set installa- q OFF: Camera is not used
tion and removal of a camera. q Original Image: Image of connected cam-
era is displayed in origi-
1. Selecting menu nal position (as in mirror,
Select “Default” on the “Service Menu” screen. used as back monitor)
q Reverse Image: Image of connected cam-
era is displayed in reverse
position (as seen directly,
used as front or side mon-
itor)
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel setting before confirmation
and return to “Default” screen
q [F6]: Confirm selection in each line
a After “Camera” screen is displayed, cam-
era 1 can be always set. When 2 or more
cameras are connected, if camera 1 is set,
the screen changes to setting of camera 2
automatically.
2. Selecting sub menu a After confirming the setting of each line
After the “Default” screen is displayed, select with [F6], return to the “Default” screen
“ Came ra ” wi th t he func tio n s wi tch es or with [F5], and the setting is effective.
numeral input switches. a If a camera is connected but not set nor-
a Select this item similarly to an item on the mally with this function, the graphic mark
“Service Menu” Screen. of camera is not displayed at [F3] in the
operator mode. Accordingly, the image of
the camera cannot be used.
a If 2 or more cameras are connected, be
sure to set the use of them from camera 1
in order.
a The function of displaying 2 images simul-
15717 taneously is effective when use of camera
1 and camera 2 is set.
a When a camera is installed, check that the
displayed image is not inverted horizon-
tally.
PC2000-8 43
Default (ECO Display) a If ECO display is turned ON, ECO is dis-

Check or change various settings related to the played when the screen changes to the
machine monitor and machine by “Default”. ordinary screen. Even if the energy saving
The ECO display setting function is used to set the guidance is turned ON, however, it is not
display of the ECO gauge and energy saving guid- displayed if the condition for display is not
ance. satisfied on the ordinary screen.
1. Selecting menu
Select “Default” on the “Service Menu” screen.
a Display of ECO gauge (a)

“ECO Display” with the function switches or
15717
a Display of energy saving guidance
3. Selecting display setting

After the “ECO Display” screen is displayed,
select the setting with the function switches.
q ON : Display ECO
q OFF: Do not display ECO
q [F3] : Move to left item
q [F4] : Move to right item
q [F5] : Cancel setting before confirmation
and return to “Default” screen
q [F6] : Confirm selection in each line
a After confirming the setting of the upper
and lower lines with [F6], return to the
“Default” screen with [F5], and the setting
is effective.
44 PC2000-8
Adjustment (Pump Absorption Torque) 3. Selecting absorption torque

The operator can adjust various items related to the After the “Pump Absorption Torque (F)” screen
machine with the machine monitor. is displayed, select a set value on the right side
The pump absorption torque (F) function is used to with the function switches.
finely adjust the absorption torque on the front side q Set value: For actual torque adjustment
of the hydraulic pump. value, see table
q [F3]: Increase set value
1. Selecting menu q [F4]: Decrease set value
Select “Adjustment” on the “Service Menu” screen. q [F6]: Confirm setting and return to Adjust-
ment menu screen
a The 3 digits on the left side do not vary
since they are the code of this function.

After the “Adjustment” screen is displayed,
select “Pump Absorption Torque (F)” with the
function switches or numeral input switches. a Relationship between set value and
a Select this item similarly to an item on the torque adjustment value
“Service Menu” screen. Set
Code Torque adjustment value
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
15720
005 –9.8 Nm {–1 kgm}
006 –19.6 Nm {–2 kgm}
007 –29.4 Nm {–3 kgm}
008 –39.2 Nm {–4 kgm}
PC2000-8 45
For the adjustment items, codes and set values, see the following table.
Item Code Default Set value Adjustment value
Main pump absorption torque 022 000 40.0 kgm
001 30.0 kgm
002 20.0 kgm
003 10.0 kgm
Q 004 0.0 kgm
005 –10.0 kgm
006 –20.0 kgm
007 –30.0 kgm
008 –40.0 kgm
Auto grease pump discharge pressure adjustment 080 000 20 kg/cm2
001 15 kg/cm2
002 10 kg/cm2
003 5 kg/cm2
Q 004 0 kg/cm2
005 –5 kg/cm2
006 –10 kg/cm2
007 –15 kg/cm2
008 –20 kg/cm2
Auto grease interval setting 081 000 30 min
001 25 min
002 20 min
003 15 min
Q 004 10 min
005 5 min
006 4 min
007 3 min
008 2 min
Auto grease pump operating time adjustment 082 000 5 min
001 4 min
002 3 min
003 2 min
Q 004 1 min
005 45 sec
006 30 sec
After-start first greasing time setting 083 000 5 min
001 4 min
002 3 min
003 2 min
Q 004 1 min
005 45 sec
006 30 sec
46 PC2000-8

Fan speed mode selection 055 Q 000 Normal
001 Fixed to 70% speed
002 Fixed to 100% speed
Radiator fan 100% speed adjustment 056 000 105 rpm
Speed adjustment mode: 100% 001 90 rpm
Set speed: 840 rpm 002 75 rpm
003 60 rpm
004 45 rpm
005 30 rpm
006 15 rpm
Q 007 0 rpm
008 –15 rpm
009 –30 rpm
010 –45 rpm
011 –60 rpm
012 –75 rpm
013 –90 rpm
014 –105 rpm
O/C fan 100% speed adjustment 058 000 105 rpm
003 60 rpm
004 45 rpm
005 30 rpm
006 15 rpm
Q 007 0 rpm
008 –15 rpm
009 –30 rpm
010 –45 rpm
011 –60 rpm
012 –75 rpm
013 –90 rpm
014 –105 rpm
PC2000-8 47

Radiator fan 70% speed adjustment 057 000 105 rpm
003 60 rpm
004 45 rpm
005 30 rpm
006 15 rpm
Q 007 0 rpm
008 –15 rpm
009 –30 rpm
010 –45 rpm
011 –60 rpm
012 –75 rpm
013 –90 rpm
014 –105 rpm
O/C fan 70% speed adjustment 059 000 105 rpm
003 60 rpm
004 45 rpm
005 30 rpm
006 15 rpm
Q 007 0 rpm
008 –15 rpm
009 –30 rpm
010 –45 rpm
011 –60 rpm
012 –75 rpm
013 –90 rpm
014 –105 rpm
48 PC2000-8
Cylinder Cut-Out
Menu Right bank Left bank
The operator can perform “Cylinder Cut-Out” oper-
Specified
ation with the machine monitor. All right All cylinders
01 cylinders are
“Cylinder Cut-Out” operation means to run the cylinders drive are driven
stopped
engine with 1 or more fuel injectors disabled electri-
Specified
cally to reduce the number of effective cylinders. All left All cylinders
02 cylinders are
This operation is used to find out a cylinder which cylinders drive are driven
stopped
does not output power normally (combustion in it is
Specified
abnormal). All right All cylinders
03 cylinders are
cylinders stop are stopped
stopped
1. Selecting menu
Specified
Select “Cylinder Cut-Out” on the “Service All left All cylinders
04 cylinders are
Menu” screen. cylinders stop are stopped
stopped
2) When “01” (All right cylinder drive) is

selected
q Shaded side is stopped and on the actual
machine, the stopped side is indicated by
light blue and driven side is indicated by
dark blue.
2. Setting of cylinders to be reduced

1) Since the V-type 12 cylinders are divided
into the r ight and l eft bank s for the
reduced cylinder mode operation, the con-
ditions of both banks are specified as fol-
lows.
q [F1]: Move selection mark (R) to left

q [F2]: Move selection mark (R) to right
q [F3]: Reset holding
q [F4]: Hold
q [F5]: Return to service menu screen
a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes white,
the cylinder is Cut-Out.
a If the machine monitor Cut-Out a cylinder
but the engine controller cannot Cut-Out
that cylinder, the background (a) of the
cylinder No. becomes yellow.
a One or more cylinders can be Cut-Out.
a In the cylinder Cut-Out operation, the
auto-deceleration function can be
selected. If the auto-deceleration is turned
ON, auto-deceleration monitor (b) is dis-
played.
PC2000-8 49
q The left-bank cylinders are indicated 2] Screen displayed while R2, R4 and
as L1 – L6 and the right-bank ones as R6 are stopped.
R1 – R6. q Injection in the crossed cylinders,
In this case, L1 – L6 can be reduced. which are indicated by gray on the
a Since “All right cylinder drive” is actual machine, is stopped.
selected, R1 – R6 cannot be q Cylinder No. in the crossed cylinders
reduced. is stopped already.
3) When “02” (All left cylinder drive) is
selected
q Shaded side is stopped and on the actual
machine, the stopped side is indicated by
light blue and driven side is indicated by
dark blue.
a The condition is reverse to “All right
cylinder drive”.
5) If stopping process of R1 – R6 is com-

pleted, the cursor is displayed and the
e ng in e c an b e sta r ted wit h L1 – L 6
stopped.
a The above process takes several
seconds to protect the fuel injection
system.
4) When “03” (All right cylinder stop) is

selected
The screen changes to the reduced cylin-
der mode operation screen and then injec-
tion is stopped in the order of the groups
of R1, R3 and R5 and that of R2, R4 and
L6.
1] Screen displayed while R1, R3 and
R5 are stopped.
q L1 to L6 cylinders are the drive side
(indicated by light blue on the actual
machine). Injection in the crossed cyl-
inders (indicated by gray on the
actual machine) is stopped.
50 PC2000-8
6) When “04” (All left cylinder stop) is [Reference]

selected q If a normally operating cylinder is Cut-Out,
a The condition is reverse to “All right cylin- the following phenomena occur.
der stop”. 1) Lowering of engine speed
2) Increase of final injection rate com-
3. Resetting Cut-Out cylinder mand (quantity)
When changing a cylinder to be Cut-Out or q If the engine is running near the high idle,
when Cylinder Cut-Out operation is finished, however, the engine speed may not lower
select a Cut-Out cylinder to be reset with the for the reason of engine control.
function switches. q In this case, lower the engine speed with
a This operation may be performed while the fuel control dial and judge by increase
the engine is running. of the injection rate command.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes blue,
the cylinder is reset.
a The Cut-Out operation is not automatically
reset after the screen returns to the opera-
tor mode. Accordingly, be sure to perform
the resetting operation after the cylinder
cut-out operation is finished.
4. Function of holding displayed information

If [F4] is pressed during the cylinder Cut-Out
operation, the displayed information is newly
held (c) (The real-time information is kept dis-
played on the left side).
While the information is held, if [F3] is pressed,
the holding function is reset.
a The holding function is effective, regard-
less of setting of the reduced cylinder
mode operation.
PC2000-8 51
No Injection 3. Starting no injection cranking

If the engine is operated after long storage of the If no injection cranking (Fuel injection in no cyl-
machine, it may be worn or damaged because of inders) becomes effective, that is displayed on
insufficient lubrication with oil. To prevent this, the the screen. Under this condition, crank the
function to lubricate the engine before starting it by engine with the starting motor.
cranking it without injecting fuel is installed. a While the screen is changing to the follow-
Set the no-injection cranking while the engine is ing screen, the screen of “Setting is being
stopped. prepared” is displayed.
a Limit the cranking time to 20 seconds to
1. Selecting menu protect the starting motor.
Select “No Injection” on the “Service Menu”
screen.
4. Finishing no injection cranking

After completing the no injection cranking
2. Displaying check screen operation, press [F6], and finish of no injection
If the “No injection” screen is displayed, the cranking is displayed and the screen returns to
machine monitor asks the operator if no injec- the “Service Menu” screen automatically.
tion cranking should be performed. Answer
with the function switch.
q [F5]: Do not perform (Return to Service
menu screen)
q [F6]: Perform
a While the screen is changing to the follow-
ing screen, the screen of “Communication
between controllers is being checked” is
displayed.
52 PC2000-8
5. Prohibiting no injection cranking Fuel Consumption

If the operator tries to perform the no injection This function calculates the hourly fuel consump-
cranking while the engine is running, the mes- tion from the actual fuel consumption in a measur-
sage that the engine is running is displayed ing period and indicates it.
and the no injection cranking is not set effec- 1. Selecting menu
tive. Select “Fuel Consumption” on the “Service
a This function can be selected even while Menu” screen.
the engine is running. If the no injection
cranking is performed, however, the mes-
sage of “Engine is running” is displayed on
the screen.
2. Starting measurement
After the screen of “Fuel Consumption” is dis-
played, start measurement with the function
switches.
q [F1]: Start
q [F2]: Clear
q [F5]: Return to Service menu screen
a When the screen of Fuel consumption is
displayed, if a data is indicated, it is the
data of the previous measurement. This
data is not an obstacle to new measure-
ment and can be reset by pressing [F2].
a If [F1] is pressed, the data is displayed on
the starting date and time side and mea-
surement starts.
a The display unit of the fuel changes

according to the unit set with the default
(unit setting) function.
SI and meter: l/h
inch: gal/h
PC2000-8 53
3. Display and function during measurement Setting of snap shot

Clock mark (a) flashes during measurement. This function sends a snap shot trigger command
a While the fuel consumption is being mea- to the VHMS controller to execute the snap shot.
sured, the operator can work with the 1. Selection of menu
operator mode and other functions. Mea- On the “Service menu” screen, select “Snap
surement is not finished until this screen is shot”.
displayed again and [F1] is pressed (Even
if the starting switch is turned OFF, this
function is kept effective, although fuel
consumption is measured only while the
engine is running).
15727
2. Start of snap shot

After the “Snap shot” screen is displayed,
press the “F1” switch, and the snap shot starts.
a The VHMS controller takes 7 minutes 30
seconds to complete the process. This
time can be checked with the bar graph
4. Finishing measurement and the executing time displayed at the
Press [F1], and measurement is finished and bottom of the screen.
the data are displayed on the finishing date
and time side.
5. Displaying fuel consumption

If the measurement is finished, the hourly fuel
consumption calculated from the fuel con-
sumption calculated by the engine controller
and the elapsed time are displayed. 15728
3. Finish of snap shot

The bar graph becomes full in 7 minutes and
30 seconds. After 5 seconds, the screen
returns to the normal screen automatically and
the snap shot finishes.
If the “F6” switch is pressed, the screen
changes to the service screen.
54 PC2000-8
Setting of PM-clinic
This function is used to perform the PM-clinic ser-
vice
1. Selection of menu
On the “Service menu” screen, select “PM-
clinic”.
15729
a There are 12 PM-clinic screen pages.

q If the “F1” switch is pressed, the next
page is displayed.
q If the “F2” switch is pressed, the pre-
vious page is displayed.
q If the “F4” switch is pressed, the cur-
rent page is held.
q If the “F3” switch is pressed, the cur-
rent page is released.
2. Start of PM-clinic
If a page is displayed and the specified opera-
tion is performed, the measured values of the
displayed items are displayed.
3. Finish of PM-clinic
If the [ ] switch is pressed, the screen
changes to the service screen and the PM-
clinic finishes.
4. For the contents of the 12 pages of the PM-

clinic, see the table in the following page.
PC2000-8 55
Component in
Page Item PM-clinic display item ISO m inch
charge
1/12 1 Engine speed r/min rpm rpm VHMS
2 Engine coolant temperature °C °C °F ENG (L/B)
3 Engine oil pressure kPa kg/cm 2
psi PUMP (1)
4 Engine oil temperature °C °C °F VHMS
5 PTO oil temperature °C °C °F VHMS
6 Hydraulic oil temperature °C °C °F VHMS
2 Intake air temperature °C °C °F ENG (L/B)
3 R/B 1-3 exhaust temperature °C °C °F PUMP (1)
4 R/B 4-6 exhaust temperature °C °C °F VHMS
5 L/B 1-3 exhaust temperature °C °C °F VHMS
2 Intake air temperature °C °C °F ENG (L/B)
3 L/B common rail pressure MPa kg/cm2 psi PUMP (1)
4 L/B boost pressure kPa kg/cm2 psi VHMS
5 Boost temperature °C °C °F VHMS
2 Ambient temperature °C °C °F ENG (L/B)
3 L/B fuel temperature °C °C °F PUMP (2)
4 R/B fuel temperature °C °C °F VHMS
5 L/B common rail pressure MPa kg/cm 2
psi VHMS
6 R/B common rail pressure MPa kg/cm 2
psi VHMS
3 Ambient pressure kPa kg/cm 2
psi PUMP (1)
4 L/B fuel temperature °C °C °F VHMS
5 R/B common rail pressure MPa kg/cm2 psi VHMS
6 Blow-by pressure MPa kg/cm2 psi VHMS
3 Ambient pressure kPa kg/cm 2
psi PUMP (1)
4 R/B fuel temperature °C °C °F VHMS
5 R/B common rail pressure MPa kg/cm 2
psi VHMS
6 Blow-by pressure MPa kg/cm 2
psi VHMS
2 Hydraulic oil temperature °C °C °F ENG (R/B)
3 P1F pump pressure MPa kg/cm2 psi PUMP (1)
4 P1R pump pressure MPa kg/cm2 psi VHMS
5 P2F pump pressure MPa kg/cm2 psi VHMS
56 PC2000-8
Component in
Page Item PM-clinic display item ISO m inch
charge
3 P1F pump pressure MPa kg/cm2 psi PUMP (1)
5 VR1 J/S differential pressure MPa kg/cm2 psi VHMS
6 VL1 J/S differential pressure MPa kg/cm2 psi VHMS
3 P2F pump pressure MPa kg/cm 2
psi PUMP (1)
4 P2R pump pressure MPa kg/cm 2
psi VHMS
5 VR2 J/S differential pressure MPa kg/cm 2
psi VHMS
6 VL2 J/S differential pressure MPa kg/cm 2
psi VHMS
psi PUMP (1)
psi VHMS
5 P1F pump EPC current mA mA mA VHMS
6 P1R pump EPC current mA mA mA VHMS
psi PUMP (1)
psi VHMS
5 P2F pump EPC current mA mA mA VHMS
6 P2R pump EPC current mA mA mA VHMS
3 O/C fan pulley pressure MPa kg/cm 2
psi PUMP (1)
4 RAD fan pump pressure MPa kg/cm 2
psi VHMS
5 RAD fan pump control EPC current mA mA mA VHMS
6 O/C fan pump control EPC current mA mA mA VHMS
PC2000-8 57
Handling controller voltage circuit 1

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.
58 PC2000-8
PC2000-8 59
SEN02010-00
PC2000-8

PC2000-8 20001 and up

VHMS controller initial setting procedure ............................................................................................. 2
Precautions for replacing VHMS controller ........................................................................................ 17
Preparation work for troubleshooting of electrical system.................................................................. 23
Pm-clinic service ................................................................................................................................ 25
Measurement procedure .................................................................................................................... 26
Measurement procedure by downloading data in VHMS controller ................................................... 32
PC2000-8 1

VHMS controller initial setting procedure 1
a Equipment used for VHMS controller initial set- 1. Confirmation of machine information,
ting engine information, transmission controller
information and controller information
Symbol Part No. Part name a This confirmation procedure is targeted at
the entire machine.
799-608-3211 Diskette
1 Confirm and record the machine informa-
799-608-3220 Wiring harness tion, engine information, VHMS controller
W Note type PC information and ORBCOMM terminal
Commercially
2
available
(Windows 98/2000/Me/XP), information.
with RS232C terminal
No. Information to be confirmed
a Initial setting of VHMS controller shall be done
according to the following procedure. This 1 Model name
operation is needed prior to a full-scale opera- 2 Machine serial No.
tion of a machine being delivered and assem- 3 Current service meter hour
bled in the field, or prior to resumption of its
4 Engine serial No.
operation after a long time of storage.
a Machine data collected with VHMS controller 5 VHMS controller serial No.
are stored and managed on WebCARE data- 6
ORBCOM terminal serial No.
base. In order to endure smooth data process- [Only for machines equipped with ORBCOMM]
ing on WebCARE , consistency must be
provided among the settings done on VHMS a VHMS controller (1) and ORBCOMM ter-
controller. Inconsistencies in the settings minal (2) are installed in the rear under the
obstruct loading of data to WebCARE, ham- operator seat.
pering appropriate use of VHMS data. The ini-
tial setting, therefore, is a must.
a For the installation procedure of the VHMS ini-
tial setting program to a PC, refer to the opera-
tion and maintenance manual being bundled
with the service kit W1.
a In the procedure, service menus of the
machine monitor are used. Thus, it is advis-
able to reference the information contained in
the “Special functions of machine monitor” to
understand their procedure beforehand.
a The initial setting procedure is described in the
“ORBCOMM installation specification” and the
“ORBCOMM-less specification”. When using
the “ORBCOMM installation specification”,
implement the procedures needed for VHMS
alone, bypassing those prepared only for ORB-
COMM installation specification.
a Check each step of the setting work referenc-
ing the “VHMS initial setting work check
sheet”.
a Information such as models shown in the fig-
ures may not be identical with actual ones.
2 PC2000-8
2. Connecting a PC 3. Confirming VHMS controller operation and

a This work is done inside the cab. confirming satellite capturing state
1) Make sure the starting switch is at OFF a This work is done inside the cab.
position. a Confirmation of capturing of the satellite is
k Before connecting or disconnect- done for [ORBCOMM installation specifi-
ing a PC, be sure to turn off the cation].
starting switch. 1) Turn the starting switch ON.
2) Using harness [1] of service kit W1, con- 2) Check the controller for normal operation
nect the PC W2 and download connector referencing 7-segment LED of VHMS con-
C53. troller.
a Then connect the PC to RS232C ter- a VHMS controller is fed with switch
minal. power supply. Thus, its operation is
judged normal if its 7-segment LED
starts flashing while rotating as the
starting switch is turned on and then if
the controller starts counting in the
ascending order.
a Download connector C53 is installed

in the front side of the right stand of
operator seat.
3) Among the 7-segment LED situated in the

right side of VHMS controller, refer to the
one that represents the decimal point to
check whether or not ORBCOMM control-
ler has captured the communication satel-
lite. [ORBCOMM installation specification]
a Check whether or not ORBCOMM
controller is capturing the communi-
cation satellite from VHMS controller.
a It is successfully capturing the satel-
lite when the LED representing the
decimal point in the right side 7-seg-
ment LED is flashing.
PC2000-8 3
4. Starting the VHMS initial setting tool 5. Initial setting of VHMS controller (Ver. 3. 5.
a This work is done inside the cab (from PC). 2. 1 or older version)
1) Turn on the PC power and start the OS. a This work is done inside the cab (from
2) Operating [VHMS initial setting tool] icon on PC).
the PC, start up the VHMS initial setting tool. a It is prohibited in the initial setting to mod-
ify the data of service meter [SMR].
Important [Machine Information]
a Appearance of the setup screen of 1) Open [Machine Information] tab.
the VHMS setting tool depends its a [Data clear and Set up] menu displays
tool. [Machine Information] tab first.
a When using Ver.3.5.2.1 or older ver- 2) Check every data for correctness.
sion (CD-ROM), the setting proce-
dure shall conform to that described
in Section 5.
a When using an update version
(Ver.3.5.2.1 or after), the procedure in
Section 6 shall be used.
a It is recommended to download the
latest VHMS version from WebCARE
to update the currently used version.
(Related material: PARTS & SER-
V IC E O PE RAT IO N T IP S S EK N-
5052)
3) Enter the 10-digit service ID to [Service ID].
a Service ID: 7826117000
4) Select [Data clear and Set up] from
[Select Function] item.
5) Click [OK] button to proceed to the setup
screen. 3) When [Date/Time] information is not appro-
priate, correct it in the following manner.
1] Press [Edit] button in the lower right
side of [Date/Time] box to display the
correction screen.
2] After correcting it to the correct infor-
mation, press [OK] button.
4 PC2000-8
4) When [Machine Information] information is [Communication Setting] [ORBCOMM installation

not appropriate, correct it in the following specification only]
manner. a This setting shall be implemented after the
1] Press [Edit] button in the lower right request for station opening has been made
side of [Machine Information] dialog and station of ORBCOMM has been opened.
box to display the correction screen. 6) Open [Communication Setting] tab.
2] After correcting it to the correct infor- 7) Check every data for correctness.
mation, press [OK] button.
5) As every data in [Machine Information]

has been checked and corrected, press
[Apply] button to settle the setting.
a As [Apply] button is pressed, a mes-
sage confirming above setting will
appear on the screen. Check the set- 8) When modifying the setting of [SHORT
ting again and, if the setting is correct, FAULT HISTORY], employ the following
press [OK] button. procedure.
a ORBCOMM installation specification 1] Select [SHORT FAULT HISTORY] from
requires the settlement operation after the screen and then press [Edit] button
[Communication Setting] is completed. in the lower left side of [File Transfer
Setting] block to display the setup
screen.
2] Correct the setting and, as it is com-
pleted, press [OK] button.
a In the initial setting, select [Occur-
rence] from [Timing] item and then
set the function to ON.
PC2000-8 5
9) When modifying the setting of [SHORT 11) As every data in [Communication Setting]
TREND ANALYSIS], employ the following has been checked and corrected, press
procedure. [Apply] button to settle the setting.
1] Select [SHORT TREND ANALYSIS] a As [Apply] button is pressed, a mes-
from the screen and then press [Edit] sage confirming above setting will
button in the lower left side of [File appear on the screen. Check the set-
Transfer Setting] block to display the ting again and, if the setting is correct,
setup screen. press [OK] button.
2] Correct the setting and, as it is com-
pleted, press [OK] button.
a In the initial setting, enter [20h] to
[SMR] and then set the function to
ON.
10) When modifying the setting of [Satellite 12) As every data in [Machine Information]
Setting], employ the following procedure. and [Communication Setting] has been
1] Press [Edit] button in the [Satellite checked and corrected, press [Exit] button
Setting] block to display the correc- to end [VHMS initial setting tool].
tion screen.
2] Set the GCC code to the region
applied and, as setting is completed,
press [OK] button.
GCC codes and applicable regions

Code Applicable region Code Applicable region
1 America 122 Korea
120 Italy 123 Brazil
121 Malaysia 130 Japan
6 PC2000-8
6. Initial setting of VHMS controller (Ver. 3. 5. 3) Confirm the machine information and, if
2. 1 or later version) they are correct, press [Next] button.
a This work is done inside the cab (from PC).
a It is prohibited in the initial setting to mod-
ify the data of service meter [SMR].
1) Select [VHMS Setting] and then press
[Next] button.
a When VHMS has been installed later,

it is required to enter the information
such as [Serial No.].
2) Select [Set up & All clear] and press [Next]

button.
PC2000-8 7
4) Select the time zone. 8) If there is no problem in the setting dis-

5) Enter the local time. played last, press [Apply] button.
6) When DST (Daylight Saving Time) (or
summer time) is currently used, press
[Next] button.
a Selecting DST advances the clock by
an hour. Thus, correction of the time
is needed again.
9) A screen message will confirm whether or

not the data before the setting is to be
saved. If the data is not necessary, select
[NO].
7) Set the GCC code to the target region of

application and, as setting is completed,
press [Next] button.
GCC codes and applicable regions

Code Applicable region Code Applicable region
1 America 122 Korea
120 Italy 123 Brazil
121 Malaysia 130 Japan
10) As correction of the first setting is com-

pleted, press [OK] button to end the pro-
gram.
8 PC2000-8
7. Performing Quick Pm a If the snap shot operation is inter-

a Perform the following procedure in the cab. rupted, the data collected up to now
a The Quick Pm means the Pm clinic per- are not recorded. In this case, repeat
formed by using the snap shot (manual) the operation from the first.
function of the machine monitor.
1) Run the engine at low idle and set the
machine in the following position.
q Swing the boom 90° to right
(with the idler on the front side).
q Set the arm vertically.
q Lower the bucket bottom to the ground
15727
and set it horizontally.
2) Set the switches and lever in the following
positions.
q Working mode switch: P-mode
q Heavy lift switch: ON
q Auto-decelerator switch: ON
q Swing lock switch: OFF
q PCC lock lever: Free 6) Operate the fuel dial, swing lock switch,
3) Set the machine monitor to display the both work equipment control levers, and
service menu. both travel levers according to the “Oper-
a For the operating method, see “Spe- a t i n g p r oc e d u r e f or Q u i c k P m ” a n d
cial function of machine monitor”. elapsed time.
4) On the initial screen of the service menu, a The elapsed time is displayed on the
select “10 Snap shot” menu. machine monitor.
k Since the operator must operate
the work equipment, swing the
boom, and drive the machine actu-
ally for the Quick Pm, take extreme
care of safety around the machine
during the work.
15728
5) Press the [F1] switch to start the snap shot

operation.
a Before starting the snap shot opera-
tion, understand the operating proce-
dure for the Quick Pm by referring to
“Operating procedure for Quick Pm”.
a The data of 48 items are recorded 7) After 5 seconds passes since the bar
and saved for 7 minutes 30 seconds graph is completed (7 minutes 30 seconds
after the [F1] switch on the machine passes after the snap shot is starts), the
monitor is pressed. initial screen of the service menu is dis-
a The data are recorded at the intervals played again.
of 10 seconds for the first 5 minutes
and at the intervals of 1 second for
the 2 minutes 20 seconds after the 5
minutes.
a To interrupt the snap shot operation,
press the “ ” switch.
PC2000-8 9
Operating procedure for Quick Pm

Time on Fuel Swing lock Data read in Pm clinic after data
No. Elapsed time Operation of lever
snap data dial switch are downloaded
Start 0:00 –330.00 • Engine speed (Low idle)
MIN
1 O O O OFF Set all levers in neutral. • Engine oil pressure (Low idle)
(Low)
Finish 0:30 –300.00 • Ambient temperature
• Engine speed (High idle)
Start 0:30 –300.00 • Engine oil pressure (High idle)
MAX Set all levers in neutral
2 O O O OFF • J/S differential pressure
(High) (Turn decelerator on).
Finish 1:00 –270.00 • Pump oil pressure
• Fan pump oil pressure
Start 1:00 –270.00
MAX Move levers finely [Note]
3 O O O OFF • Engine speed (Auto deceleration)
(High) (Turn decelerator off).
Finish 1:30 –240.00
Start 1:30 –240.00 Raise right-hand track
MAX • Pump pressure
4 O O O OFF shoe and drive it idle
(High) (actuating pressure)
Finish 2:30 –180.00 (Set lever to stroke end).
Swing 180°.
Start 2:30 –180.00
MAX Raise left-hand track shoe • Pump pressure
5 O O O OFF
(High) and drive it idle (Set lever (actuating pressure)
Finish 3:30 –120.00
to stroke end).
Start 3:30 –120.00
MAX • Swing oil pressure
6 O O O ON R.H. swing relief.
(High) (relief pressure)
Finish 4:00 0–90.00
Start 4:00 0–90.00
7 O O O ON L.H. swing relief.
Finish 4:30 0–60.00
Start 4:30 0–60.00
MAX
8 O O O ON Arm OUT relief. • Arm OUT oil pressure
(High)
Finish 5:00 0–30.00
Start 5:00 0–30.00
MAX
9 O O O ON Bucket DUMP relief. • Bucket DUMP oil pressure
(High)
Finish 5:30 0–00.00
Start 5:30 0–00.00
MAX
10 O O O ON Bucket CURL relief. • Bucket CURL oil pressure
(High)
Finish 6:00 0–30.00
Start 6:00 0–30.00
MAX
11 O O O ON Arm IN relief. • Arm IN oil pressure
(High)
Finish 6:30 0–60.00
• Boom RAISE oil pressure
Start 6:30 0–60.00
MAX • Blow-by pressure
12 O O O ON Boom RAISE relief.
(High) • Exhaust temperature
Finish 7:00 0–90.00
• Boost pressure
Start 7:00 0–90.00 Set all levers in neutral
MAX • Engine speed
13 O O O ON (1st deceleration o 2nd
(High) (1st deceleration speed)
Finish 7:30 –120.00 deceleration)
MIN
14 — 7:30 –120.00 ON Finish
(Low)
Note: To turn off the decelerator and set the engine speed to high idle, move one of both work equipment control
levers and both travel levers to a degree that the work equipment does not move or the machine does not
swing or travel. (If the PPC oil pressure switch is turned ON, the auto-decelerator is turned OFF.)
10 PC2000-8
Snap shot item table

No. Item Unit No. Item Unit
Sampling time sec 43 Arm throttle selector valve L —
1 Engine speed rpm 44 Arm throttle selector valve R —
2 Fuel injection rate mm3/st 45 Swing brake valve —
3 Blow-by pressure kPa 46 Swing priority selector valve —
4 Left-bank front exhaust temperature °C 47 Travel back pressure valve —
5 Left-bank rear exhaust temperature °C 48 Swing back pressure valve —
6 Right-bank front exhaust temperature °C
7 Right-bank rear exhaust temperature °C
8 Engine oil pressure MPa
9 engine oil temperature °C
10 Engine coolant temperature °C
11 Intake air pressure kPa
12 Intake air temperature °C
13 Ambient temperature °C
14 Pump 1F oil pressure MPa
15 Pump 1R oil pressure MPa
16 Pump 2F oil pressure MPa
17 Pump 2R oil pressure MPa
18 Fan pump F pressure MPa
19 Fan pump R pressure MPa
20 Hydraulic oil temperature °C
21 Pump 1F control current mA
22 Pump 1R control current mA
23 Pump 2F control current mA
24 Pump 2R control current mA
25 Engine speed command value V
26 Auto-deceleration command value V
27 Fuel injection timing deg
28 Fuel injection pressure MPa
29 PTO oil temperature °C
30 Boom raise oil pressure MPa
31 Boom lower oil pressure MPa
32 Arm in oil pressure MPa
33 Arm out oil pressure MPa
34 Bucket curl oil pressure MPa
35 Bucket dump oil pressure MPa
36 Right travel oil pressure switch —
37 Left travel oil pressure switch —
38 Right swing oil pressure MPa
39 Left swing oil pressure MPa
40 Service valve pressure switch —
41 Straight travel valve —
42 2-stage main relief signal —
PC2000-8 11
8. Download of setting data a Enter [User Name] and [Password].

1) Using harness [1] of service kit W1, con- a For the operating procedure, see the
nect PC W2 to download connector C53 in VHMS analysis tool operation and
the cab or download connector VDL on maintenance manual.
the ground.
3) Using [Download] function, download the

data currently recorded on VHMS to PC.
a For the operating procedure, see the
a Download connector C53 in the cab is VHMS analysis tool operation and
installed in the front side of the right maintenance manual.
stand of operator seat. a After making sure the download is
complete, proceed to the next step.
9. Confirmation of download data

1) Check the setting data using [View] function.
a For the operating procedure, see the
2) Operating [VHMS analysis tool] on PC, VHMS analysis tool operation and
start up the VHMS analysis tool. maintenance manual.
a Make sure that [MFA0] code, which
was used in the quick snapshot, is
indicated in [Fault History].
a Make sure the snap shot data are
recorded.
2) As check of the setting data is finished,

end [VHMS analysis tool].
12 PC2000-8
10. Disconnecting the PC 11. Report to Komatsu

1) Make sure the starting switch is at OFF As steps 1 – 9 are completed, send VHMS/
position. WebCARE setting report to VHMS/WebCARE
k Before connecting or disconnect- Support Center in Komatsu Headquarters.
ing a PC, be sure to turn off the a This report is a must since setting on the
starting switch. receiving end in the satellite communica-
2) End the OS of PC W2 and then turn off the tion must be done by Komatsu.
PC power. a In this case, send VHMS data via Notes
(LAN) or E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: [email protected]
3) When the data was download into the cab,

disconnect harness [1] of service kit W1
from download connector C53.
PC2000-8 13
[For storage] Date of setting:

DB/branch
VHMS initial setting work check sheet office name
Data entered by:
Setup step Check item Result
Model name
Confirmation of machine body and Serial No.
1
component nameplates Engine serial No.
VHMS controller serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
Is “Data Clear and Set up” selected for the setting tool
4 Starting of VHMS initial setting tool yes no
mode?
Is model name identical with machine body? yes no

Initial setting of VHMS controller
Is machine body serial No. correctly entered? yes no
(Setting of machine body informa- Is engine serial No. correctly entered? yes no
5 tion)
In this step, basic machine body Is today's date entered? yes no
information are set on VHMS con- Is current time entered? yes no
troller Is SMR correctly entered? yes no
6 Saving of settings Is LED (7-segment) turned off? yes no
7 Confirmation of VHMS function Is LED operation normal? yes no
Is service mode “SNAPSHOT” turned on and is the

8 Execution of quick Pm yes no
switch hit?
9 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
10 Download Is LED operation normal? yes no
Are all files downloaded? yes no

Hour,
The time downloaded (Reference wrist watch)
minute:
[Confirmation of data]
11 Confirmation of download data
Is [MFA0] error present in Fault History? yes no
Are SMR and time in Fault History consistent with set-
yes no
tings?
Is any data missing in Snap Shot0? yes no
12 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
14 PC2000-8
[For storage] Date of setting:

DB/branch
ORBCOMM station opening work office name
check sheet Data entered by:
Setup step Check item Result
Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
VHMS controller serial No.
ORBCOMM terminal serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
4 Starting of VHMS initial setting tool Is “Set up” selected for the setting tool mode? yes no
Entry of setting to S.Fault History

Initial setting of VHMS controller Presence/absence of communication On Off
1. Setting of communication
(Setting of machine body infor- Number of cases (Default is 8 cases)
mation and PLM are completed) Entry of setting of S.Trend Analysis setting
Presence/absence of communication On Off
Interval (Default is 20H)
5
Entry of setting of S.Payload data
Presence/absence of communication On Off
Tabulation start time
Interval of tabulation (in days) day
2. Setting for start of communica-
Is GCC code set? (130 for Japan) yes no
tion
6 Saving of settings Is LED (7-segment) turned off after data was stored? yes no
How is decimal point display in VHMS monitor

ORBCOMM controller performance
7 (7-segment)? yes no
check
(OFF, ON, long/short flashing)
PC2000-8 15
16 PC2000-8
Precautions for replacing VHMS 2. Confirmation, saving and loading of VHMS

controller 1 controller setting information (Ver. 3. 5. 2. 1
or older version)
a Care should be paid to the following equipment a This work is done inside the cab (from PC).
when replacing VHMS controller a Setting information is saved from the
VHMS controller to be replaced to the PC
Symbol Part No. Part name and the saved information is loaded to the
799-608-3211 Diskette new VHMS controller after the replace-
1 ment.
799-608-3220 Wiring harness
2-1. Confirmation and saving of VHMS controller
W Note type PC
Commercially setting information prior to replacement
2 (Windows 98/2000/Me/XP), 1) Connect the PC and start the VHMS initial
available
with RS232C terminal setting tool.
a See the “VHMS controller initial set-
a When it is required to replace a VHMS control- ting procedure” for this operation.
ler, setup of the replacing VHMS controller 2) Select [Save/Load] and press [OK] button.
shall be conducted before and after the
replacement according to the following proce-
dure.
a Machine data collected with VHMS controller
are stored and managed on WebCARE data-
base. In order to endure smooth data process-
ing on WebCARE , consistency must be
provided among the settings done on VHMS
controller. Inconsistencies in the settings
obstruct loading of data to WebCARE, ham-
pering appropriate use of VHMS data. Setting
work after replacement, therefore, is a must.
a Check each step of the setting work referenc-
ing the “VHMS initial setting work check
sheet”.
a Information such as models shown in the fig-
ures may not be identical with actual ones.
[Operations needed prior to replacement of

VHMS controller]
1. Download of the remaining data
a Using [Download] function, download the 3) Confirm every information before the
currently recorded and remained data on replacement.
VHMS to PC. 4) Select [Save] from [File] of the menu.
a For the operating procedure, refer to “8.
Download of setting data” in “VHMS con-
troller initial setting procedure”.
PC2000-8 17
3) Select [Load] from [File] of the menu.
5) Reconfirm the information and then press

[OK] button to save the information. 4) Currently saved information will be dis-
6) Select [Exit] from [File] of the menu to end played. Press [OK] button.
the VHMS setting tool.
7) Disconnect the PC.
a Refer to “10. Disconnecting the PC” in
“VHMS controller initial setting proce-
dure”.
8) Turns the PC power off.
9) Proceed to replacement of VHMS control-
lers.
2-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
ting procedure” for this operation.
2) Select [Save/Load] and press [OK] button.
5) Display the saved information on another

screen.
6) Press [Edit] button and adjust the time.
18 PC2000-8
7) After adjusting time, press [OK] button. 9) The confirmation screen will ask whether
or not the data before the above setup is
to be saved. Press [NO] button.
a It is not necessary to save the data before
the setting.
8) Press [Apply] button to display contents of

the setting. Check the setting again and, if
it is acceptable, press [OK] button.
10) The setup result is displayed. Confirm the

contents and press [Close] button.
11) Select [Exit] from [File] of the menu to end

the VHMS initial setting tool.
PC2000-8 19
3. Confirmation, saving and loading of VHMS 4) Confirm every information before the
controller setting information (Ver. 3. 5. 2. 1 replacement and then press [Save] but-
or later version) ton.
a Setting information is saved from the VHMS
controller to be replaced to the PC and the
saved information is loaded to the new
VHMS controller after the replacement.
3-1. Confirmation of VHMS controller setting infor-
mation prior to replacement
1) Connect the PC and start the VHMS initial
setting tool.
ting procedure” for this operation.
2) Select [When VHMS needs to be replaced]
and then press [Next] button.
5) Select [Exit] from [File] of the menu to end

the VHMS initial setting tool.
6) Disconnect the PC.
a Refer to “10. Disconnecting the PC” in
“VHMS controller initial setting proce-
dure”.
7) Turns the PC power off.
8) Proceed to replacement of VHMS control-
lers.
3-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
3) Select [Save current setting before initial setting tool.
replacement of VHMS controller] and a See the “VHMS controller initial set-
press [Next] button. ting procedure” for this operation.
2) Select [When VHMS needs to be
replaced] and then press [Next] button.
20 PC2000-8
3) Select [Use previous setting after replace- 6) The confirmation screen will ask whether
ment of VHMS controller] and press [Next] or not the data before the above setup is
button. to be saved. Press [NO] button.
a It is not necessary to save the data
before the setting.
4) Currently saved information will be dis-

played. Press [Next] button.
7) The above completes modification of the

setting. Press [OK] button to end the
VHMS initial setting tool.
5) Adjust the time and press [Apply] button.
PC2000-8 21
[Operations needed after replacement of VHMS

controller]
a Execute the quick Pm referring “7. Executing
quick Pm” in “VHMS controller initial setting
procedure”.
a Download the data referring “8. Download of
setting data” in “VHMS controller initial setting
procedure”.
a After the replacement, send VHMS/WebCARE
setting report sheet to VHMS/WebCARE Sup-
port Center in Komatsu Headquarters.
a Also send two sets of data, the downloaded
before and after the VHMS replacement, via
Notes (LAN) or E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: [email protected]
22 PC2000-8
Preparation work for 2. Engine controller

troubleshooting of electrical 1) Remove controller cover (3).
q Left bank
system 1
a When carrying out troubleshooting of an elec-

tric circuit related to the machine monitor,
engine controller, or VHMS controller, expose
the related connectors according to the follow-
ing procedure.
1. Machine monitor
Insert or connect troubleshooting T-adapters in
or to connectors CM01 and CM02 on the rear
side of machine monitor (1).
q Right bank
BWP15643
2) Insert or connect troubleshooting T-adapt-

ers in or to connectors ENG, CE05 and
CE06 of right bank engine controller (1).
q Right bank
PC2000-8 23
3. Pump controller
1) Remove the controller cover bolts and
controller cover in the operator's cab.
ers in or to connectors CP01, CP02 and
CP03 of pump controller 1.
ers in or to connectors CP04, CP05 and
CP06 of pump controller 2.
4. VHMS controller
1) Open the distribution board cover.
ers in or to connectors CV01, CV02A,
CV02B, CV03A, CV04A and CV04B of the
VHMS controller (1).
24 PC2000-8
Pm-clinic service 1
PC2000-8 25
Measurement procedure 1 3. Measurement procedure by oil pressure

gauge, fan tachometer, etc.
Outline of measurement procedure for PM- Measure each data with an oil pressure gauge,
clinic fan tachometer, etc.
There are the following 3 types of measurement
procedure for PM clinic of PC2000-8. 4. Measurement procedure by downloading
a Basically, apply measurement procedure 1 or data in VHMS controller
2. Connect a personal computer to the VHMS
controller and execute the quick PM clinic with
1. Measurement procedure by machine moni- the machine monitor, and then download the
tor PM clinic data to the personal computer.
Read the data on the PM clinic screen with a The following tools are necessary to this
“PM clinic function” of the machine monitor. measurement procedure.

799-608-3211 • Diskette
1
790-608-3220 • Wiring harness
W Notebook personal computer
Commercially
2 OS: Windows98/2000/Me/XP
15732 available
with “RS232C terminal”
2. Measurement procedure by stopwatch,

scale, etc.
Measure each data with a stopwatch, scale,
etc.
26 PC2000-8
Preparation for measurement for PM clinic Measurement procedure by machine monitor

1. Check safety around the machine and start the 1. Start of engine
engine. 1) Check that the machine monitor is not dis-
playing the abnormality screen.
2. Set the machine monitor to display the service 2) Prepare the PM clinic sheet. Check safety
menu selection screen, and then select the around the machine, sound the horn, and
“PM clinic” menu and display “PM clinic (1/12)” start the engine.
screen. 3) Turn the swing lock switch in the OFF
a For the operating method, see “Testing position.
an d a dj u s t i ng , Sp ec i a l f un c t i on s o f 4) Set the lock lever in the FREE position.
machine monitor”
2. Check of indication of engine coolant tem-
perature gauge and PTO oil temperature
gauge
1) Set the machine monitor to display the
monitor screen (1/2).
2) Check the indication of the engine coolant
15732 temperature gauge and PTO oil tempera-
ture gauge.
15744
3. Warm up the engine to increase the engine

coolant temperature and hydraulic oil tempera-
ture.
q Engine coolant temperature: Min. 40ºC
q Hydraulic oil temperature: Min. 40ºC
4. Stop the machine on a level ground.
5. Prepare for locking the travel system.

k When measuring the travel relief pres-
sure, lock the sprocket on the side to
be measured.
k When measuring the no-load travel
speed, push up the track shoe on the
side to be measured.
6. Lower the work equipment to the ground and

stop the engine.
PC2000-8 27
3. Change of display of machine monitor 5. Measuring with “PM clinic (2/12)”

Set the machine monitor to display the service 1) Display “PM clinic (2/12)”.
menu and select the “PM clinic” menu. 2) Measure the engine speed, intake air
a For the operating method, see “Functions pressure and exhaust temperature (at the
and operation of machine monitor”. front and rear of the right bank and left
bank).
a For the measurement conditions, see
the check sheet.
15732
15733
4. Measuring with “PM clinic (1/12)”

1) Display “PM clinic (1/12)”.
2) Measure the engine speed, engine cool-
ant temperature, engine oil pressure, 6. Measuring with “PM clinic (3/12)”
engine oil temperature, PTO oil tempera- 1) Display “PM clinic (3/12)”.
ture and hydraulic oil temperature. 2) Measure the engine speed, intake air tem-
a For the measurement conditions, see perature, left-bank common rail pressure,
the check sheet. left-bank boost pressure and exhaust tem-
perature (at the front of the left bank).
the check sheet.
15744
15734
28 PC2000-8
7. Measuring with “PM clinic (4/12)” 9. Measuring with “PM clinic (6/12)”
1) Display “PM clinic (4/12)”. 1) Display “PM clinic (6/12)”.
2) Measure the engine speed, ambient tem- 2) Measure the engine speed, ambient tem-
perature, left-bank fuel temperature, right- perature, right-bank fuel temperature,
bank fuel temperature and common rail right-bank common rail pressure and
pressure (of the right and left banks). blow-by pressure.
a For the measurement conditions, see a For the measurement conditions, see
the check sheet. the check sheet.
15735 15737
10. Measuring with “PM clinic (7/12)”

8. Measuring with “PM clinic (5/12)” 1) Display “PM clinic (7/12)”.
1) Display “PM clinic (5/12)”. 2) Measure the engine speed, hydraulic oil
2) Measure the engine speed, ambient tem- temperature, P1F pump pressure, P1R
perature, left-bank fuel temperature, left- pump pressure, P2F pump pressure and
bank common rail pressure and blow-by P2R pump pressure.
pressure. a For the measurement conditions, see
a For the measurement conditions, see the check sheet.
the check sheet.
15738
15736
PC2000-8 29
1) Display “PM clinic (8/12)”. 1) Display “PM clinic (10/12)”.
2) Measure the engine speed, hydraulic oil 2) Measure the engine speed, hydraulic oil
temperature, P1F pump pressure, P1R temperature, P1F pump pressure, P1R
pump pressure, VR1 J/S differential pres- pump pressure, P1F pump control EPC
sure and VL1 J/S differential pressure. current and P1R pump control EPC cur-
a For the measurement conditions, see rent.
the check sheet. a For the measurement conditions, see
the check sheet.
15739
15741
1) Display “PM clinic (9/12)”.
2) Measure the engine speed, hydraulic oil 1) Display “PM clinic (11/12)”.
temperature, P2F pump pressure, P2R 2) Measure the engine speed, hydraulic oil
pump pressure, VR2 J/S differential pres- temperature, P2F pump pressure, P2R
sure and VL2 J/S differential pressure. pump pressure, P2F pump control EPC
a For the measurement conditions, see current and P2R pump control EPC cur-
the check sheet. rent.
the check sheet.
15740
15742
30 PC2000-8
15. Measuring with “PM clinic (12/12)” 17. Measuring fan speed
1) Display “PM clinic (12/12)”. Using a tachometer, measure the RAD and O/C
2) Measure the engine speed, ambient tem- fan speeds.
perature, fan pump pressure (O/C), fan a See “Testing and adjusting (Part 2)”, Mea-
pump pressure (RAD), fan pump control suring fan speed.
EPC (RAD) current and fan pump control
EPC (O/C) current
the check sheet.
15666
15743
18. Measuring work equipment speed and

hydraulic drift
Using a stopwatch, scale, etc., measure the
work equipment speed and hydraulic drift.
16. Measuring PPC basic pressure
a For the measurement conditions, see the
check sheet.
a Connect a pressure gauge to the PPC
basic pressure pickup coupler to measure
the PPC basic pressure.
15669
PC2000-8 31
Measurement procedure by 3. Change of display of machine monitor

downloading data in VHMS 1) Set the machine monitor to display the
service menu selection screen.
controller 1 a See “Functions and operation of
machine monitor”.
1. Connection of personal computer 2) Select “Snap shot”.
1) Check that the starting switch is in the
OFF position.
k Be sure to connect and disconnect
the personal computer while start-
ing switch is in the OFF position.
2) Connect personal computer W2 and
download connector C53 by wiring har- 15732
ness [1] of service kit W1.
a Download connector C53 is installed
to the top of the left console.
a Connect the personal computer to the
RS232C terminal.
4. Execution of snap shot

1) Continue the operation on the screen to
start the snap shot.
a While the screen at right is displayed,
press the F1 button, and the check
message is displayed.
a Before starting the snap shot, fully
understand the operating procedure
for the snap shot.
2. Start of engine
1) Check that the machine monitor is not dis-
playing the abnormality screen.
2) Prepare the PM clinic sheet. Check safety 15727
around the machine, sound the horn, and
start the engine.
3) Turn the swing lock switch in the OFF
position.
4) Set the PPC lock lever in the FREE posi-
tion.
32 PC2000-8
2) Operate the switches and levers at each

execution time according to the “Operat-
ing procedure for quick PM clinic” shown
in the following table.
a The execution times are displayed on
k Since the work equipment and
machine are operated actually dur-
ing the quick PM clinic, take care of
the safety around the machine
extremely during the work.
15728
PC2000-8 33
Operating procedure for Quick Pm

Time on Fuel Swing lock Data read in Pm clinic after data
No. Elapsed time Operation of lever
snap data dial switch are downloaded
Start 0:00 –330.00 • Engine speed (Low idle)
MIN
1 O O O OFF Set all levers in neutral. • Engine oil pressure (Low idle)
(Low)
Finish 0:30 –300.00 • Ambient temperature
• Engine speed (High idle)
Start 0:30 –300.00 • Engine oil pressure (High idle)
MAX Set all levers in neutral
2 O O O OFF • J/S differential pressure
(High) (Turn decelerator on).
Finish 1:00 –270.00 • Pump oil pressure
• Fan pump oil pressure
Start 1:00 –270.00
MAX Move levers finely [Note]
3 O O O OFF • Engine speed (Auto deceleration)
(High) (Turn decelerator off).
Finish 1:30 –240.00
Start 1:30 –240.00 Raise right-hand track
MAX • Pump pressure
4 O O O OFF shoe and drive it idle
(High) (actuating pressure)
Finish 2:30 –180.00 (Set lever to stroke end).
Swing 180°.
Start 2:30 –180.00
MAX Raise left-hand track shoe • Pump pressure
5 O O O OFF
(High) and drive it idle (Set lever (actuating pressure)
Finish 3:30 –120.00
to stroke end).
Start 3:30 –120.00
6 O O O ON R.H. swing relief.
Finish 4:00 0–90.00
Start 4:00 0–90.00
7 O O O ON L.H. swing relief.
Finish 4:30 0–60.00
Start 4:30 0–60.00
MAX
8 O O O ON Arm OUT relief. • Arm OUT oil pressure
(High)
Finish 5:00 0–30.00
Start 5:00 0–30.00
MAX
9 O O O ON Bucket DUMP relief. • Bucket DUMP oil pressure
(High)
Finish 5:30 0–00.00
Start 5:30 0–00.00
MAX
10 O O O ON Bucket CURL relief. • Bucket CURL oil pressure
(High)
Finish 6:00 0–30.00
Start 6:00 0–30.00
MAX
11 O O O ON Arm IN relief. • Arm IN oil pressure
(High)
Finish 6:30 0–60.00
• Boom RAISE oil pressure
Start 6:30 0–60.00
MAX • Blow-by pressure
12 O O O ON Boom RAISE relief.
(High) • Exhaust temperature
Finish 7:00 0–90.00
• Boost pressure
Start 7:00 0–90.00 Set all levers in neutral
MAX • Engine speed
13 O O O ON (1st deceleration o 2nd
(High) (1st deceleration speed)
Finish 7:30 –120.00 deceleration)
MIN
14 — 7:30 –120.00 ON Finish
(Low)
Note: To turn off the decelerator and set the engine speed to high idle, move one of both work equipment control
levers and both travel levers to a degree that the work equipment does not move or the machine does not
swing or travel. (If the PPC oil pressure switch is turned ON, the auto-decelerator is turned OFF.)
34 PC2000-8
5. Downloading of snap shot data

1) Turn the personal computer ON and start
the OS.
2) Click the icon of [VHMS Analysis Tool] on
the personal computer to start the VHMS
analysis tool.
a Input [User Name] and [Password].
a For the operation procedures, see the
operation manual for VHMS Analysis
Tool.
3) Use the [Download] function to download

the data recorded in the VHMS controller
to the personal computer.
a For the operation procedures and
data analyzing method, see the oper-
ation manual for VHMS Analysis Tool.
PC2000-8 35
Pm-Clinic service
Chassis serial No.
PC2000-8
Backhoe
Engine serial No. (SAA12V140E-3)
Hour inspection
Work direction No. Date of execution Service meter Inspector
Interview with operator and walk-around inspection Accepted Rejected

Is there any abnormality before starting inspection?
Max. level of (F) coolant temperature Max. (F) PTO oil temperature Ambient temperature
Blue Red Blue Red Max. ˚C
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
Min. ˚C
(During work) (During work)
Altitude m
Max. level of (R) coolant temperature Max. (R) PTO oil temperature
Blue Red Blue Red
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
(During work) (During work)
Measurement Standard value Service limit Measurement

Condition Unit Accepted Rejected
items for new machine value result
After starting engine
Engine: Low idle 775 – 875 775 – 875
1-1
Engine: High idle 1930 – 2030 1930 – 2030
Engine: Full throttle
Boom: Raise relief 1680 – 1880 1680 – 1880
Engine
speed Engine: Full throttle rpm
1680 – 1880 1680 – 1880
(in DH mode) Boom: Raise relief + Heavy lift: ON
Auto-deceleration switch: ON
Fuel control dial: Max. 1300 – 1500 1300 – 1500
Control lever: Neutral
1-2 kPa Max. 2.94 Min. 5.88
1,780 rpm full throttle
{mmAq} {Max. 300} {Min. 600}
1. Engine
Blow-by pressure
1-3 Min. 0.08 Min. 0.06
Engine: Low idle (SAE10)
{Min. 0.8} {Min. 0.6}
Engine Min. 0.08 Min. 0.06
MPa
lubricating oil Engine: Low idle (SAE30)
{kg/cm2} {Min. 0.8} {Min. 0.6}
pressure
0.29 – 0.44 Min. 0.19
Engine: High idle (SAE30)
{3.0 – 4.5} {Min. 1.9}
1-4
kPa Min. 127 Limit is
Boost 1,780 rpm full throttle {mmHg} {Min. 950} not set
pressure
1-5 1,780 rpm full throttle Max. 650 Max. 700
Exhaust ˚C
temperature Ambient temperature 25 25 — —
Metal powder must not be

2. PTO
2-1 —
Visual check of filter collected.
2-2
Check of center bearing thermo-label 120˚C range must not be black.
˚C
2-3
PTO oil temperature Max. 120˚C Max. 120˚C
1. Boom RAISE 6.7 – 8.3 Max. 9.0

2. Boom
4.8 – 5.8 Max. 6.4
3. Work equipment speed
LOWER Engine: Full throttle

3. Arm IN DH mode 6.7 – 8.3 Max. 9.0
4. Arm OUT Hydraulic oil temperature: 45 - 55˚C 4.7 – 5.7 Max. 6.2
5. Bucket CURL 4.5 – 5.5 Max. 6.0
sec
Swing: Measure time for
6. Bucket DUMP 5 turns after 1 turn. 3.5 – 4.3 Max. 4.9
7. Swing 5 turns Travel: Raise each track and measure 5 turns 57.5 – 67.5 Max. 70.0
8. Drive right with no load after 1 turn.
track 5 turns 90.5 – 110.5 90.5 – 110.5
9. Drive left
90.5 – 110.5 90.5 – 110.5
track 5 turns
36 PC2000-8
Standard value for Measurement
Measurement items Condition Unit Service limit value Accepted Rejected
new machine result
Set work equipment in measuring posture and stop engine.
Hydraulic drift of Max. 1,200 Max. 1,800
Whole work equipment Work equipment
4 Hydraulic drift
bucket tooth tip {Max. 650} {Max. 1000}

posture: Boom and
arm in level, bucket Max. 60 Max. 90
Boom cylinder Cylinder retraction
curled, rated load on mm/15 {Max. 35} {Max. 50}
work equipment [no min Max. 165 Max. 250
Arm cylinder load] Cylinder extension
{Max. 70} {Max. 105}
Hydraulic oil
temperature: 45 – 55ºC Cylinder retraction Max. 50 Max. 80
Bucket cylinder
{Max. 15} {Max. 30}
Standard value for Service limit value Measurement result Accepted Rejected
Measurement items Condition Unit
new machine F engine R engine
5-1 Control lever:
Control pressure (PPC 3.24 – 3.73 3.04 – 3.73
Neutral {33 – 38} {31 – 38}
basic pressure)
Control lever: Min. 1.28 MPa Min. 1.28 MPa
Neutral {Min. 13.1 kg/cm2} {Min. 13.1 kg/cm2}
Right travel lever: MPa
5-2 Stroke end {kg/cm2} Max. 0.17 MPa Max. 0.17 MPa
Jet sensor differential Track: Turning with {Max. 1.7 kg/cm2} {Max. 1.7 kg/cm2}
pressure no load
Left travel lever:
Stroke end Max. 0.17 MPa Max. 0.17 MPa
Track: Turning with {Max. 1.7 kg/cm2} {Max. 1.7 kg/cm2}
no load
Control lever: 160 – 280 160 – 280
Neutral
Right travel lever:
Stroke end P1 : 390 – 510 P1 : 390 – 510
5-3 Track: Turning with P2 : 615 – 735 P2 : 615 – 735
mA
Pump EPC current no load
Left travel lever:
Stroke end P1 : 390 – 510 P1 : 390 – 510
Track: Turning with P2 : 615 – 735 P2 : 615 – 735
no load
Boom: Raise relief 28.4 – 30.4 27.4 – 30.4
(Normal) {290 – 310} {280 – 310}
(Heavy lift ON) {317 – 337} {307 – 337}
28.4 – 30.4 27.4 – 30.4
Arm: In relief
5-4 {290 – 310} {280 – 310}
P1F pump pressure 28.4 – 30.4 27.4 – 30.4
Arm: Out relief
{290 – 310} {280 – 310}
28.4 – 30.4 27.4 – 30.4
Bucket: Curl relief
{290 – 310} {280 – 310}
Swing: Relief 28.4 – 30.4 27.4 – 30.4
{290 – 310} {280 – 310}
Hydraulic oil
temperature: 45 – 55ºC Boom: Raise relief 28.4 – 30.4 27.4 – 30.4
5 Hydraulic system
Mode: P (Normal) {290 – 310} {280 – 310}

Engine: Full throttle Boom: Raise relief 31.1 – 33.1 30.1 – 33.1
Fan: 100% speed mode (Heavy lift ON) {317 – 337} {307 – 337}
5-5 Auto-decelerator: OFF 28.4 – 30.4 27.4 – 30.4
P1R pump pressure Arm: In relief {290 – 310} {280 – 310}
28.4 – 30.4 27.4 – 30.4
Arm: Out relief
MPa {290 – 310} {280 – 310}
{kg/cm2} 28.4 – 30.4 27.4 – 30.4
Bucket: Curl relief
{290 – 310} {280 – 310}
(Normal) {290 – 310} {280 – 310}
(Heavy lift ON) {317 – 337} {307 – 337}
5-6 28.4 – 30.4 27.4 – 30.4
P2F pump pressure Arm: In relief
{290 – 310} {280 – 310}
28.4 – 30.4 27.4 – 30.4
Arm: Out relief
{290 – 310} {280 – 310}
28.4 – 30.4 27.4 – 30.4
Bucket: Curl relief
{290 – 310} {280 – 310}
(Heavy lift ON) {317 – 337} {307 – 337}
28.4 – 30.4 27.4 – 30.4
Arm: In relief
5-7 {290 – 310} {280 – 310}
P2R pump pressure 28.4 – 30.4 27.4 – 30.4
Arm: Out relief
{290 – 310} {280 – 310}
28.4 – 30.4 27.4 – 30.4
Bucket: Curl relief
{290 – 310} {280 – 310}
5-8
Control lever: STD : 575 – 675 STD : 575 – 675
Fan pump EPC
Neutral 55ºC : 505 – 605 55ºC : 505 – 605
(Radiator) current
mA
5-9
Fan pump EPC (Oil Control lever: STD : 600 – 700 STD : 600 – 700
Neutral 55ºC : 505 – 605 55ºC : 505 – 605
cooler) current
5-10 Control lever: STD : 790 – 890 STD : 790 – 890
Fan speed (Radiator) Neutral 55ºC : 1050 – 1150 55ºC : 1050 – 1150
rpm
5-11 Control lever: STD : 710 – 810 STD : 710 – 810
Fan speed (Oil cooler) Neutral 55ºC : 1050 – 1150 55ºC : 1050 – 1150
Mode: P
5-12
Engine: Full throttle
Hydraulic oil
Fan: 100% speed mode Bucket: Dump relief ºC Max. 100ºC Max. 100ºC
temperature
Auto-decelerator:
PC2000-8 37
There must not be excessive metal powder or

Visual check of hydraulic tank strainer (Every 2,000 H)
6
foreign matter.
Memo: Enter phenomena and information you noticed during today's check.
38 PC2000-8
Pm-Clinic service PC2000-8
Visual check of welded structures (For PC2000-8)

If any crack is found, draw its shape below.
Arm Boom Revolving frame

1. Arm cylinder bracket 5. Boom top bracket 9. Boom bracket
Left Right Left Right Left Right
2. Arm foot 6. Boom cylinder bracket
Left Right End plate Left Right Track frame
3. Arm top boss 7. Boom lower plate
10. Circle bracket
Left Right Left Right
Front Rear
4. Arm cylinder bracket 8. Boom foot
Left Right
Left Right Left Right
11. Track frame mounting section
Front Rear
Left Right
PC2000-8 39
SEN02010-00
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 10-06 (01)
40
SEN01629-00
PC2000-8

PC2000-8 20001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic diagrams and drawings................................................................................................................... 3
Hydraulic circuit diagram...................................................................................................................... 3
PC2000-8 1
SEN01629-00 90 Diagrams and drawings
2 PC2000-8
Hydraulic circuit diagram
Hydraulic diagrams and drawings PC2000-8
1
Hydraulic circuit diagram 1
SEN01629-00
PC2000-8 3
PC2000-8 5
SEN01629-00
6
SEN01630-00
PC2000-8

PC2000-8 20001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical diagrams and drawingss ................................................................................................................. 3
Electrical circuit diagram (1/2) .............................................................................................................. 3
Electrical circuit diagram (2/2) .............................................................................................................. 5
PC2000-8 1
SEN01630-00 90 Diagrams and drawings
2 PC2000-8
Electrical circuit diagram (1/2)
Electrical diagrams and drawingss PC2000-8
SEN01630-00
PC2000-8 3
Electrical circuit diagram (2/2) PC2000-8
SEN01630-00
PC2000-8 5
PC2000-8 7
SEN01630-00

Shop Manual Pc2000-8 Sen01607-00pd

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SEN01607-00

Copyright 2006 Komatsu

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

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

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN01607-00

00 Index and foreword SEN01608-00

10 Structure, function and maintenance standard SEN01613-00

90 Diagrams and drawings SEN01628-00

Foreword and general information SEN01610-00

10 Structure, function and maintenance standard

Hydraulic system, Part 1 SEN01618-00

90 Diagrams and drawings

PC2000-8 Hydraulic excavator

Form No. SEN01609-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Foreword and general information (Rev. 2005/11)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness

5. Points to remember when troubleshooting

Points to remember when handling hydraulic equipment

1. Be careful of the operating environment.

2. Disassembly and maintenance work in the

4. Do not let any dirt or dust get in during

5. Change hydraulic oil when the temperature