Description
Komatsu PC4000-6 Hydraulic Mining Shovel Troubleshooting Manual — TS 08199-xD-GB-2
This Komatsu PC4000-6 Hydraulic Mining Shovel Troubleshooting Manual is the complete fault-finding and diagnostic reference for machines from serial number 08199 and up. Published under document number TS 08199-xD-GB-2 by Komatsu Mining Germany GmbH, this 494-page PDF walks a technician through every stage of troubleshooting — from safety fundamentals and component location through to G-code-driven diagnostics and symptom-based fault isolation.
The manual is built around the machine’s VHMS monitoring and MTC control system, and it assumes the reader has access to the machine’s wiring diagrams, hydraulic circuit diagrams, and the Cummins QSK60 engine documentation. It is not a general introduction to the shovel — it is the document a trained technician reaches for when a fault code appears, a function fails, or a symptom needs to be traced to a root cause.
File Details
- Manual type: Troubleshooting Manual
- Brand: Komatsu (Komatsu Mining Germany GmbH)
- Model: PC4000-6 Hydraulic Mining Shovel
- Serial number coverage: 08199 and up
- Document number: TS 08199-xD-GB-2
- Language: English
- Page count: 494
- File format: PDF
Chapters Covered
- 1 Safety — Safety Information, Overview, Sound Pressure Level in the Operator’s Cab, General Precautions, Precautions for Maintenance, Additional Safety Information for Troubleshooting and Adjustments, Special Safety Equipment
- 2 Introduction & General Information for Troubleshooting — General Precautions, Preparations for Work, Precautions During Work, Fundamental Requirements, Points to Remember, Sequence of Events, Handling of Electric Equipment and Hydraulic Components, General Working Procedures, Cylinder Bypass Test, Information About MTC & Nodes, Basics About “How to Crimp”, Cable Shielding
- 3 Mounting Locations and Connector Types — Component Location, View Onto the Superstructure, Location of Engine Electrical Parts, Location of Hydraulic Components, Location of Remote Control Valves, Location of High Pressure Sensors, SLS and CLS Grease Barrel Components, Electrical Components in the Cab Base, Hydraulic Oil Tank Electrical Components, Hydraulically Operated Access Ladder, Connector Types Overview
- 4 Standard Value Table for Electrical Components
- 5 References for Troubleshooting (CAN Bus & Node Outputs) — CAN-Bus Trouble or Node Output Trouble, Sequence of CAN Nodes, Troubleshooting for Relay Monitored Node Outputs
- 6 Tables for Testing and Troubleshooting — PT100 Temperature Sensor Tables (Centigrade–Volt and Centigrade–Ohm), Table of Trouble Codes (G-Codes), Table of Instruction Messages, Table of Binary Codes, Binary Output Signals on the VHMS Monitor, Power Supply, Cable Colour Identification
- 7 Troubleshooting by Trouble Code — Individual troubleshooting charts for G00001 through G00491, covering gate valve, pump controller, hydraulic oil level, starter, VHMS, emergency safety circuit, CAN bus, ladder, service arm, parking brakes, pilot control, and many more
- 8 Troubleshooting by Symptoms — Engine and Related Electrical System (SEL001–SEL012), Hydraulic System (SHY001–SHY020), Mechanical System (SME001–SME011), Additional Systems (SAD001–SAD004)
What makes this manual different from a general service guide is the depth of the diagnostic path. Chapter 7 is organised by G-code — every stored trouble code in the VHMS system has its own multi-page chart with possible causes, test conditions, nominal values, step-by-step inspection procedures, and final checks. Chapter 8 takes the opposite approach: when there is no stored code, the symptom-based charts (SEL, SHY, SME, SAD) walk through engine, hydraulic, mechanical, and auxiliary system problems from the operator’s complaint to the failed component. Between them, the two chapters cover the full range of what can go wrong on a PC4000-6.
Supporting that diagnostic core are the reference chapters a technician needs close at hand: the standard value table for electrical components in Chapter 4 (with expected resistances, voltages, and measurement conditions for sensors, solenoids, and switches); the CAN bus and node output reference in Chapter 5; and the testing tables in Chapter 6, including the PT100 temperature sensor conversion charts and the full G-code and instruction message tables. Chapter 3 provides the component locations that make all of this usable — where the sensors, relays, nodes, and valves actually sit on the machine.
The manual also covers the MTC (Machine Control) and ICN-D/ICN-V node architecture, including the DIP switch settings, LED status indications, and connector types used throughout the machine. For technicians who need to repair a damaged connector, the “How to Crimp” section gives the wire stripping, crimp tool adjustment, and inspection procedure for the Deutsch HDT 48 tool.
Which G-Codes and Symptoms Are Covered
The G-code troubleshooting charts in Chapter 7 span the full VHMS fault range. Examples include G00001 (main shut-off gate valve), G00003 (pump controller), G00005 and G00007 (hydraulic oil level), G00012 and G00013 (lubrication grease level), G00031 (engine low idle), G00032 (starter), G00035 (PTO gear oil loss), G00043 (output short-circuit), G00048 (emergency safety circuit), G00060 (fire in the power house), G00061 and G00062 (engine speed monitoring), G00063 (hydraulic oil temperature), G00064 (hydraulic oil level monitoring), G00066 (hydraulic oil overheat), G00067 (battery voltage too high), G00069 and G00070 (PTO gear oil temperature), G00071 (PTO gear lubrication), G00081 (lubrication system), G00086 (SHUTDOWN), G00090 and G00099 (power supply), G00091 and G00096 (pilot control cut-out), G00092–G00095 (emergency shut-down switches), G00100 (maintenance safety switch), G00104 and G00105 (battery current and charging), G00107–G00118 (slew and travel parking brake controls), G00140 and G00141 (X1 and X2 pressure monitoring), G00147 (PTO gear lubrication monitoring), G00148 (fuel level monitoring), G00151 (PTO gear oil filter), G00154–G00170 (return oil, leak oil, breather, air cleaner, and filter monitoring), G00176–G00178 (battery voltage and charging current), G00179–G00181 (X1 and X2 control pressure), G00184–G00189 (lubrication system empty and trouble), G00207 (engine remote oil tank), G00216 (software compatibility), G00218–G00220 (transfer pump), G00223–G00226 (starter control), G00231–G00238 (pilot control levers and supply), G00240–G00262 (hydraulic oil temperature, emergency shut-down, maintenance safety switch, cooler screen), G00308–G00333 (CAN bus, ladder, service arm, parking brake, pilot control, battery charger), G00351 and G00352 (engine running and standstill), and G00417–G00491 (VHMS controller communication and system errors).
The symptom-based charts in Chapter 8 cover engine no-start, engine stops during operation, engine speed hunting, engine no-stop, lack of output power, black exhaust smoke, excessive oil consumption, contaminated oil, excessive fuel consumption, oil in coolant, rising oil level, coolant overheating, hydraulic lack of power, engine stall, no work equipment travel or swing, hydraulic drift, time lag, machine deviation during travel, swing problems, floating system faults, abnormal noise from SRV/MRV, track tensioning, ladder and refilling arm movement, grease pump faults, pump bearing lubrication, track chain movement, parking brake faults, abnormal noise from engine/PTO/pumps, excessive vibration, swing shock, fan hub bearing noise, travel gearbox noise, work equipment grease noise, idler movement, PTO shaft seal leaks, air conditioner faults, and travel alarm faults.
What You Can Do With This Manual
- Diagnose every stored G-code in the VHMS system with a structured troubleshooting chart
- Trace symptoms that have no stored code using the SEL, SHY, SME, and SAD charts
- Check electrical components against the standard value table before condemning a part
- Locate sensors, relays, nodes, valves, and connectors on the machine using Chapter 3
- Interpret CAN bus and node output errors using the REAL TIME MONITOR and binary codes
- Test and replace components according to the specified nominal values and procedures
- Understand the MTC, ICN-D, and ICN-V node architecture, LED indications, and DIP switch settings
- Repair Deutsch connectors correctly using the crimping instructions and tool settings
- Carry out cylinder bypass tests and air bleeding procedures correctly and safely
- Reset the machine after an emergency stop or maintenance safety switch event
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Komatsu PC4000-6 Hydraulic Mining Shovel Troubleshooting Manual – Serial 08199 & Up (PDF)” are as follows:
+1 SAFETYp. 17
1.1 SAFETY INFORMATIONp. 18
+1.2 OVERVIEWp. 19
1.2.1 NORMAL OPERATIONSp. 19
1.2.2 REGULAR MAINTENANCEp. 19
1.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIRp. 19
1.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATORp. 19
1.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CABp. 20
+1.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATORp. 21
1.4.1 UNDERSTANDING THE MACHINEp. 21
+1.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATORp. 21
1.4.2.1 ENSURING SAFE OPERATIONp. 21
+1.4.3 PREPARATIONS FOR SAFE OPERATIONp. 21
1.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENTp. 21
1.4.3.2 INSPECTING THE MACHINEp. 21
1.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENTp. 22
1.4.3.4 KEEP MACHINE CLEANp. 22
1.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENTp. 22
1.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KITp. 23
1.4.3.7 IF A PROBLEM IS FOUNDp. 23
+1.4.4 FIRE PREVENTIONp. 23
1.4.4.1 PRECAUTIONS TO PREVENT FIREp. 23
1.4.4.2 ACTION IF FIRE OCCURSp. 24
1.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CABp. 25
+1.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINEp. 25
1.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINEp. 25
1.4.5.2 NO JUMPING ON OR OFF THE MACHINEp. 25
1.4.5.3 NO PEOPLE ON THE ATTACHMENTp. 25
1.4.5.4 WORKING IN HIGH PLACESp. 25
1.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCKp. 26
1.4.5.6 LEAVING THE MACHINEp. 26
+1.4.6 BURN PREVENTIONp. 27
1.4.6.1 Hot coolantp. 27
1.4.6.2 Hot oilp. 27
1.4.7 PRECAUTIONS WHEN CLEANING CAB GLASSp. 27
+1.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURESp. 28
1.4.8.1 UNAUTHORIZED MODIFICATIONp. 28
1.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONSp. 28
+1.4.9 PRECAUTIONS AT JOBSITEp. 29
1.4.9.1 VISIBILITY FROM OPERATOR’S SEATp. 30
1.4.9.2 CAMERA SYSTEM WITH MONITORSp. 30
1.4.9.3 ENSURE GOOD VISIBILITYp. 30
1.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALSp. 30
1.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONSp. 31
1.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLESp. 31
1.4.9.7 WORKING ON LOOSE GROUNDp. 32
1.4.9.8 GAS, DUST, STEAM AND SMOKEp. 32
1.4.9.9 VENTILATION OF ENCLOSED AREASp. 33
+1.4.10 STARTING ENGINEp. 34
1.4.10.1 WARNING TAGp. 34
1.4.10.2 CHECKS BEFORE STARTING ENGINEp. 34
1.4.10.3 PRECAUTION WHEN STARTING ENGINEp. 34
1.4.10.4 PRECAUTION IN COLD AREASp. 35
+1.4.11 OPERATIONp. 35
1.4.11.1 CHECKS BEFORE OPERATIONp. 35
1.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSEp. 36
1.4.11.3 PRECAUTIONS WHEN travellingp. 37
1.4.11.4 TRAVELLING ON SLOPESp. 38
1.4.11.5 OPERATIONS ON SLOPESp. 39
1.4.11.6 PROHIBITED OPERATIONSp. 39
1.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACESp. 40
1.4.11.8 PARKING THE MACHINEp. 40
1.4.11.9 TRANSPORTATIONp. 40
+1.5 PRECAUTION FOR MAINTENANCEp. 41
+1.5.1 GENERAL PRECAUTIONSp. 41
1.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIESp. 42
1.5.1.2 STOP ENGINE FOR MAINTENANCEp. 43
1.5.1.3 WARNING TAGp. 44
1.5.1.4 KEEP WORKPLACE CLEAN AND TIDYp. 45
1.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERSp. 45
1.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNINGp. 46
1.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTSp. 46
1.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENTp. 47
1.5.1.9 NOISEp. 47
1.5.1.10 WHEN USING A HAMMERp. 47
1.5.1.11 PROPER TOOLSp. 48
1.5.1.12 ACCUMULATORp. 48
1.5.1.13 PERSONNELp. 48
+1.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCEp. 49
1.5.2.1 PRECAUTION WHEN WELDINGp. 49
1.5.2.2 BATTERY HANDLINGp. 49
+1.5.3 PRECAUTIONS WITH HIGH PRESSURE Fluidp. 50
1.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSUREp. 50
1.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPESp. 51
1.5.3.3 REPLACEMENT OF HOSE LINESp. 51
1.5.3.4 INSPECTION OF HOSE LINESp. 51
1.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTSp. 52
1.5.3.6 PRECAUTIONS FOR HIGH VOLTAGEp. 52
1.5.3.7 AIR CONDITIONING MAINTENANCEp. 52
1.5.3.8 COMPRESSED AIRp. 53
1.5.3.9 WASTE MATERIALSp. 53
+1.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTSp. 54
1.6.1 INSPECTION OF THE HYDRAULIC SYSTEMp. 54
1.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTSp. 54
1.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATORp. 54
+1.7 SPECIAL SAFETY EQUIPMENTp. 55
1.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CABp. 56
1.7.2 OBJECT HANDLINGp. 56
1.7.3 LIGHTINGp. 56
1.7.4 WARNING BEACONp. 56
+1.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)p. 56
1.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)p. 56
1.7.5.2 INSTRUCTIONS FOR USEp. 58
1.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALLp. 60
1.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1)p. 60
1.7.5.5 INSTRUCTIONS FOR USEp. 62
+2 Introduction & General Information for Troubleshootingp. 63
+2.1 Overviewp. 64
2.1.1 General advice when using troubleshooting chartsp. 64
2.2 General Precautionsp. 65
2.3 Preparations For Workp. 66
2.4 Precautions During Workp. 66
+2.5 Precautions When Carrying Out Any Operationp. 67
2.5.1 Precautions when carrying out removal workp. 67
2.5.2 Precautions when carrying out installation workp. 67
2.5.3 Precautions when completing the operationp. 68
+2.6 Fundamental Requirements for Troubleshootingp. 69
2.6.1 Technical documentationp. 69
+2.6.2 Toolsp. 69
2.6.2.1 Reference Guide for Deutsch Removal Toolsp. 72
2.6.3 Personnelp. 73
2.7 Points To Remember When Troubleshootingp. 73
2.8 Sequence Of Events In Troubleshootingp. 75
2.9 Checks Before Troubleshootingp. 76
+2.10 Handling Of Electric Equipment And Hydraulic Componentsp. 77
2.10.1 Points to remember when handling electric equipmentp. 77
2.10.2 Points To Remember When Handling Hydraulic Equipmentp. 79
+2.11 General working proceduresp. 82
2.11.1 Air Bleeding of Various Hydraulic Partsp. 82
2.11.2 Air bleeding from the hydraulic pumpsp. 82
2.11.3 Air bleeding from hydraulic cylindersp. 82
2.12 Cylinder bypass testp. 83
+2.13 Information about MTC & Nodesp. 84
+2.13.1 Outline of the MTC and its connector locationsp. 84
2.13.1.1 View onto the MTC connectors* LH & RHp. 84
2.13.1.2 General description of the MTCp. 84
2.13.1.3 Information about the LED indications at the MTCp. 85
+2.13.2 Information about the ICN-D nodep. 85
2.13.2.1 View onto an ICN-D node without wiringp. 86
2.13.2.2 View onto the Status LEDs at the ICN-D nodep. 87
2.13.2.3 General information on the LED controlp. 87
+2.13.3 Information about the ICN-V nodep. 89
2.13.3.1 View onto an ICN-V nodep. 89
2.13.3.2 View onto an open ICN-V node and its DIP-switchesp. 90
2.13.4 DIP switches at the ICN-D and ICN-V nodesp. 91
+2.14 Basics about "How to crimp"p. 92
2.14.1 Stripping a wire for use with the HDT 48 crimp toolp. 92
2.14.2 View onto the Deutsch crimp tool HDT 48p. 92
+2.14.3 Adjustment of the wire size at the Deutsch crimp tool HDT 48p. 93
2.14.3.1 Wire cross section units in mm2 and AWGp. 93
2.14.4 Crimping instructions (for Deutsch crimp tool HDT 48)p. 94
2.15 Cable Shieldingp. 95
+3 Mounting Locations and Connector Typesp. 97
+3.1 Component locationp. 98
3.1.1 View onto the Superstructurep. 98
3.1.2 Location of Engine Electrical Parts (1)p. 100
3.1.3 Location of Engine Electrical Parts (2)p. 102
3.1.4 Location of Hydraulic Components (1)p. 103
3.1.5 Location of Hydraulic Components (2)p. 105
3.1.6 Location of the Remote Control Valvesp. 106
3.1.7 Location of the High Pressure Sensorsp. 108
3.1.8 View onto the SLS and CLS Grease Barrel and the Lubrication Cycle Componentsp. 109
3.1.9 View onto the Electrical Components in the Cab Basep. 111
3.1.10 Hydraulic Oil Tank – Location of Electrical Componentsp. 113
3.1.11 Hydraulically Operated Access Ladderp. 115
3.2 Connector Types Overviewp. 117
4 Standard Value Table for Electrical Componentsp. 123
+5 References for Troubleshooting (CAN Bus & Node Outputs)p. 135
+5.1 CAN-Bus trouble or Node Output Troublep. 136
5.1.1 Trouble CAN-BUS or CAN-Hardware (G00308)p. 137
5.1.2 Trouble output short-circuit (G00043)p. 138
5.2 Sequence of the CAN nodes at the CAN busp. 140
+5.3 Troubleshooting for Relay Monitored Node Outputsp. 141
G00107 – Trouble slew parking brake control 56K250ap. 142
+G00109 – Trouble slew parking brake control 56K250bp. 142
View onto the CoDeSys HMI Visualization screen for trouble code G00107p. 144
Wiring Diagram (56K250a & 56K250b) for trouble code G00107p. 145
5.3.2 Output Checkp. 146
G00108 – Trouble slew parking brake control Output to 56K250ap. 147
+G00110 – Trouble slew parking brake control Output to 56K250bp. 147
View onto the CoDeSys HMI Visualization screen for trouble code G00108p. 149
Wiring Diagram (56K250a & 56K250b) for trouble code G00108p. 150
+6 Tables for Testing and Troubleshootingp. 153
6.1 Index of Tables in this sectionp. 154
6.2 Test Value Table for Temperature Sensors (PT100) g Centigrade – Voltp. 155
6.3 Test Value Table for Temperature Sensors (PT100) g Centigrade – Ohmp. 156
6.4 Table of Trouble Codes (G-Codes)p. 157
6.5 Table of Instruction Messagesp. 163
+6.6 Table of Binary Codesp. 166
6.6.1 Table of Add-On Binary Codes for G00308p. 168
6.7 Binary Output Signals on the VHMS Monitorp. 169
6.8 Power Supplyp. 171
6.9 Cable colour identificationp. 172
+7 Troubleshooting by Trouble Codep. 173
+G00001 – Trouble Shut-Off (gate) valvep. 174
View onto the gap of proximity switch 40B031p. 176
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITORp. 177
View onto the setting for SHUTDOWN BYPASS on the VHMS monitorp. 177
Wiring Diagram (40B031) for trouble code G00001 (Main gate valve open)p. 178
+G00002 – Test speed 1800 1/min engine 1p. 179
Wiring Diagram (11S041-1) for trouble code G00002p. 180
G00003 – Trouble pump controllerp. 181
+G00005 – Low hydraulic oil levelp. 185
Wiring Diagram, oil level label, and defined position of the attachment (G00005)p. 187
+G00007 – Trouble hydraulic oil levelp. 188
Wiring Diagram (40B004) and the defined position of the attachment (G00007)p. 189
G00012 – Central lubrication system grease level too lowp. 190
+G00013 – Slew ring gear lubr. system grease level too lowp. 190
Wiring Diagram (62B108 & 62B109) for trouble codes G00012 & G00013p. 194
Wiring Diagram (junction box) for trouble codes G00012 & G00013p. 195
+G00020 – Trouble Shut-Off (gate) valve (Start blocked)p. 196
View onto the gap of proximity switch 40B031 (G00020)p. 198
Wiring Diagram (40B031) for trouble code G00020 (Main gate valve closed)p. 199
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITORp. 200
View onto the setting for SHUTDOWN BYPASS on the VHMS monitorp. 200
+G00031 – Set engine to low idlep. 201
Wiring Diagram (20S030) for trouble code G00031p. 202
Input signal of the engine speed switch 20S030 on the REAL TIME MONITORp. 202
+G00032 – Trouble starterp. 203
Wiring Diagram (Cold Start Signal) for trouble code G00032p. 204
Wiring Diagram ("Engine running" signal) for trouble code G00032p. 205
G00033 – Trouble VHMS-Controllerp. 206
G00034 – Trouble VHMS-Displayp. 207
+G00035 – Trouble totally loss gear oil (PTO 1)p. 208
View onto the location of sensor 57B175-1 at the PTO (G00035)p. 210
Input signal (analog) of the PTO 1 gear oil sensor 57B175-1 on the REAL TIME MONITORp. 211
View onto the setting for SHUTDOWN BYPASS on the VHMS monitorp. 211
Wiring Diagram (57B175-1) for trouble code G00035p. 212
G00039 – Actuate engine speed selector switchp. 213
G00043 – Trouble output short-circuitp. 214
+G00048 – Trouble emergency safety circuitp. 215
Wiring Diagram (11K044a) for trouble code G00048p. 215
G00053 – Reset emergency safety circuitp. 216
+G00054 – Monitoring idle position cut offp. 217
Wiring Diagram (11K032) for trouble code G00054p. 218
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054)p. 219
Exemplary view onto the VHMS Failure History (G00054)p. 219
+G00060 – Fire in the power housep. 220
Wiring Diagram (fire alarm) for trouble code G00060p. 222
Wiring Diagram (10B351 in the safety circuit) for G00060p. 223
+G00061 – Trouble monitoring, engine 1 speed too lowp. 224
Input signal (analog) of 51K003b-1 on the REAL TIME MONITOR (G00061)p. 225
Wrong signal of the engine speed converter on the REAL TIME MONITOR (G00061)p. 226
Wiring Diagram (engine speed) for trouble code G00061p. 226
+G00062 – Trouble monitoring, engine 1 speed too highp. 227
Wiring Diagram (engine speed) for trouble code G00062p. 228
+G00063 – Trouble monitoring hydraulic oil tempp. 229
Wiring Diagram (59B015) for trouble code G00063p. 230
+G00064 – Trouble monitoring hydraulic oil levelp. 231
Wiring Diagram (40B004) for trouble code G00064p. 233
+G00065 – Very low hydraulic oil levelp. 234
View onto the hydraulic oil level labelp. 234
+G00066 – Trouble hydraulic oil temperaturep. 235
Wiring Diagram (57K506a-1 / 57K506b-1) and location for G00066p. 237
Hydraulic oil temperature tablep. 237
+G00067 – Trouble battery voltage too highp. 238
Wiring Diagram (11T080) and component location for G00067p. 239
G00067 – Input signal of 11T080 on the REAL TIME MONITORp. 239
+G00069 – Trouble monitoring oil temperature gear (PTO 1)p. 240
Input of 57B049-1 on the REAL TIME MONITOR (G00069)p. 241
Gear oil temperature (PTO 1) on the Main Gauge Screen (G00069)p. 241
Wiring Diagram (57B049-1) and component location for G00069p. 242
+G00070 – Trouble oil temperature gear (PTO 1)p. 243
Location of the PTO 1 gear oil level dipstick and temperature sensor 57B049-1p. 245
+G00071 – Trouble gear lubrication (PTO 1)p. 246
Wiring Diagram (57B017-1) for trouble code G00071p. 247
+G00081 – Trouble lubrication systemp. 248
Operation cycles of the lubrication systemsp. 250
Wiring Diagram (11K050) for trouble code G00081p. 251
Wiring Diagram (pilot control slew & stick) for trouble code G00081p. 252
G00086 – SHUTDOWNp. 253
G00087 – Stop all movements for low idlep. 254
G00090 – Trouble power supplyp. 255
+G00099 – Trouble power supplyp. 255
Wiring Diagram (stabilized power supply) for G00090 & G00099p. 256
+G00091 – Pilot control cut outp. 257
View onto the lock lever and the cover of 20S105 (G00091)p. 258
G00092 – Emergency shut-down at access ladderp. 259
G00093 – Emergency shut-down at valve blockp. 259
G00094 – Emergency shut-down at hydraulic control panelp. 259
+G00095 – Emergency shut-down in cabinp. 259
Wiring Diagram (emergency switches) for G00092~G00095p. 260
+G00096 – Pilot control cut outp. 261
Wiring Diagram (20S094) for trouble code G00096p. 262
+G00100 – Maintenance Safety Switchp. 263
Wiring Diagram (50S058) for trouble code G00100p. 264
G00102 – Switch off wiper [S/N 08199 only]p. 265
+G00103 – Faulty switch 20M004 [S/N 08199 only]p. 266
Wiring Diagram 1 (wiper) for trouble code G00103 [S/N 08199 only]p. 268
Wiring Diagram 2 (wiper) for trouble code G00103 [S/N 08199 only]p. 269
+G00104 – Trouble battery currentp. 270
Wiring Diagram (battery current) for trouble code G00104p. 272
+G00105 – Trouble battery charging current too lowp. 273
Wiring Diagram (11T080) for trouble code G00105p. 274
G00107 – Trouble slew parking brake control 56K250ap. 275
+G00109 – Trouble slew parking brake control 56K250bp. 275
View onto the CoDeSys HMI Visualization screen for trouble code G00107p. 277
Wiring Diagram (56K250a & 56K250b) for trouble code G00107p. 278
G00108 – Trouble slew parking brake control Output to 56K250ap. 279
+G00110 – Trouble slew parking brake control Output to 56K250bp. 279
View onto the CoDeSys HMI Visualization screen for trouble code G00108p. 281
Wiring Diagram (56K250a & 56K250b) for trouble code G00108p. 282
G00111 – Trouble travel parking brake control 56K251ap. 283
G00113 – Trouble travel parking brake control 56K251bp. 283
G00112 – Trouble travel parking brake control Output to 56K251ap. 284
G00114 – Trouble travel parking brake control Output to 56K251bp. 284
G00115 – Trouble slew hydraulic brake control 56K252ap. 285
G00117 – Trouble slew hydraulic brake control 56K252bp. 285
G00116 – Trouble slew hydraulic brake control Output to 56K252ap. 286
G00118 – Trouble slew hydraulic brake control Output to 56K252bp. 286
+G00140 – Trouble monitoring X1-1 pressurep. 287
Wiring Diagram (57B085-1) for trouble code G00140p. 289
+G00141 – Trouble monitoring X2 pressurep. 290
Wiring Diagram (57B086) for trouble code G00141p. 292
+G00147 – Trouble monitoring gear lubrication (PTO 1)p. 293
Wiring Diagram (57B017-1) for trouble code G00147p. 295
+G00148 – Trouble monitoring fuel levelp. 296
Wiring Diagram (31B063) and component location for G00148p. 298
+G00151 – Trouble monitoring gear (PTO) oil filter 1p. 299
Wiring Diagram (57B027-1) and component location for trouble code G00151p. 301
+G00154 – Trouble monitoring return oil filterp. 302
Wiring Diagram (40B163) for trouble code G00154p. 304
+G00155 – Trouble monitoring leak oil filterp. 305
Wiring Diagram (40B164) for trouble code G00155p. 307
+G00159 – Trouble monitoring breather filterp. 308
Wiring Diagram (40B024) for trouble code G00159p. 310
+G00160 – Trouble monitoring engine air cleaner 1p. 311
Wiring diagram (52B018-1 & 52B019-1) for trouble code G00160p. 313
+G00161 – Trouble monitoring battery voltagep. 314
Wiring Diagram (11T080) for trouble code G00161p. 316
+G00162 – Trouble monitoring charging-/discharging currentp. 317
Wiring Diagram (battery charging current) for trouble code G00162p. 319
+G00164 – Trouble air cleaner 1p. 320
View onto the engine air cleaner (G00164)p. 321
+G00165 – Trouble breather filter hydraulic oil tankp. 322
Label showing temperature information and defined positions (G00165)p. 323
+G00166 – Trouble oil filter gear (PTO 1)p. 324
View onto the PTO 1 gear oil filter with pressure sensor 57B027-1 (G00166)p. 325
G00169 – Trouble return oil filter hydraulic oil tankp. 326
G00170 – Trouble leak oil filter hydraulic oil tankp. 327
+G00176 – Trouble battery voltage too lowp. 328
Wiring Diagram (batteries) for trouble code G00176p. 330
+G00177 – Trouble battery charging circuitp. 331
Wiring Diagram (measuring points 1-4) for trouble code G00177p. 332
+G00178 – Trouble battery charging current too highp. 333
Wiring Diagram (51T017) for trouble code G00178p. 334
+G00179 – Trouble control pressure X1-1p. 335
View onto the valve cartridge block (G00179)p. 336
+G00180 – Trouble pilot pressure X2 too lowp. 337
Valve cartridge block with X2 pressure sensor 57B086 & M1.2p. 338
+G00181 – Trouble pilot pressure X2 too highp. 339
Valve cartridge block with X2 pressure sensor 57B086 & M1.2p. 340
G00184 – Central lubrication system emptyp. 341
+G00187 – Slew ring gear lubrication system emptyp. 341
Grease level (CLS & SLS) on the REAL TIME MONITORp. 342
G00185 – Trouble central lubrication systemp. 343
+G00188 – Trouble slew ring gear lubrication systemp. 343
Allocation of vent valves and end-of-line switchesp. 344
Action chart for lube cyclesp. 345
View onto the vent valve (62Q507a/62Q509a)p. 346
Wiring Diagram (80B043 & 62B046) for trouble codes G00185/G00188p. 347
G00186 – Trouble central lubrication systemp. 348
+G00189 – Trouble slew ring gear lubrication systemp. 348
Allocation of vent valvesp. 348
Action chart for lube cyclesp. 349
View onto the vent valve (62Q507a/62Q509a)p. 350
G00207 – Engine remote oil tank 1 emptyp. 351
G00216 – Trouble software not compatiblep. 352
G00218 – Switch off all motors for running transfer pumpp. 354
+G00220 – Trouble transfer pump motor overheatedp. 355
Wiring Diagram (transfer pump) for trouble code G00220p. 356
G00223 – Trouble starter control 51K001a-1p. 357
G00225 – Trouble starter control 51K001b-1p. 357
G00224 – Trouble starter control Output to 51K001a-1p. 358
G00226 – Trouble starter control Output to 51K001b-1p. 358
+G00231 – Trouble pilot control lever 20S019p. 359
Wiring Diagram (20S019) for trouble code G00231p. 360
Wiring Diagram (20S020) for trouble code G00232p. 361
+G00233 – Trouble pilot control 11Q045p. 362
Wiring Diagram (11Q045) for trouble code G00233p. 363
G00234 – Trouble pilot control 11K111ap. 364
G00236 – Trouble pilot control 11K111bp. 364
G00235 – Trouble pilot control Output to 11K111ap. 365
G00237 – Trouble pilot control Output to 11K111bp. 365
+G00238 – Trouble supply by key switch 11Q044p. 366
Input signal of 11Q044 on the REAL TIME MONITOR (G00238)p. 366
Wiring Diagram (11Q044) for trouble code G00238p. 367
G00240 – Trouble hydraulic oil temperaturep. 368
G00242 – Engine 1 already runningp. 369
G00243 – Fill up fuel tankp. 369
+G00245 – Engine shutdown from groundp. 370
Input signal of 54S007 & 54S008 on the REAL TIME MONITOR (G00245)p. 371
G00246 – Hydraulic oil temperaturep. 372
G00252 – Emergency shut-down at access ladderp. 373
G00253 – Emergency shut-down at valve blockp. 373
G00254 – Emergency shut-down at hydraulic control panelp. 373
+G00255 – Emergency shut-down in cabinp. 373
Wiring Diagram (emergency switches) for trouble codes G00252~G00255p. 374
G00257 – Hydraulic oil temperaturep. 375
+G00261 – Maintenance Safety Switchp. 376
Wiring Diagram (50S058) for trouble code G00261p. 377
+G00262 – Trouble screen at hydr. cooler entry cloggedp. 378
40B166 and 40B165 on the REAL TIME MONITOR 03 Hydraulic (G00262)p. 378
Location of 40B166 and 40B165 at the hydraulic oil tank (G00262)p. 379
Wiring Diagram (40B166 & 40B165) for trouble code G00262p. 380
G00308 – Trouble CAN-Bus or CAN-Hardwarep. 381
G00309 – Trouble ladder up 56K253ap. 384
G00311 – Trouble ladder up redundant 56K253bp. 384
G00310 – Trouble ladder up Output to 56K253ap. 385
G00312 – Trouble ladder up redundant Output to 56K253bp. 385
G00313 – Trouble ladder down 56K254ap. 386
G00315 – Trouble ladder down redundant 56K254bp. 386
G00314 – Trouble ladder down Output to 56K254ap. 387
G00316 – Trouble ladder down redundant Output to 56K254bp. 387
G00317 – Trouble service arm up 56K255ap. 388
G00319 – Trouble service arm up redundant 56K255bp. 388
G00318 – Trouble service arm up Output to 56K255ap. 389
G00320 – Trouble service arm up redundant Output to 56K255bp. 389
G00321 – Trouble service arm down 56K256ap. 390
G00323 – Trouble service arm down redundant 56K256bp. 390
G00322 – Trouble service arm down Output to 56K256ap. 391
G00324 – Trouble service arm down redundant Output to 56K256bp. 391
G00325 – Trouble service arm Inputp. 392
G00326 – Trouble ladder Inputp. 392
G00327 – Trouble parking brake Inputp. 392
G00328 – Trouble start Inputp. 392
+G00330 – Trouble pilot control 11Q111p. 395
Wiring Diagram (11Q111/11K126) for trouble code G00330p. 397
G00331 – Automatic after_running engine 1p. 398
+G00333 – Trouble battery charger relayp. 399
Wiring Diagram (11Q122) for trouble code G00333p. 400
G00351 – Engine 1 runningp. 401
G00352 – Engine 1 standstillp. 401
G00417 – Communication failure PLC [MTC] VHMS-controllerp. 402
G00420 – Connector sel errorp. 403
G00421 – Farm sys errorp. 404
G00422 – Can-net sys (J1939)p. 405
G00423 – Application sys errorp. 406
+G00425 – Settings impossible to take over into the PLCp. 407
Wiring Diagram overview for G00425: VHMS monitor → VHMS controller → MTCp. 408
+G00491 – Communication failure MH800 VHMS-Controllerp. 409
Wiring Diagram overview for G00491: VHMS monitor (MH801) → VHMS controllerp. 410
+8 Troubleshooting by Symptomsp. 413
8.1 Symptoms of the Engine and Related Electrical Systemp. 414
+SEL001 – Engine does not start (engine does not rotate)p. 414
Wiring Diagram 1 (engine start) for trouble code SEL001p. 416
Wiring Diagram 2 (engine start) for trouble code SEL001p. 418
+SEL002 – Engine stops while in operationp. 419
View onto the fuel system water separator (SEL002)p. 421
SEL003 – Engine speed is hunting during boom-up movementp. 422
SEL004 – Engine does not stopp. 423
+SEL005 – Engine lacks output (no power)p. 424
Judgment Table for SEL005p. 425
+SEL006 – Exhaust smoke is blackp. 426
Judgment Table for SEL006p. 427
+SEL007 – Oil consumption is excessivep. 428
Judgment Table for SEL007p. 429
+SEL008 – Oil becomes contaminated quicklyp. 430
Judgment Table for SEL008p. 431
+SEL009 – Fuel consumption is excessivep. 432
Judgment Table for SEL009p. 433
+SEL010 – Oil is in engine coolantp. 434
Judgment Table for SEL010p. 435
+SEL011 – Oil level risesp. 436
Judgment Table for SEL011p. 437
+SEL012 – Coolant temperature becomes too high (overheating)p. 438
Judgment Table for SEL012p. 439
8.2 Symptoms of the Hydraulic Systemp. 440
SHY001 – All the work equipment shows lack of power or slow movement (especially the "boom up" function)p. 440
SHY002 – Engine speed sharply drops or engine stalls too muchp. 442
SHY003 – No work equipment, travel or swing movementp. 444
SHY004 – Work equipment has too much hydraulic driftp. 445
SHY005 – Work equipment has big time lagp. 447
SHY006 – Machine deviates during travel movementp. 448
SHY007 – Hydraulic system has lack of power (Energy Efficiency)p. 449
SHY008 – Machine does not swingp. 451
SHY009 – Swing acceleration is poorp. 452
SHY010 – Excessive overrun when stopping swingp. 454
SHY011 – Floating system without functionp. 456
SHY012 – Abnormal noise coming from SRV or MRVp. 457
SHY013 – Track tensioning system without functionp. 458
SHY014 – Ladder does not move, or slow movementp. 459
SHY015 – Refilling arm does not move, or slow movementp. 461
SHY016 – The hydraulic driven grease pump does not movep. 463
SHY017 – Trouble pump bearing lubricationp. 465
SHY018 – Abnormal track chain movement during diggingp. 466
SHY019 – Swing parking brake without functionp. 467
SHY020 – Travel parking brake without functionp. 468
8.3 Symptoms of the Mechanical Systemp. 469
+SME001 – Abnormal noise is madep. 469
Judgment Table for SME001p. 470
SME002 – Abnormal noise around the PTO / hydraulic pumpsp. 471
+SME003 – Vibration is excessive (engine mountings)p. 473
Judgment Table for SME003p. 474
SME004 – Vibration is excessive (engine torsion)p. 475
SME005 – There is a big shock when stopping swingp. 476
SME006 – There is a big abnormal noise when moving/stopping swingp. 477
SME007 – Fan hub bearing noise is abnormalp. 479
SME008 – Abnormal noise coming from a travel gearboxp. 480
SME009 – Abnormal noise coming from the work equipment (lack of grease)p. 482
SME010 – Abnormal idler movementp. 484
SME011 – Leak at the PTO shaft sealp. 485
8.4 Symptoms of Additional Systemsp. 487
+SAD001 – Air conditioner does not workp. 487
View onto the A/C unit (SAD001)p. 488
+SAD002 – Air conditioner compressor clutch is burntp. 489
View onto the A/C compressor and its mounting (SAD002)p. 490
SAD003 – Air conditioning system defective (pipes and hoses full of moisture)p. 491
+SAD004 – Travel alarm does not soundp. 492
Wiring Diagram (60P140) for trouble code SAD004p. 493
Correct troubleshooting on a machine of this size is not just about speed — it is about not replacing a serviceable component, not missing a root cause, and not creating a new fault while chasing the old one. The Komatsu PC4000-6 Hydraulic Mining Shovel Troubleshooting Manual gives you the test conditions, nominal values, and decision points that turn a vague fault into a confirmed diagnosis.
The PDF is delivered instantly after payment — no shipping, no waiting for a physical book. It can be viewed on any device, printed for the workshop, and kept on hand for the next fault. Whether you are maintaining a fleet or keeping a single shovel productive, this is the document that makes the difference between guessing and knowing.
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