Komastu Hydraulic Mining Shovel PC4000E-6 Shop Manual(08288-xE-GB-1) – PDF DOWNLOAD

Komastu Hydraulic Mining Shovel PC4000E-6 Shop Manual(08288-xE-GB-1) – PDF DOWNLOAD

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Komastu Hydraulic Mining Shovel PC4000E-6 Shop Manual(08288-xE-GB-1) – PDF DOWNLOAD

BEFORE READING THIS MANUAL
This manual gives details of the methods of inspection, maintenance and troubleshooting for this machine that
must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental
safety rules for the inspection, maintenance and troubleshooting of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
inspection, maintenance or troubleshooting. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that may involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety
precautions. If you carry out any inspection, maintenance and troubleshooting under conditions that are not
described in this manual, understand that it is your responsibility to take the necessary precautions to ensure
safety. In no event should you or others engage in prohibited uses or actions described in this manual.
Improper inspection, maintenance and troubleshooting of the machine can be hazardous and could result in
serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
This manual uses the international units (SI) for units of measurement. For reference, units that have been used in
the past are given in ( ).
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the
latest available information concerning your machine or with questions regarding information contained in this
manual.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it
has been shipped. If the machine has been purchased in another country, it may lack certain safety devices
and specifications that are necessary for use in your country. If there is any question about whether your
product complies with the applicable standards and regulations of your country, consult Komatsu or your
Komatsu distributor before operating the machine.
TABLE OF CONTENTS:

Komastu Hydraulic Mining Shovel PC4000E-6 Shop Manual(08288-xE-GB-1) – PDF DOWNLOAD

SHOP MANUAL Cover………………………………………………………………………………………. 1
00 FOREWORD & SAFETY
…………………………………………………………………………………… 3
1 Foreword…………………………………………………………………………………………. 5
1.1 BEFORE READING THIS MANUAL……………………………………………………………………. 6
1.2 CONTENTS OF THIS BINDER………………………………………………………………………. 7
1.2.1 Contacting the Service………………………………………………………………….. 7
1.2.2 Guarantee……………………………………………………………………………… 7
1.3 DIVISION OF THE BINDER……………………………………………………………………….. 8
2 Safety ………………………………………………………………………………………….. 9
2.1 SAFETY INFORMATION…………………………………………………………………………… 10
2.2 OVERVIEW……………………………………………………………………………………. 11
2.2.1 NORMAL OPERATIONS………………………………………………………………………. 11
2.2.2 REGULAR MAINTENANCE…………………………………………………………………….. 11
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR…………………………………………………… 11
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR…. 11
2.3 SOUND PRESSURE AND VIBRATION LEVELs IN THE OPERATOR’S CAB………………………………………… 12
2.3.1 SOUND…………………………………………………………………………………. 12
2.3.2 VIBRATION……………………………………………………………………………… 12
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR…………………………………………. 13
2.4.1 UNDERSTANDING THE MACHINE……………………………………………………………….. 13
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR……………………………………… 13
2.4.2.1 ENSURING SAFE OPERATION……………………………………………………………. 13
2.4.3 PREPARATIONS FOR SAFE OPERATION………………………………………………………….. 13
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT……………………………………….. 13
2.4.3.2 INSPECTING THE MACHINE…………………………………………………………….. 13
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT……………………………………. 14
2.4.3.4 KEEP MACHINE CLEAN………………………………………………………………… 14
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT……………………………………………. 14
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT………………………………………….. 15
2.4.3.7 IF A PROBLEM IS FOUND……………………………………………………………… 15
2.4.4 FIRE PREVENTION………………………………………………………………………… 15
2.4.4.1 PRECAUTIONS TO PREVENT FIRE………………………………………………………… 15
2.4.4.2 ACTION IF FIRE OCCURS……………………………………………………………… 17
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB………………………………………………….. 17
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…………………………………………….. 18
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE…………………………….. 18
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE……………………………………………………. 18
2.4.5.3 NO PEOPLE ON THE ATTACHMENT………………………………………………………… 18
2.4.5.4 WORKING IN HIGH PLACES…………………………………………………………….. 18
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK…………………………………………………… 19
2.4.5.6 LEAVING THE MACHINE……………………………………………………………….. 19
2.4.6 BURN PREVENTION………………………………………………………………………… 19
2.4.6.1 Hot coolant………………………………………………………………………. 19
2.4.6.2 Hot oil………………………………………………………………………….. 20
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS………………………………………………………. 20
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES………………………………………………. 20
2.4.8.1 UNAUTHORIZED MODIFICATION………………………………………………………….. 21
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS……………………………………….. 21
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)………………………………………………………. 21
2.4.10 PRECAUTIONS AT JOBSITE…………………………………………………………………. 22
2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT……………………………………………………. 23
2.4.10.2 CAMERA SYSTEM WITH MONITORS……………………………………………………….. 23
2.4.10.3 ENSURE GOOD VISIBILITY……………………………………………………………. 23
2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS……………………………………………… 23
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS………………………………………….. 24
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES……………………………………………… 24
2.4.10.7 WORKING ON LOOSE GROUND…………………………………………………………… 25
2.4.10.8 GAS, DUST, STEAM AND SMOKE………………………………………………………… 25
2.4.10.9 VENTILATION OF ENCLOSED AREAS……………………………………………………… 26
2.4.11 STARTING motor………………………………………………………………………… 27
2.4.11.1 WARNING TAG……………………………………………………………………… 27
2.4.11.2 CHECKS BEFORE STARTING motor………………………………………………………. 27
2.4.11.3 PRECAUTION WHEN STARTING motor…………………………………………………….. 27
2.4.11.4 PRECAUTION IN COLD AREAS………………………………………………………….. 28
2.4.12 OPERATION…………………………………………………………………………….. 28
2.4.12.1 CHECKS BEFORE OPERATION…………………………………………………………… 28
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE……………………………………. 29
2.4.12.3 PRECAUTIONS WHEN travelling……………………………………………………….. 30
2.4.12.4 TRAVELLING ON SLOPES……………………………………………………………… 31
2.4.12.5 OPERATIONS ON SLOPES……………………………………………………………… 32
2.4.12.6 PROHIBITED OPERATIONS…………………………………………………………….. 32
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES……………………………………….. 33
2.4.12.8 PARKING THE MACHINE………………………………………………………………. 33
2.4.12.9 TRANSPORTATION…………………………………………………………………… 33
2.5 PRECAUTION FOR MAINTENANCE……………………………………………………………………. 34
2.5.1 GENERAL PRECAUTIONS…………………………………………………………………….. 34
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES………………………. 35
2.5.1.2 STOP motor FOR MAINTENANCE…………………………………………………………. 36
2.5.1.3 WARNING TAG………………………………………………………………………. 37
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY………………………………………………………. 38
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS……………………………………………… 38
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING……………………………….. 39
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS………………………………………….. 39
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT……………………………….. 40
2.5.1.9 NOISE……………………………………………………………………………. 40
2.5.1.10 WHEN USING A HAMMER………………………………………………………………. 40
2.5.1.11 PROPER TOOLS…………………………………………………………………….. 41
2.5.1.12 ACCUMULATOR……………………………………………………………………… 41
2.5.1.13 PERSONNEL……………………………………………………………………….. 41
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE………………………………………………… 42
2.5.2.1 PRECAUTION WHEN WELDING……………………………………………………………. 42
2.5.2.2 BATTERY HANDLING………………………………………………………………….. 42
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID……………………………………………………… 43
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE…………………………………………………. 43
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES………………………………………………. 44
2.5.3.3 REPLACEMENT OF HOSE LINES………………………………………………………….. 44
2.5.3.4 INSPECTION OF HOSE LINES…………………………………………………………… 44
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS………………………………………… 45
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE……………………………………………………….. 45
2.5.3.7 AIR CONDITIONING MAINTENANCE……………………………………………………….. 45
2.5.3.8 COMPRESSED AIR……………………………………………………………………. 46
2.5.3.9 WASTE MATERIALS…………………………………………………………………… 46
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS…………………………………. 47
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM……………………………………………………….. 47
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS……………………………… 47
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…………………………………………….. 47
2.7 SPECIAL SAFETY EQUIPMENT……………………………………………………………………… 48
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB…………………………………… 49
2.7.2 OBJECT HANDLING………………………………………………………………………… 49
2.7.3 LIGHTING………………………………………………………………………………. 49
2.7.4 WARNING BEACON…………………………………………………………………………. 49
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)………………………………… 49
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…………………………… 49
2.7.5.2 INSTRUCTIONS FOR USE………………………………………………………………. 51
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL……………………………………… 53
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS…… 53
2.7.5.5 INSTRUCTIONS FOR USE………………………………………………………………. 55
01 SPECIFICATION……………………………………………………………………………………….. 57
PC4000E-6………………………………………………………………………………………….. 59
10 STRUCTURE & FUNCTION ………………………………………………………………………………… 67
TOC……………………………………………………………………………………………….. 69
1 Introduction……………………………………………………………………………………… 81
1.1 Foreword……………………………………………………………………………………. 82
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels……. 84
1.3 Explanation of abbreviations………………………………………………………………….. 85
1.4 Diagrams and illustrations in this manual………………………………………………………. 86
2 Specifications……………………………………………………………………………………. 87
2.1 Lifting Gears……………………………………………………………………………….. 88
2.2 Safety hints for sling accessory………………………………………………………………. 90
2.3 Standard Tightening Torque Chart………………………………………………………………. 91
2.4 Conversion Table…………………………………………………………………………….. 92
2.5 Blind plugs…………………………………………………………………………………. 98
2.6 Classification of threads to the nominal width………………………………………………….. 100
2.7 Plugs and fittings according to ISO 8434-1 / DIN 2353……………………………………………. 101
3 Main assembly groups………………………………………………………………………………. 103
3.1 General layout………………………………………………………………………………. 104
3.2 Superstructure………………………………………………………………………………. 106
3.3 Machine house……………………………………………………………………………….. 108
3.4 Hydraulic oil tank…………………………………………………………………………… 110
3.5 Hydraulic oil cooler…………………………………………………………………………. 112
3.6 High voltage switch cabinet…………………………………………………………………… 114
3.7 Cab base……………………………………………………………………………………. 120
3.7.1 Extra low voltage switch board (Location 11)………………………………………………. 122
3.7.2 Low voltage switch board (Location 12)……………………………………………………. 122
3.8 Operator’s cab………………………………………………………………………………. 124
3.9 Control blocks………………………………………………………………………………. 126
3.10 Slew gear………………………………………………………………………………….. 128
3.10.1 Slew gear L&S…………………………………………………………………………. 128
3.10.2 Slew gear SIEBENHAAR…………………………………………………………………… 130
3.11 Rotary joint……………………………………………………………………………….. 132
3.12 Undercarriage………………………………………………………………………………. 134
3.13 Slew ring………………………………………………………………………………….. 136
3.14 Attachment…………………………………………………………………………………. 138
3.14.1 Front Shovel Attachment (FSA)…………………………………………………………… 138
3.14.2 Backhoe Attachment (BHA)……………………………………………………………….. 140
3.15 Counterweight………………………………………………………………………………. 142
4 Drive……………………………………………………………………………………………. 145
4.1 Electric drive – Safety and operation instruction documents………………………………………. 146
4.2 Prime drive assembly…………………………………………………………………………. 148
4.3 Electric motors……………………………………………………………………………… 150
4.3.1 Location of attaching parts……………………………………………………………… 150
4.3.1.1 Motor type plate………………………………………………………………….. 151
4.3.1.2 Type plate for the motor bearings…………………………………………………… 152
4.3.2 Motor bearings & grease equipment………………………………………………………… 154
4.3.3 Monitoring of the motor bearing temperature……………………………………………….. 156
4.3.4 Monitoring of the motor winding temperature……………………………………………….. 157
4.3.5 Junction box for the motor monitoring device………………………………………………. 158
4.3.6 Checking the bearing condition…………………………………………………………… 159
4.3.7 Capacitor assembly……………………………………………………………………… 160
4.4 Air-to-air motor cooling system……………………………………………………………….. 162
4.5 Initial Start-up procedure……………………………………………………………………. 163
4.5.1 Main supply cable………………………………………………………………………. 164
4.5.2 Motor protection relay (SPAM 150 C)………………………………………………………. 166
4.5.3 Motor alignment………………………………………………………………………… 168
4.5.4 Motor rotation direction………………………………………………………………… 170
4.5.5 Starting & Re-starting the electric motor…………………………………………………. 170
4.5.6 Supervision during the first motor running period………………………………………….. 171
4.6 Flexible coupling……………………………………………………………………………. 172
4.6.1 Coupling inspection…………………………………………………………………….. 173
4.6.2 Coupling replacement……………………………………………………………………. 174
4.7 Pump distributor gearbox (PTO)………………………………………………………………… 176
4.7.1 Pump drive shaft housing / spline lubrication……………………………………………… 178
4.7.1.1 Oil level in the main pump drive shaft housing……………………………………….. 179
4.7.2 PTO lubrication and cooling……………………………………………………………… 180
4.7.2.1 Checks and adjustments…………………………………………………………….. 182
4.8 Hydraulic pumps – location, drive speed and flow rates…………………………………………… 184
4.8.1 Pump data……………………………………………………………………………… 186
5 Hydraulic oil tank………………………………………………………………………………… 187
5.1 General layout………………………………………………………………………………. 188
5.2 Hydraulic oil tank, location of the electric equipment…………………………………………… 190
5.3 Suction oil tank with strainers……………………………………………………………….. 192
5.4 Return oil collector pipe with strainer………………………………………………………… 194
5.5 Back pressure valve………………………………………………………………………….. 196
5.6 Transfer pump……………………………………………………………………………….. 198
5.7 Return and leak oil filter……………………………………………………………………. 200
5.8 Breather filter……………………………………………………………………………… 202
6 Hydraulic oil cooling……………………………………………………………………………… 205
6.1 Overall view of the hydraulic oil cooling………………………………………………………. 206
6.2 Function of the hydraulic oil cooling circuit…………………………………………………… 208
6.3 Adjustment of the back pressure valve………………………………………………………….. 210
6.4 Two stage cooler fan RPM control………………………………………………………………. 212
6.4.1 Pressure reducing valve…………………………………………………………………. 214
6.4.2 Solenoid valves………………………………………………………………………… 216
6.4.3 Fan pump………………………………………………………………………………. 218
6.5 Checks and Adjustments of the cooler fan drive speeds……………………………………………. 220
6.5.1 Function Check of Fan Speed Control………………………………………………………. 224
7 Controlling………………………………………………………………………………………. 225
7.1 General layout………………………………………………………………………………. 226
7.2 Control and filter panel……………………………………………………………………… 228
7.3 Valve cartridge block………………………………………………………………………… 230
7.4 Pilot pressure supply and adjustments………………………………………………………….. 232
7.4.1 Pilot pressure control (PPC) circuit……………………………………………………… 232
7.4.2 Checks and adjustment of pilot pressure…………………………………………………… 236
7.4.3 Remote control valves arrangement………………………………………………………… 238
7.5 Function of the electro-hydraulic control system………………………………………………… 240
7.5.1 Electronic hand lever (joystick)…………………………………………………………. 244
7.5.1.1 Voltage supply of hand lever 20S020…………………………………………………. 245
7.5.1.2 Direction signal course from hand lever to controllers………………………………… 246
7.5.1.3 Double ratiometric* output diagram………………………………………………….. 247
7.6 Foot pedal control…………………………………………………………………………… 248
7.6.0.1 Voltage supply of Foot lever (20S021a)………………………………………………….. 250
7.6.0.2 Direction signal course from foot pedal to controllers……………………………………. 251
7.6.0.3 Double ratiometric* output diagram for 2 direction pedal………………………………….. 252
7.6.0.4 Single ratiometric* output diagram for 1 direction pedal………………………………….. 252
7.7 Hand lever & foot pedal monitoring…………………………………………………………….. 253
7.7.1 Lever monitoring screen (exemplary)………………………………………………………. 254
7.7.2 Valve monitoring screen (exemplary)………………………………………………………. 256
7.8 Valve solenoid adjustment…………………………………………………………………….. 257
7.8.1 Overview sol min/max current & adjustment range……………………………………………. 258
7.9 ACCEL & DECEL time adjustment…………………………………………………………………. 259
7.9.1 Accel & Decel times…………………………………………………………………….. 259
8 Components……………………………………………………………………………………….. 263
8.1 Main control blocks and high pressure filters (FSA)……………………………………………… 264
8.2 Main control blocks and high pressure filters (BHA)……………………………………………… 266
8.3 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA)……………….. 268
8.4 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA)……………….. 270
8.5 Single control blocks (floating) for stick and boom (FSA)………………………………………… 272
8.6 Restrictor block with secondary relief valve……………………………………………………. 274
8.7 Anti-cavitation valve (ACV) block……………………………………………………………… 276
8.8 Remote control valves………………………………………………………………………… 278
8.9 4/3 Directional solenoid valves……………………………………………………………….. 280
8.10 Proportional solenoid valves…………………………………………………………………. 282
8.11 High-pressure filter (screen)………………………………………………………………… 284
8.12 Control blocks and valves……………………………………………………………………. 286
8.12.1 Spool types…………………………………………………………………………… 292
8.12.2 MRV, SRV and ACV………………………………………………………………………. 294
8.12.3 Load holding valve…………………………………………………………………….. 296
8.13 Travel brake valve………………………………………………………………………….. 300
8.14 Pressure reducing valve……………………………………………………………………… 302
8.15 4/2 Directional valves………………………………………………………………………. 304
8.16 Pressure double stage valve………………………………………………………………….. 306
8.17 Hydraulic cylinder………………………………………………………………………….. 308
8.17.1 Cylinder data markings…………………………………………………………………. 311
9 Main hydraulic pumps and pump regulation…………………………………………………………….. 313
9.1 General…………………………………………………………………………………….. 314
9.1.1 Pump locations and pump data…………………………………………………………….. 316
9.2 Main pumps………………………………………………………………………………….. 318
9.2.1 Hydraulic pump type HPV375+375…………………………………………………………… 318
9.2.1.1 Main pump sectional drawings……………………………………………………….. 320
9.2.2 Servo valve……………………………………………………………………………. 322
9.2.2.1 VC valve  servo piston……………………………………………………………. 323
9.2.2.2 EPC valve………………………………………………………………………… 328
9.3 Electronic pump regulation system……………………………………………………………… 330
9.3.1 Cut-off function……………………………………………………………………….. 332
9.3.2 Slew control…………………………………………………………………………… 333
9.3.3 Altitude pump displacement………………………………………………………………. 333
9.3.4 Temperature control…………………………………………………………………….. 334
9.3.4.1 Hydraulic oil temperature charts……………………………………………………. 334
9.3.4.2 Pump flow control…………………………………………………………………. 335
9.3.5 Energy efficiency………………………………………………………………………. 335
9.4 Pump controller (14K305)……………………………………………………………………… 336
9.4.1 pin arrangement at the connectors of the pump controller (14K305)……………………………. 338
9.5 Monitoring, error indication, adjustment……………………………………………………….. 342
9.5.1 Monitoring items of the pump controller…………………………………………………… 342
9.5.2 Error indication of the pump controller…………………………………………………… 346
9.5.2.1 Error messages (pump controller) – Mechanical systems…………………………………. 346
9.5.2.2 Caution symbols (pump controller)…………………………………………………… 347
9.5.2.3 Failure codes for pump controller…………………………………………………… 347
9.5.3 Adjustable parameters of the pump controller………………………………………………. 348
9.5.3.1 Pump sol ’min’ current values according to pump type plate…………………………….. 350
9.5.3.2 Pump sol ’max’ current values according to pump type plate…………………………….. 351
9.6 Checks and adjustments……………………………………………………………………….. 353
9.6.1 Motor power check………………………………………………………………………. 353
9.6.2 Cut-off function check………………………………………………………………….. 356
9.6.2.1 Cut-off for clam close (FSA only)…………………………………………………… 357
9.7 Electronic load limiting control………………………………………………………………. 358
9.7.1 Load limiting control input signals at 14K305……………………………………………… 359
9.7.2 Load limiting control output signals from 14K305…………………………………………… 360
9.7.3 Signal rectifier module (12T431)…………………………………………………………. 361
9.7.4 Checks and adjustment of 12T431………………………………………………………….. 364
9.7.4.1 Testing the signal rectifier 12T431 for voltage………………………………………. 365
9.7.4.2 Testing the signal rectifier 12T431 for current………………………………………. 365
10 Operating hydraulics……………………………………………………………………………… 367
10.1 General……………………………………………………………………………………. 368
10.1.1 Floating system (FSA only)……………………………………………………………… 370
10.2 Hydraulics for the attachment cylinders……………………………………………………….. 374
10.2.1 Electric / hydraulic flowchart “Boom UP” (FSA)……………………………………………. 374
10.2.2 Electric / hydraulic flowchart “boom up” (BHA)……………………………………………. 376
10.2.3 Electric / hydraulic flowchart “boom down” (FSA)………………………………………….. 378
10.2.4 Electric / hydraulic flowchart “Boom down” (BHA)………………………………………….. 380
10.2.5 Electric / hydraulic flowchart “Stick out” (FSA)………………………………………….. 382
10.2.6 Electric / hydraulic flowchart “Stick out” (BHA)………………………………………….. 384
10.2.7 Electric / hydraulic flowchart “Stick in” (FSA)…………………………………………… 386
10.2.8 Electric / hydraulic flowchart “Stick in” (BHA)…………………………………………… 388
10.2.9 Electric / hydraulic flowchart “Bucket fill” (FSA)………………………………………… 390
10.2.10 Electric / hydraulic flowchart “Bucket fill” (BHA)……………………………………….. 392
10.2.11 Electric / hydraulic flowchart “Bucket dump” (FSA)……………………………………….. 394
10.2.12 Electric / hydraulic flowchart “Bucket dump” (BHA)……………………………………….. 396
10.2.13 Electric / hydraulic flowchart “Clam open” (FSA)…………………………………………. 398
10.2.14 Electric / hydraulic flowchart “Clam close” (FSA)………………………………………… 400
10.2.15 Checks & adjustments of the main relief valve (MRV)………………………………………. 402
10.2.16 Checks and adjustments of the secondary relief valves (SRV)……………………………….. 404
10.2.16.1 Boom cylinders, piston side (BHA & FSA), boom up……………………………………. 404
10.2.16.2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down……………………………….. 408
10.2.16.3 Stick cylinders, piston side (FSA), stick out………………………………………. 412
10.2.16.4 Stick cylinders, piston side (BHA), stick in……………………………………….. 416
10.2.16.5 Stick cylinders, piston rod side (FSA), stick in……………………………………. 420
10.2.16.6 Stick cylinders, piston rod side (BHA), stick out…………………………………… 424
10.2.16.7 Bucket cylinders, piston side (FSA), bucket fill……………………………………. 428
10.2.16.8 Bucket cylinders, piston side (BHA), bucket fill……………………………………. 432
10.2.16.9 Bucket cylinders, piston rod side (FSA), bucket dump………………………………… 436
10.2.16.10 Bucket cylinders, piston rod side (BHA), bucket dump……………………………….. 440
10.2.16.11 Clam cylinders, piston rod side (FSA), clam open…………………………………… 444
10.2.16.12 Clam cylinders, piston side (FSA), clam close……………………………………… 448
10.2.17 Checks and adjustments of the lowering speed…………………………………………….. 452
10.2.17.1 Checks and adjustments of the lowering speed – boom (FSA)……………………………. 452
10.2.17.2 Checks and adjustments of the lowering speed – boom (BHA)……………………………. 458
10.2.17.3 Checks and adjustments of the lowering speed – stick (FSA)…………………………… 460
10.2.17.4 Checks and adjustments of the lowering speed – stick (BHA)…………………………… 466
10.2.17.5 Checks and adjustments of the lowering speed – bucket (FSA)………………………….. 468
10.2.17.6 Checks and adjustments of the lowering speed – bucket (BHA)………………………….. 470
10.2.17.7 Checks and adjustments of the lowering speed – clam (FSA)……………………………. 472
10.3 Hydraulics for the slew circuit………………………………………………………………. 474
10.3.1 Slew circuit………………………………………………………………………….. 474
10.3.2 Slew motor……………………………………………………………………………. 478
10.3.3 Slew gearbox (L&S)…………………………………………………………………….. 480
10.3.4 Slew gearbox (SIEBENHAAR)………………………………………………………………. 482
10.3.5 Slew parking brake (L&S)……………………………………………………………….. 484
10.3.6 Slew parking brake (SIEBENHAAR)…………………………………………………………. 486
10.3.7 Slew brake valve………………………………………………………………………. 488
10.3.8 Electric / hydraulic flowchart “Slew left”……………………………………………….. 492
10.3.9 Electric / hydraulic flowchart “Slew right”………………………………………………. 494
10.3.10 Checks and adjustments for the slew circuit……………………………………………… 496
10.3.10.1 checks & adjustments, slew speed………………………………………………….. 496
10.3.10.2 Checks & adjustments, double stage valve…………………………………………… 498
10.3.10.3 Checks of the brake pilot pressure………………………………………………… 501
10.3.11 Function check for the hydraulic slew brake……………………………………………… 502
10.3.12 Function check for the slew parking brake……………………………………………….. 504
10.4 Hydraulics for the travel system……………………………………………………………… 506
10.4.1 Travel circuit………………………………………………………………………… 506
10.4.2 Travel motor………………………………………………………………………….. 508
10.4.3 Rotary joint………………………………………………………………………….. 510
10.4.4 Travel gearbox………………………………………………………………………… 512
10.4.4.1 Travel gearbox (L & S)……………………………………………………………. 512
10.4.4.2 Travel gearbox (Zollern)………………………………………………………….. 514
10.4.5 Travel parking brake…………………………………………………………………… 516
10.4.5.1 Travel parking brake (Zollern)…………………………………………………….. 516
10.4.5.2 Travel parking brake (L&S)………………………………………………………… 517
10.5 Travel brake valve………………………………………………………………………….. 518
10.5.1 Electric / hydraulic flowchart “travel forward”…………………………………………… 520
10.5.2 Electric / hydraulic flowchart “travel backwards………………………………………….. 522
10.5.3 Checks and adjustments…………………………………………………………………. 524
10.5.3.1 Checks and adjustments for the travel circuit……………………………………….. 524
10.5.3.2 Function check for the travel parking brake…………………………………………. 528
11 Hydraulic track tensioning system………………………………………………………………….. 531
11.1 General……………………………………………………………………………………. 532
11.2 Functional description………………………………………………………………………. 534
11.3 Double stage valve………………………………………………………………………….. 536
11.4 Tensioning cylinder…………………………………………………………………………. 538
11.5 Adjustments / checks………………………………………………………………………… 540
12 Access ladder, hydraulically operated………………………………………………………………. 543
12.1 General……………………………………………………………………………………. 544
12.2 Function of the hydraulically operated access ladder……………………………………………. 546
12.3 Adjustments / checks………………………………………………………………………… 550
13 Central refilling system………………………………………………………………………….. 553
13.1 General……………………………………………………………………………………. 554
13.1.1 Central refilling system overview……………………………………………………….. 556
14 Hints for reading the Hydraulic Diagram…………………………………………………………….. 559
14.1 General……………………………………………………………………………………. 560
14.2 Hydraulic symbols…………………………………………………………………………… 562
14.2.1 Lines, unions…………………………………………………………………………. 563
14.2.2 Components, valves…………………………………………………………………….. 565
14.2.3 Sensors………………………………………………………………………………. 565
14.2.4 Valves, valve components……………………………………………………………….. 566
14.2.5 Pump, motor, cylinder………………………………………………………………….. 570
15 Hints for reading the electric Wiring Diagram……………………………………………………….. 575
15.1 General……………………………………………………………………………………. 576
15.2 Reference code of the electrical components……………………………………………………. 577
15.2.1 Area code…………………………………………………………………………….. 577
15.2.2 Component identifying letter……………………………………………………………. 578
15.3 Graphical symbols…………………………………………………………………………… 579
15.4 Concept of the Wiring Diagram………………………………………………………………… 583
15.4.1 Cover page of the Komatsu W/D…………………………………………………………… 583
15.4.2 Example 1 from the schematics in the W/D…………………………………………………. 585
15.4.3 Example 2 from the schematics in the W/D…………………………………………………. 587
15.4.4 Table of contents in the W/D (page 1 of 2)……………………………………………….. 589
15.4.5 Location list…………………………………………………………………………. 591
15.4.6 Cross reference list for electr. components in the W/D…………………………………….. 592
15.4.7 Cross reference list for terminals in the W/D…………………………………………….. 594
15.4.8 Cross reference list for connectors in the W/D……………………………………………. 596
15.4.9 Cross reference list for terminal boards in the W/D……………………………………….. 598
15.4.10 Connection table……………………………………………………………………… 600
15.5 Cable and connector marking………………………………………………………………….. 602
15.6 Cable color identification…………………………………………………………………… 604
16 KOMTRAX Plus Monitoring & Control System……………………………………………………………. 605
16.1 General……………………………………………………………………………………. 606
16.1.1 Global layout PC4000E-6………………………………………………………………… 606
16.1.2 Controller system overview PC4000E-6…………………………………………………….. 607
16.1.3 Interface connection…………………………………………………………………… 609
16.1.4 General description……………………………………………………………………. 610
16.2 KOMTRAX Plus – Operator level………………………………………………………………… 611
16.2.1 Main gauge screens…………………………………………………………………….. 612
16.2.2 Operator menus & icons & functions of keys F1…F6………………………………………… 616
16.2.2.1 Operator menu: Energy Consumption – Operation Records………………………………… 618
16.2.2.2 Operator menu: Energy Consumption – Average Energy Consumption Logs……………………. 620
16.2.2.3 Operator menu: Machine Setting…………………………………………………….. 622
16.2.2.4 Operator menu: Maintenance………………………………………………………… 623
16.2.2.5 Reset of ’remaining time’ till next maintenance interval……………………………… 625
16.2.2.6 Usage limitation…………………………………………………………………. 626
16.2.2.7 Operator menu: Monitor Setting – Screen Adjustment…………………………………… 627
16.2.2.8 Operator menu: Monitor Setting – Clock Adjustment – Calender………………………….. 628
16.2.2.9 Operator menu: Monitor Setting – Clock Adjustment – Time……………………………… 629
16.2.2.10 Operator menu: Monitor Setting – Clock Adjustment – 12h/24h Mode……………………… 630
16.2.2.11 Operator menu: Monitor Setting – Clock Adjustment – Daylight Saving Time………………. 631
16.2.2.12 Operator menu: Monitor Setting – Language & ID Key Information……………………….. 632
16.3 Error and status indication on the operator level………………………………………………. 633
16.3.1 Prompts (status indications)……………………………………………………………. 633
16.3.2 Cautions……………………………………………………………………………… 634
16.3.3 Emergency shutdown screen (example)……………………………………………………… 635
16.3.4 Fault levels for error messages…………………………………………………………. 636
16.3.5 Action code L01……………………………………………………………………….. 638
16.3.6 Action code L02……………………………………………………………………….. 639
16.3.7 Action code L03……………………………………………………………………….. 640
16.3.8 Action code L04……………………………………………………………………….. 641
16.3.9 Error list……………………………………………………………………………. 642
16.4 Table of failure codes………………………………………………………………………. 643
16.4.1 Failure codes without monitor indication…………………………………………………. 656
16.4.2 Additional text information for action codes……………………………………………… 656
16.5 Flow charts of KOMTRAX Plus screens…………………………………………………………… 657
16.5.1 Flow chart Operator Level………………………………………………………………. 657
16.5.2 Flow chart Service Level……………………………………………………………….. 658
16.6 KOMTRAX Plus service level…………………………………………………………………… 659
16.6.1 Entering the Service Level……………………………………………………………… 659
16.6.2 Key symbols (F1…F6) on the Service Level……………………………………………….. 661
16.6.3 Service Menu selection screens………………………………………………………….. 662
16.6.4 Service Menu – item 01 Monitoring / Custom……………………………………………….. 664
16.6.4.1 Monitoring list for: ELEC controller……………………………………………….. 664
16.6.4.2 Monitoring list for: PUMP controller……………………………………………….. 666
16.6.4.3 Monitoring list for: VALVE0 controller……………………………………………… 669
16.6.4.4 Monitoring list for: VALVE1 controller……………………………………………… 672
16.6.4.5 Monitoring list for: VALVE2 controller……………………………………………… 675
16.6.4.6 Monitoring list for: MON (monitor)…………………………………………………. 677
16.6.4.7 Monitoring list for: KOM PLS (K+ controller)………………………………………… 679
16.6.5 How to perform the monitoring function…………………………………………………… 682
16.6.6 Service Menu – item 02 PM Clinic………………………………………………………… 684
16.6.6.1 PM Clinic (General)………………………………………………………………. 684
16.6.6.2 PM Clinic (Power Check)…………………………………………………………… 685
16.6.6.3 Functions of PM CLINIC (POWER CHECK)……………………………………………….. 686
16.6.7 Service Menu – item 03 Memory Clear……………………………………………………… 687
16.6.8 Service Menu – item 04 Abnormality record………………………………………………… 688
16.6.8.1 Reset error messages……………………………………………………………… 689
16.6.9 Service Menu – item 05 Maintenance record………………………………………………… 690
16.6.10 Service Menu – item 06 Maintenance Mode Setting………………………………………….. 691
16.6.11 Service Menu – item 07 Snap Shot……………………………………………………….. 692
16.6.12 Service Menu – item 08 Phone Number Entry……………………………………………….. 693
16.6.13 Service Menu – item 09 Unit……………………………………………………………. 694
16.6.14 Service Menu – item 10 Adjustment………………………………………………………. 695
16.6.14.1 Adjustments for: ELEC controller………………………………………………….. 695
16.6.14.2 Adjustments for: PUMP controller………………………………………………….. 697
16.6.14.3 Pump sol ’min’ current values according to pump type plate…………………………… 700
16.6.14.4 Pump sol ’max’ current values according to pump type plate…………………………… 701
16.6.14.5 Adjustments for: VALVE0 controller………………………………………………… 702
16.6.14.6 Accel & Decel times……………………………………………………………… 709
16.6.14.7 Adjustments for: VALVE2 controller………………………………………………… 710
16.6.15 Service Menu – item 11 Machine Configuration…………………………………………….. 712
16.6.15.1 Details of Machine Configuration for PC4000E-6……………………………………… 713
16.7 Wiring of the KOMTRAX Plus controller…………………………………………………………. 716
16.7.0.1 Memories in the KOMTRAX Plus controller………………………………………………… 719
16.8 Interface-Connection to K+ controller…………………………………………………………. 720
16.9 KOMTRAX Plus controller……………………………………………………………………… 721
16.10 7-segment error code indication……………………………………………………………… 722
16.11 CR720 controller…………………………………………………………………………… 723
16.11.1 Location of CR720 controllers………………………………………………………….. 724
16.11.2 In case of CR720 trouble………………………………………………………………. 724
16.11.3 Connectors and pin arrangement of CR720 controllers………………………………………. 726
16.12 Controller replacement procedure…………………………………………………………….. 727
17 Lubrication system……………………………………………………………………………….. 733
17.1 General overview (SLS & CLS 1 )………………………………………………………………. 734
17.1.1 General description……………………………………………………………………. 735
17.2 Basic function of the lubrication systems……………………………………………………… 736
17.3 Lubrication systems (CLS 1 & SLS)…………………………………………………………….. 738
17.3.1 Lubrication pump station……………………………………………………………….. 738
17.3.2 General Information on CLS 1……………………………………………………………. 740
17.3.3 General information on the SLS………………………………………………………….. 740
17.3.4 Manual lube activation…………………………………………………………………. 740
17.4 Lubrication cycle…………………………………………………………………………… 741
17.4.1 Operation and control………………………………………………………………….. 741
17.4.2 Lubrication cycle – processing………………………………………………………….. 742
17.4.3 Time segments & switch points of a lubrication cycle………………………………………. 743
17.4.4 Lubrication modes……………………………………………………………………… 744
17.4.4.1 Automatic lubrication mode………………………………………………………… 744
17.4.4.2 Manual lubrication mode…………………………………………………………… 744
17.4.4.3 Reduced Pause Time for service…………………………………………………….. 744
17.5 Hydraulically driven lube pump……………………………………………………………….. 746
17.5.1 Adjustment of lube pump speed & working pressure………………………………………….. 748
17.5.1.1 Stroke speed adjustment…………………………………………………………… 749
17.5.1.2 Working pressure adjustment……………………………………………………….. 750
17.6 Lubricant injectors…………………………………………………………………………. 752
17.6.1 Tightening torques for fittings at grease injectors……………………………………….. 753
17.6.2 Description…………………………………………………………………………… 753
17.6.3 Adjustment of the lubricant output………………………………………………………. 754
17.6.4 Operation principle of lubricant injectors……………………………………………….. 756
17.6.4.1 Function description……………………………………………………………… 757
17.6.5 Connection of one or more injectors……………………………………………………… 758
17.7 End-line switch…………………………………………………………………………….. 760
17.7.1 Description…………………………………………………………………………… 761
17.7.2 Vent valve description…………………………………………………………………. 761
17.7.3 CLS 1 end-line switch adjustment………………………………………………………… 762
17.7.4 SLS end-line switch adjustment………………………………………………………….. 764
17.8 Lubricant level sensors……………………………………………………………………… 766
17.8.1 Description…………………………………………………………………………… 767
17.8.1.1 Checks………………………………………………………………………….. 767
17.9 Commissioning………………………………………………………………………………. 768
17.9.1 Commissioning of the CLS 1 lubrication system…………………………………………….. 768
17.9.2 Fine adjustment……………………………………………………………………….. 769
17.9.3 Commissioning of the SLS lubrication system………………………………………………. 770
18 Deep temperature equipment (option)………………………………………………………………… 773
18.1 General information…………………………………………………………………………. 774
18.1.1 Introduction………………………………………………………………………….. 774
18.1.2 Deep temperature components overview…………………………………………………….. 774
18.1.3 Power supply preconditions for preheating………………………………………………… 775
18.1.4 Power requirements for preheating systems………………………………………………… 776
18.2 Preheating procedure………………………………………………………………………… 777
18.2.1 Global flow chart of the preheating procedure…………………………………………….. 777
18.2.2 Starting the preheating procedure……………………………………………………….. 778
18.2.3 Preheating of operator’s cab and Diesel engine [coolant system]…………………………….. 779
18.2.4 Preheating of lubricants and superstructure (Diesel) [electric system]………………………. 780
18.3 Constant heating of travel motors (TTT equipment below-40°C only)………………………………… 781
18.4 Component location………………………………………………………………………….. 782
18.4.1 Electric heating elements for hydraulic & batteries [electric machine]………………………. 782
18.4.2 Electric heating elements for hydraulics [Diesel machine]………………………………….. 784
18.4.3 Electric heating elements for engines & batteries [Diesel machine]………………………….. 786
18.5 Components of TT equipment…………………………………………………………………… 788
18.5.1 Preheating components on a Diesel machine………………………………………………… 788
18.5.2 Preheating components on an electric machine……………………………………………… 789
18.5.3 Exemplary Wiring Diagrams for preheating systems………………………………………….. 790
18.5.3.1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3……………………………. 790
18.5.3.2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3……………………………. 791
18.5.3.3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3……………………………. 792
18.5.3.4 Wiring diagram “Suction Oil Manifold Preheating”…………………………………….. 793
18.5.3.5 Wiring diagram “PTO Preheating”……………………………………………………. 794
18.5.3.6 Wiring diagram “Battery heater pads”……………………………………………….. 795
40 TROUBLESHOOTING
…………………………………………………………………………………….. 797
TOC……………………………………………………………………………………………….. 799
1 Introduction……………………………………………………………………………………… 827
1.1 Overview……………………………………………………………………………………. 828
1.1.1 General advice when using troubleshooting charts…………………………………………… 828
1.2 General Precautions………………………………………………………………………….. 829
2 General Information for Troubleshooting……………………………………………………………… 831
2.1 Preparations For Work………………………………………………………………………… 832
2.2 Precautions During Work………………………………………………………………………. 832
2.3 Precautions When Carrying Out Any Operation…………………………………………………….. 833
2.3.1 Precautions when carrying out removal work………………………………………………… 833
2.3.2 Precautions when carrying out installation work……………………………………………. 833
2.3.3 Precautions when completing the operation…………………………………………………. 834
2.4 Fundamental Requirements for Trouble shooting…………………………………………………… 835
2.4.1 Technical documentation…………………………………………………………………. 835
2.4.2 Tools…………………………………………………………………………………. 835
2.4.2.1 Reference Guide for Deutsch Removal Tools……………………………………………. 839
2.4.3 Personnel……………………………………………………………………………… 840
2.5 Points To Remember When Trouble- shooting………………………………………………………. 840
2.6 Sequence Of Events In Troubleshooting………………………………………………………….. 842
2.7 Checks Before Troubleshooting…………………………………………………………………. 843
2.8 Handling Of Electric Equipment And Hydraulic Components………………………………………….. 844
2.8.1 Points to remember when handling electric equipment………………………………………… 844
2.8.2 Points To Remember When Handling Hydraulic Equipment……………………………………….. 847
2.9 General working procedures……………………………………………………………………. 849
2.9.1 Air Bleeding of Various Hydraulic Parts…………………………………………………… 849
2.9.2 Air bleeding from the hydraulic pumps…………………………………………………….. 849
2.9.3 Air bleeding from hydraulic cylinders…………………………………………………….. 849
2.10 Cylinder bypass test………………………………………………………………………… 850
2.11 Basics about “How to crimp”………………………………………………………………….. 851
2.11.1 Stripping a wire for use with the HDT 48 crimp tool……………………………………….. 851
2.11.2 View onto the Deutsch crimp tool HDT 48………………………………………………….. 851
2.11.3 Adjustment of the wire size at the Deutsch crimp tool HDT 48……………………………….. 852
2.11.3.1 Wire cross section units in mm2 and AWG…………………………………………….. 852
2.11.4 Crimping instructions (for Deutsch crimp tool HDT 48)……………………………………… 853
2.12 Cable Shielding…………………………………………………………………………….. 854
3 Mounting Locations and Connector Types………………………………………………………………. 855
3.1 Component Location (exemplarily)………………………………………………………………. 856
3.1.1 Side View onto the Excavator…………………………………………………………….. 856
3.1.2 Superstructure…………………………………………………………………………. 858
3.1.3 Machine House………………………………………………………………………….. 860
3.2 Rotary joint………………………………………………………………………………… 862
3.3 Capacitor…………………………………………………………………………………… 864
3.4 High Voltage Switch Cabinet – View 1…………………………………………………………… 866
3.4.1 High Voltage Switch Cabinet – View 2……………………………………………………… 868
3.4.2 High Voltage Switch Cabinet – View 3……………………………………………………… 870
3.5 Cab Support…………………………………………………………………………………. 872
3.5.1 Extra low voltage switch board (Location 11)………………………………………………. 874
3.5.2 Low voltage switch board (Location 12)……………………………………………………. 874
3.6 Location of the Control Blocks………………………………………………………………… 876
3.7 Control and filter panel – location of components……………………………………………….. 878
3.8 Location of the suction oil tank with strainers…………………………………………………. 880
3.9 Arrangement of the remote control valves……………………………………………………….. 882
3.10 Hydraulic oil tank – Location of the electrical components………………………………………. 884
3.11 General overview on SLS & CLS1……………………………………………………………….. 886
3.12 Batteries, battery main switches & safety switch for maintenance…………………………………. 888
3.13 Hydraulically operated access ladder………………………………………………………….. 890
3.14 Receiver panel for the refilling system……………………………………………………….. 892
3.15 Connector Types Overview…………………………………………………………………….. 894
4 Standard Value Table for Electrical Components……………………………………………………….. 899
5 Tables for Testing and Troubleshooting………………………………………………………………. 915
5.1 Test Value Tables for Temperature Sensors (PT100)……………………………………………….. 916
5.2 Table of failure codes……………………………………………………………………….. 918
5.3 Tables of Symptom Codes………………………………………………………………………. 931
5.3.1 Symptoms of the E-Motor(s) and Related parts………………………………………………. 931
5.3.2 Symptoms of the Hydraulic System…………………………………………………………. 931
5.3.3 Symptoms of the Mechanical System………………………………………………………… 932
5.3.4 SYMPTOMS OF ADDITIONAL SYSTEMS…………………………………………………………… 932
5.4 Cable colour identification…………………………………………………………………… 932
6 Troubleshooting by Trouble Code…………………………………………………………………….. 933
B@HANS – Hyd Oil Overheat………………………………………………………………………… 934
Hydraulic oil temperature table……………………………………………………………….. 935
Location and W/D of 57K506a-1 / 57K506b-1 for message B@HANS……………………………………… 936
6A1BMA – Trouble Shut-Off (gate) valve not open error……………………………………………….. 937
View onto the gap of proximity switch 40B031……………………………………………………. 938
Wiring Diagram (40B031) for message 6A1BMA……………………………………………………… 939
K@3A00 – Fire In System………………………………………………………………………….. 940
Wiring Diagram (fire warning) for message K@3A00………………………………………………… 941
Wiring Diagram (controller input of 20K351) for message K@3A00……………………………………. 942
Wiring Diagram (10B350 in the emergency stop line) for message K@3A00……………………………… 943
B@F0MA – CLS1 Lubrication System Error…………………………………………………………….. 944
B@CPMA – SLS Lubrication System Error……………………………………………………………… 945
K@3B00 – Fire in the switch cabinet……………………………………………………………….. 946
Wiring Diagram 1 (temperature sensors) for message K@3B00………………………………………… 947
Wiring Diagram 2 (control unit in the cab) for message G00059…………………………………….. 948
G@01NS – Electric motor1 winding overheat………………………………………………………….. 949
Monitoring motor winding temperature & net-line voltage for G@01NS………………………………… 950
Wiring Diagram (monitoring motor winding temperature) for G@01NS………………………………….. 951
G@02NS – Electric motor1 bearing overheat………………………………………………………….. 952
Monitoring motor bearing temperature for G@02NS…………………………………………………. 953
Wiring Diagram (monitoring motor bearing temperature) for G@02NS………………………………….. 954
G@03KG – Capacitor1 voltage high error…………………………………………………………….. 955
Wiring Diagram (capacitor pressure monitoring) for G@03KG………………………………………… 956
Capacitor pressure monitoring screen for message G@03KG………………………………………….. 956
G@00K3 – Ground leakage tripped…………………………………………………………………… 957
Wiring Diagram (12F431) for message G@00K3……………………………………………………… 958
G@00MA – Electric motor1 abnormality………………………………………………………………. 959
Monitoring motor protection relay for G@00MA……………………………………………………. 960
G@00NZ – 3 phase current rotation direction error…………………………………………………… 961
Wiring Diagram (phase sequence monitoring) for message G@00NZ…………………………………….. 962
Phase sequence relay monitoring for message G@00NZ………………………………………………. 963
G@00N8 – Trouble restart motor 1, temperature too high………………………………………………. 964
Monitoring motor protection relay for G@00N8 (motor start blocked)………………………………… 965
G@20MA -Trouble cab heater safety relay……………………………………………………………. 966
Wiring Diagram 1 for G@20MA…………………………………………………………………… 967
Wiring Diagram 2 for G@20MA…………………………………………………………………… 968
B@F0N9 – CLS1 pressure increase time too long………………………………………………………. 969
B@CPN9 – SLS pressure increase time too long……………………………………………………….. 969
Allocation of vent valves and end-of-line switches………………………………………………. 970
View onto the vent valve (62Q507a & 62Q509a)……………………………………………………. 971
Wiring Diagram – lube pump & vent valve (CLS1 & SLS)…………………………………………….. 972
B@F0N0 – CLS1 pressure decrease time too long………………………………………………………. 973
B@CPN0 – SLS pressure decrease time too long……………………………………………………….. 973
View onto the vent valve (62Q507a & 62Q509a)……………………………………………………. 974
B@F0ZK – CLS1 grease level too low………………………………………………………………… 975
B@CPZK – SLS grease level too low…………………………………………………………………. 975
Wiring Diagram – grease level sensors (CLS1 & SLS)………………………………………………. 977
B@HAZK – Hydraulic oil level too low………………………………………………………………. 978
Hydraulic oil level in defined machine position…………………………………………………. 979
Wiring Diagram – hydraulic oil level sensor 40B004………………………………………………. 980
Wiring Diagram – hydraulic oil level pressure transducer 40B105…………………………………… 981
B@CBNS – PTO1 Gear Oil Temp High………………………………………………………………….. 982
View onto the universal pump distributor gearbox (PTO)…………………………………………… 984
B@CBZG – PTO1 Gear Lubrication Error………………………………………………………………. 985
PTO lube oil pressure monitoring………………………………………………………………. 986
Shutdown adjustment for PTO lube oil pressure…………………………………………………… 986
G@06N8 – Transformer1 Temp Too High……………………………………………………………….. 987
Transformer temperature signal & motor voltage monitoring………………………………………… 988
Wiring Diagram – transformer temperature monitoring……………………………………………… 989
G@04MA – Earth Fault Tripped……………………………………………………………………… 990
RCD LV and welding sockets monitoring………………………………………………………….. 991
Wiring Diagram – controller input for G@04MA……………………………………………………. 991
Wiring Diagram – 12F451 & 12F452 (option)………………………………………………………. 992
G@22N8 – Trouble temperature cab base……………………………………………………………… 993
Cab base temperature signal indication…………………………………………………………. 994
Wiring Diagram – temperature monitoring LV cabinet (10B001)………………………………………. 994
View onto temperature sensor 10B001……………………………………………………………. 995
G@23N8 – Trouble temperature high voltage cabinet…………………………………………………… 996
HV cabinet temperature signal indication……………………………………………………….. 997
Wiring Diagram – temperature monitoring HV cabinet (32B802)………………………………………. 997
View onto temperature sensor 32B802……………………………………………………………. 998
G@24NS – Cab Heating1 Error………………………………………………………………………. 999
G@25NS – Cab Heating2 Error………………………………………………………………………. 999
View onto the heater air inlet & outlet grids in the operator’s cab………………………………..1000
View onto the heater air inlet & outlet grids in the operator’s cab………………………………..1001
Wiring Diagram – control of heater overheat protection (100°C)…………………………………….1002
G@40KU – Emergency Voltage Too High………………………………………………………………..1003
Emergency voltage monitoring screen for message G@40KU……………………………………………1003
G@40KL – Emergency Voltage Too Low…………………………………………………………………1004
Emergency voltage monitoring screen for message G@40KL……………………………………………1004
B@H2NX – Breather Filter Clogging………………………………………………………………….1005
Location of 40B024 and hydraulic oil level definitions……………………………………………1006
B@M9NX – PTO1 Gear Oil Filter Clogging……………………………………………………………..1007
View onto the PTO1 gear oil filter with pressure sensor 57B027-1…………………………………..1008
B@HBNX – Return Oil Filter Clogging………………………………………………………………..1009
B@L4NX – Leak Oil Filter Clogging………………………………………………………………….1010
B@L5N9 – Pilot Press X2 Too Low……………………………………………………………………1011
Valve cartridge block, location of components……………………………………………………1012
B@L5N0 – Pilot Press X2 Too High…………………………………………………………………..1013
Valve cartridge block, location of components……………………………………………………1014
B@HANX – Screen At Hyd Cooler Entry Clogging………………………………………………………..1015
Hydraulic oil tank & transfer pump, location of components………………………………………..1016
G@00MC – Motor1 Main Relay Circuit Abnormality………………………………………………………1018
G@00MC – failure detection criteria…………………………………………………………….1019
Wiring Diagram 1 for message G@00MC…………………………………………………………….1022
Wiring Diagram 2 for message G@00MC…………………………………………………………….1023
Wiring Diagram 3 for message G@00MC…………………………………………………………….1024
989HMA – Emergency stop line abnormality……………………………………………………………1025
Wiring Diagram – emergency line for 989HMA………………………………………………………1026
Monitoring screens for message 989HMA…………………………………………………………..1027
DGT3MA – PTO1 oil temperature sensor abnormality…………………………………………………….1028
Wiring Diagram and location of 57B049…………………………………………………………..1029
DGH2MA – Hydraulic oil temp sensor abnormality………………………………………………………1030
Wiring Diagram and monitoring selection for 59B015……………………………………………….1031
DHQ7MA – PTO1 lube pressure sensor abnormality………………………………………………………1032
Wiring Diagram and monitoring selection for 57B017-1……………………………………………..1033
G@00KP – Motor1 voltage low error………………………………………………………………….1034
Wiring Diagram of signal rectifier module 12T431…………………………………………………1036
DHPEMA – Pump-1/2 pressure sensor abnormality……………………………………………………….1037
DHPGMA – Pump-3/4 pressure sensor abnormality……………………………………………………….1037
DHPJMA – Pump-5/6 pressure sensor abnormality……………………………………………………….1037
DHPLMA – Pump-7/8 pressure sensor abnormality……………………………………………………….1037
Wiring Diagram – power and GND supply for pump pressure transducers………………………………..1039
DJK3MA – Motor voltage sensor abnormality…………………………………………………………..1040
Wiring Diagram of signal rectifier module 12T431…………………………………………………1041
DJK4MA – Motor current sensor abnormality…………………………………………………………..1042
Wiring Diagram of signal rectifier module 12T431…………………………………………………1043
DA27KP – 24V sensor power abnormality………………………………………………………………1044
Wiring Diagram – 24V sensor power supply for DA27KP………………………………………………1045
DA26KP – 5V sensor2 power abnormality………………………………………………………………1046
Wiring Diagram – 5V sensor power supply for DA26KP……………………………………………….1047
DA22KK – Solenoid Power Low Error(Pump Con)…………………………………………………………1048
DA22MA – Solenoid Power Circuit Abnormality…………………………………………………………1049
Wiring Diagram 1 – emergency stop line for DA22MA………………………………………………..1050
Wiring Diagram 2 for DA22MA……………………………………………………………………1051
DXAAKA – Pump1 Solenoid open circuit……………………………………………………………….1052
DXABKA – Pump2 Solenoid open circuit……………………………………………………………….1052
DXACKA – Pump3 Solenoid open circuit……………………………………………………………….1052
DXADKA – Pump4 Solenoid open circuit……………………………………………………………….1052
DXAEKA – Pump5 Solenoid open circuit……………………………………………………………….1052
DXAFKA – Pump6 Solenoid open circuit……………………………………………………………….1052
DXAGKA – Pump7 Solenoid open circuit……………………………………………………………….1052
DXAHKA – Pump8 Solenoid open circuit……………………………………………………………….1052
Wiring Diagram – EPC valve control……………………………………………………………..1054
DXAAKB – Pump1 Solenoid short circuit………………………………………………………………1055
DXABKB – Pump2 Solenoid short circuit………………………………………………………………1055
DXACKB – Pump3 Solenoid short circuit………………………………………………………………1055
DXADKB – Pump4 Solenoid short circuit………………………………………………………………1055
DXAEKB – Pump5 Solenoid short circuit………………………………………………………………1055
DXAFKB – Pump6 Solenoid short circuit………………………………………………………………1055
DXAGKB – Pump7 Solenoid short circuit………………………………………………………………1055
DXAHKB – Pump8 Solenoid short circuit………………………………………………………………1055
Wiring Diagram – EPC valve control……………………………………………………………..1057
DWA5KA – CLS pump solenoid open circuit…………………………………………………………….1058
DWA8KA – SLS pump solenoid open circuit…………………………………………………………….1058
Wiring Diagram – CLS/SLS pump solenoid control…………………………………………………..1059
DWA5KB – CLS pump solenoid short circuit……………………………………………………………1060
DWA8KB – SLS pump solenoid short circuit……………………………………………………………1060
Wiring Diagram – CLS/SLS pump solenoid control…………………………………………………..1061
DWA5KY – CLS pump solenoid hot short circuit………………………………………………………..1062
DWA8KY – SLS pump solenoid hot short circuit………………………………………………………..1062
Wiring Diagram – CLS/SLS pump solenoid / hot short circuit………………………………………..1063
DWA7KA – CLS line release solenoid open circuit……………………………………………………..1064
DWA9KA – SLS lube line release sol. open circuit…………………………………………………….1064
Wiring Diagram – CLS/SLS lube line release solenoid control……………………………………….1065
DWA7KB – CLS line release solenoid short circuit…………………………………………………….1066
DWA9KB – SLS lube line release solenoid short circuit………………………………………………..1066
Wiring Diagram – CLS/SLS lube line release solenoid control……………………………………….1067
DWA7KY – CLS line release sol. hot short circuit…………………………………………………….1068
DWA9KY – SLS lube line release sol hot short circuit…………………………………………………1068
Wiring Diagram – CLS/SLS lube line release solenoid / hot short circuit…………………………….1069
DWAAKA – PTO lube preload solenoid open circuit……………………………………………………..1070
Wiring Diagram and monitoring screen for message DWAAKA…………………………………………..1071
DWAAKB – PTO lube preload solenoid short circuit…………………………………………………….1072
Wiring Diagram and monitoring screen for message DWAAKB…………………………………………..1073
DWAAKY – PTO lube preload sol. hot short circuit…………………………………………………….1074
Wiring Diagram for message DWAAKY………………………………………………………………1075
D166KA – Oil cooler fan sol(Min)relay open circuit…………………………………………………..1076
Wiring Diagram – relay 11K068 for 57K506a (D166KA)……………………………………………….1077
D166KB – Oil cooler fan sol(Min)relay short circuit………………………………………………….1078
Wiring Diagram – relay 11K068 for 57K506a (D166KB)……………………………………………….1079
D167KA – Oil cooler fan sol(Mid)relay open circuit…………………………………………………..1080
Wiring Diagram – relay 11K069 for 57K506b (D167KA)……………………………………………….1081
D167KB – Oil cooler fan sol(Mid)relay short circuit………………………………………………….1082
Wiring Diagram – relay 11K069 for 57K506b (D167KB)……………………………………………….1083
D168KA – Oil cooler preload sol relay open circuit…………………………………………………..1084
Wiring Diagram – relay 11K070 for 40K601 (D168KA)………………………………………………..1085
D168KB – Oil cooler preload sol relay short circuit………………………………………………….1086
Wiring Diagram – relay 11K070 for 40K601 (D168KB)………………………………………………..1087
D1E9KB – Wiper fast relay short circuit…………………………………………………………….1088
D1ETKB – Wiper slow relay short circuit…………………………………………………………….1088
D1EBKB – Wiper stop relay short circuit…………………………………………………………….1088
Wiring Diagram – wiper motor control……………………………………………………………1089
D1E9KA – Wiper fast relay open circuit……………………………………………………………..1090
D1ETKA – Wiper slow relay open circuit……………………………………………………………..1090
D1EBKA – Wiper stop relay open circuit……………………………………………………………..1090
Wiring Diagram – wiper motor control……………………………………………………………1091
D162KA – Horn relay open circuit…………………………………………………………………..1092
Wiring Diagram – signal horn control……………………………………………………………1093
D162KB – Horn relay short circuit………………………………………………………………….1094
Wiring Diagram – signal horn control……………………………………………………………1095
D1F0KA – Engine1/motor1 shutdown relay open circuit………………………………………………….1096
Wiring Diagram 1 – engine1/motor1 shutdown relay 12K408a-1………………………………………..1097
Wiring Diagram 2 – engine1/motor1 shutdown relay 12K408a-1………………………………………..1098
D1F0KB – Engine1/motor1 shutdown relay short circuit…………………………………………………1099
Wiring Diagram 1 – engine1/motor1 shutdown relay 12K408a-1………………………………………..1100
Wiring Diagram 2 – engine1/motor1 shutdown relay 12K408a-1………………………………………..1101
D1F0KY – Engine1/motor1 shutdown relay hot short…………………………………………………….1102
Wiring Diagram 1 for D1F0KY……………………………………………………………………1103
Wiring Diagram 2 for D1F0KY……………………………………………………………………1104
D110KA – Battery relay open circuit………………………………………………………………..1105
Wiring Diagram – battery relay 11Q044d………………………………………………………….1106
D110KB – Battery relay short circuit……………………………………………………………….1107
Wiring Diagram – battery relay 11Q044d………………………………………………………….1108
DA29KQ – Model Selection Abnormality……………………………………………………………….1109
Monitoring screen for machine selection…………………………………………………………1109
Wiring Diagram – model selection abnormality (DA29KQ)…………………………………………….1110
DA2YKQ – Motor Selection Abnormality……………………………………………………………….1111
Monitoring screen for motor selection…………………………………………………………..1111
Wiring Diagram – motor selection abnormality (DA2YKQ)…………………………………………….1112
DA2XKQ – Motor1 Frequency Select Abnormality………………………………………………………..1113
Monitoring screen for frequency selection……………………………………………………….1113
Wiring Diagram – motor frequency select abnormality (DA2XKQ)………………………………………1114
DA20KQ – Pump Con Selection Abnormality…………………………………………………………….1115
Monitoring screen for pump controller selection………………………………………………….1115
DA20MC – Pump Con Error…………………………………………………………………………..1116
DDABMC – Lock lever switch abnormality……………………………………………………………..1117
Wiring Diagram – lock lever switch 20S105 (DDABMC)……………………………………………….1118
DKURMA – R lever right-left potentio abnormality…………………………………………………….1119
Wiring Diagram – right lever right-left potentiometer input (DKURMA)……………………………….1120
DKUSMA – R lever right-left redu pot abnorm(VALVE/M)…………………………………………………1121
Wiring Diagram – right lever redundant right-left potentiometer input (DKUSMA)………………………1122
DKUQL8 – R lever right-left potentio error………………………………………………………….1123
Wiring Diagram – right lever main + redundant right-left signal voltage (DKUQL8)…………………….1124
DKUQL4 – R lever right-left sig. mismatch(VALVE/M)…………………………………………………..1125
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1………………………………1127
DKUNMA – R lever front-back potentio abnormality…………………………………………………….1128
Wiring Diagram – right lever front-back potentiometer input (DKUNMA)……………………………….1129
DKUPMA – R lever front-back redu pot abnorm(VALVE/M)…………………………………………………1130
Wiring Diagram – right lever redundant front-back potentiometer input (DKUPMA)………………………1131
DKUML8 – R lever front-back potentio error………………………………………………………….1132
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8)………………………..1133
DKUML4 – R lever front-back sig. mismatch(VALVE/M)…………………………………………………..1134
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1………………………………1136
DKUXMA – Left lever right-left potentio abnormality………………………………………………….1137
Wiring Diagram – left lever right-left potentiometer input (DKUXMA)………………………………..1138
DKUYMA – L lever right-left redu pot abnorm(VALVE/M)…………………………………………………1139
Wiring Diagram – left lever redundant right-left potentiometer input (DKUYMA)……………………….1140
DKUWL8 – L lever right-left potentio error………………………………………………………….1141
Wiring Diagram – left lever main + redundant right-left signal voltage (DKUWL8)……………………..1142
DKUWL4 – L lever right-left sig. mismatch(VALVE/M)…………………………………………………..1143
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1………………………………1145
DKUUMA – L lever front-back potentio abnormality…………………………………………………….1146
Wiring Diagram – left lever front-back potentiometer input (DKUUMA)………………………………..1147
DKUVMA – L lever front-back redu pot abnorm(VALVE/M)…………………………………………………1148
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/M) for DKUVMA…………………………….1149
DKUTL8 – L lever front-back potentio error………………………………………………………….1150
Wiring Diagram – L lever front-back potentio error (DKUTL8)……………………………………….1151
DKUTL4 – L lever front-back sig. mismatch(VALVE/M)…………………………………………………..1152
Wiring Diagram – L lever front-back sig. mismatch(VALVE/M) for DKUTL4………………………………1154
DKW1MA – R pedal potentio abnormality………………………………………………………………1155
Wiring Diagram – R pedal potentio abnormality (DKW1MA)……………………………………………1156
DKW2MA – R pedal redundant pot abnormality(VALVE/M)………………………………………………….1157
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA……………………………..1158
DKW0L8 – R pedal potentio error……………………………………………………………………1159
Wiring Diagram – R pedal potentio error (DKW0L8)…………………………………………………1160
DKW0L4 – R pedal signal mismatch(VALVE/M Con)……………………………………………………….1161
Wiring Diagram – R pedal signal mismatch(VALVE/M Con) for DKW0L4…………………………………..1163
DKW4MA – L pedal potentio abnormality………………………………………………………………1164
Wiring Diagram – L pedal potentio abnormality (DKW4MA)……………………………………………1165
DKW5MA – L pedal redundant pot abnormality(VALVE/M)………………………………………………….1166
Wiring Diagram – L pedal redundant pot abnormality(VALVE/M) for DKW5MA……………………………..1167
DKW3L8 – L pedal potentio error……………………………………………………………………1168
Wiring Diagram – L pedal potentio error (DKW3L8)…………………………………………………1169
DKW3L4 – L pedal signal mismatch(VALVE/M Con)……………………………………………………….1170
Wiring Diagram – L pedal signal mismatch(VALVE/M Con) for DKW3L4…………………………………..1172
DKW7MA – Clam open potentio abnormality…………………………………………………………….1173
Wiring Diagram – Clam open potentio abnormality (DKW7MA)………………………………………….1174
DKW8MA – Clam open redu pot abnormality(VALVE/M)…………………………………………………….1175
Wiring Diagram – Clam open redu pot abnormality(VALVE/M) for DKW8MA………………………………..1176
DKW6L8 – Clam open potentio error………………………………………………………………….1177
Wiring Diagram – Clam open potentio error (DKW6L8)……………………………………………….1178
DKW6L4 – Clam open signal mismatch(VALVE/M Con)……………………………………………………..1179
Wiring Diagram – Clam open signal mismatch(VALVE/M Con) for DKW6L4…………………………………1181
DKWAMA – Clam close potentio abnormality……………………………………………………………1182
Wiring Diagram – Clam close potentio abnormality (DKWAMA)…………………………………………1183
DKWBMA – Clam close redundant pot abnorm(VALVE/M)……………………………………………………1184
Wiring Diagram – Clam close redundant pot abnorm(VALVE/M) for DKWBMA……………………………….1185
DKW9L8 – Clam close potentio error…………………………………………………………………1186
Wiring Diagram – Clam close potentio error (DKW9L8)………………………………………………1187
DKW9L4 – Clam close signal mismatch(VALVE/M Con)…………………………………………………….1188
Wiring Diagram – Clam close signal mismatch(VALVE/M Con) for DKW9L4………………………………..1190
DKWDMA – Hydraulic slew brake potentio abnormality…………………………………………………..1191
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA)………………………………..1192
DKWEMA – Hyd. slew brake redu pot abnorm(VALVE/M)……………………………………………………1193
Wiring Diagram – Hyd. slew brake redu pot abnorm(VALVE/M) for DKWEMA……………………………….1194
DKWCL8 – Hydraulic slew brake potentio error………………………………………………………..1195
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8)……………………………………..1196
DKWCL4 – Hyd. slew brake sig. mismatch(VALVE/M)……………………………………………………..1197
Wiring Diagram – Hyd. slew brake sig. mismatch(VALVE/M) for DKWCL4…………………………………1199
DW4BKA – Travel parking brake solenoid open circuit………………………………………………….1200
Wiring Diagram and monitoring screen for message DW4BKA…………………………………………..1201
DW4BKB – Travel parking brake sol. short circuit…………………………………………………….1202
Wiring Diagram – Travel parking brake sol. short circuit (DW4BKB)………………………………….1203
DW4BKY – Travel parking brake sol. hot short circuit…………………………………………………1204
Wiring Diagram – Travel parking brake sol. hot short circuit (DW4BKY)………………………………1205
DW45KA – Slew parking brake solenoid open circuit……………………………………………………1206
Wiring Diagram and monitoring screen for message DW45KA…………………………………………..1207
DW45KB – Slew parking brake solenoid short circuit…………………………………………………..1208
Wiring Diagram – Slew parking brake solenoid short circuit (DW45KB)………………………………..1209
DW45KY – Slew parking brake sol. hot short circuit…………………………………………………..1210
Wiring Diagram – Slew parking brake sol. hot short circuit (DW45KY)………………………………..1211
DXN0KA – Slew1 epc solenoid open circuit……………………………………………………………1212
DXN1KA – Bucket/Boom1 epc solenoid open circuit……………………………………………………..1212
DXN2KA – Boom1 epc solenoid open circuit (BH only)…………………………………………………..1212
DXN3KA – Stick1 epc solenoid open circuit…………………………………………………………..1212
DXN4KA – Boom2 epc solenoid open circuit……………………………………………………………1212
DXN5KA – Clam2 epc solenoid open circuit……………………………………………………………1212
DXN6KA – Stick2 epc solenoid open circuit (BH only)………………………………………………….1212
DXN7KA – Stick/Bucket2 epc solenoid open circuit…………………………………………………….1212
DXN8KA – Bucket2 epc solenoid open circuit (BH only)…………………………………………………1212
DXN9KA – Travel2 left epc solenoid open circuit……………………………………………………..1212
DXNAKA – Slew3 epc solenoid open circuit……………………………………………………………1212
DXNBKA – Bucket3 epc solenoid open circuit………………………………………………………….1212
DXNCKA – Boom3 epc solenoid open circuit……………………………………………………………1212
DXNDKA – Boom4 epc solenoid open circuit……………………………………………………………1212
DXNEKA – Bucket4 epc solenoid open circuit………………………………………………………….1212
DXNFKA – Stick4 epc solenoid open circuit…………………………………………………………..1212
DXNGKA – Travel4 right epc solenoid open circuit…………………………………………………….1212
Details of the above 6-digit failure codes (front shovel attachment only)…………………………..1213
Wiring Diagram for EPC 61K620 – 61K621 – 61K622………………………………………………….1214
Wiring Diagram for EPC 61K624 – 61K625………………………………………………………….1215
Wiring Diagram for EPC 61K626 – 61K627………………………………………………………….1216
Wiring Diagram for EPC 61K628 – 61K629 – 61K630………………………………………………….1217
Wiring Diagram for EPC 61K632 – 61K633………………………………………………………….1218
Wiring Diagram for EPC 61K634 – 61K635………………………………………………………….1219
Exemplary monitoring screens…………………………………………………………………..1220
DXN0KB – Slew1 epc solenoid short circuit…………………………………………………………..1221
DXN1KB – Bucket/Boom1 epc solenoid short circuit…………………………………………………….1221
DXN2KB – Boom1 epc solenoid short circuit (BH only)………………………………………………….1221
DXN3KB – Stick1 epc solenoid short circuit………………………………………………………….1221
DXN4KB – Boom2 epc solenoid short circuit…………………………………………………………..1221
DXN5KB – Clam2 epc solenoid short circuit…………………………………………………………..1221
DXN6KB – Stick2 epc solenoid short circuit (BH only)…………………………………………………1221
DXN7KB – Stick/Bucket2 epc solenoid short circuit……………………………………………………1221
DXN8KB – Bucket2 epc solenoid short circuit (BH only)………………………………………………..1221
DXN9KB – Travel2 left epc solenoid short circuit…………………………………………………….1221
DXNAKB – Slew3 epc solenoid short circuit…………………………………………………………..1221
DXNBKB – Bucket3 epc solenoid short circuit…………………………………………………………1221
DXNCKB – Boom3 epc solenoid short circuit…………………………………………………………..1221
DXNDKB – Boom4 epc solenoid short circuit…………………………………………………………..1221
DXNEKB – Bucket4 epc solenoid short circuit…………………………………………………………1221
DXNFKB – Stick4 epc solenoid short circuit………………………………………………………….1221
DXNGKB – Travel4 right epc solenoid short circuit……………………………………………………1221
Details of the above 6-digit failure codes (front shovel attachment only)…………………………..1222
DXN0KY – Slew1 epc solenoid hot short circuit……………………………………………………….1223
DXN1KY – Bucket/Boom1 epc sol. hot short circuit…………………………………………………….1223
DXN2KY – Boom1 epc solenoid hot short circuit (BH only)………………………………………………1223
DXN3KY – Stick1 epc solenoid hot short circuit………………………………………………………1223
DXN4KY – Boom2 epc solenoid hot short circuit……………………………………………………….1223
DXN5KY – Clam2 epc solenoid hot short circuit……………………………………………………….1223
DXN6KY – Stick2 epc solenoid hot short circuit (BH only)……………………………………………..1223
DXN7KY – Stick/Bucket2 epc sol. hot short circuit……………………………………………………1223
DXN8KY – Bucket2 epc solenoid hot short circuit (BH only)…………………………………………….1223
DXN9KY – Travel2 left epc sol. hot short circuit…………………………………………………….1223
DXNAKY – Slew3 epc solenoid hot short circuit……………………………………………………….1223
DXNBKY – Bucket3 epc solenoid hot short circuit……………………………………………………..1223
DXNCKY – Boom3 epc solenoid hot short circuit……………………………………………………….1223
DXNDKY – Boom4 epc solenoid hot short circuit……………………………………………………….1223
DXNEKY – Bucket4 epc solenoid hot short circuit……………………………………………………..1223
DXNFKY – Stick4 epc solenoid hot short circuit………………………………………………………1223
DXNGKY – Travel4 right epc sol. hot short circuit……………………………………………………1223
Details of the above 6-digit failure codes (front shovel attachment only)…………………………..1224
Wiring Diagram for EPC 61K620 – 61K621 – 61K622………………………………………………….1225
Wiring Diagram for EPC 61K624 – 61K625………………………………………………………….1226
Wiring Diagram for EPC 61K626 – 61K627………………………………………………………….1227
Wiring Diagram for EPC 61K628 – 61K629 – 61K630………………………………………………….1228
Wiring Diagram for EPC 61K632 – 61K633………………………………………………………….1229
Wiring Diagram for EPC 61K634 – 61K635………………………………………………………….1230
DWADKA – Ladder speed control solenoid open circuit………………………………………………….1231
Wiring Diagram and monitoring screen for message DWADKA…………………………………………..1232
DWADKB – Ladder speed control sol. short circuit…………………………………………………….1233
Wiring Diagram and monitoring screen for message DWADKB…………………………………………..1234
DWADKY – Ladder speed control sol. hot short circuit…………………………………………………1235
Wiring Diagram – Ladder speed control sol. hot short circuit (DWADKY)………………………………1236
DBW5MA – 5V sensor1 power abnormality………………………………………………………………1237
DBW6MA – 5V sensor2 power abnormality………………………………………………………………1237
Wiring Diagram – 5V power supply and GND output at VALVE0…………………………………………1241
DBW9KQ – Model Selection Abnormality……………………………………………………………….1242
Monitoring screen for machine selection…………………………………………………………1242
Wiring Diagram – model selection abnormality (DBW9KQ)…………………………………………….1243
DBWZKQ – Lever control selection abnormality………………………………………………………..1244
Monitoring screen for lever control (lever pattern) selection……………………………………..1244
Wiring Diagram – Lever control selection abnormality (DBWZKQ)……………………………………..1245
DBWYKQ – Attachment selection abnormality…………………………………………………………..1246
Monitoring screen for attachment selection………………………………………………………1246
Wiring Diagram – Attachment selection abnormality (DBWYKQ)………………………………………..1247
DBW2KK – Solenoid Power Low Error(VALVE/M Con)………………………………………………………1248
DBW0KQ – VALVE/M Con Selection Abnormality………………………………………………………….1250
Wiring Diagram and monitoring screen for message DBW0KQ…………………………………………..1251
DDDWMC – Ladder operation switch abnormality………………………………………………………..1252
Wiring Diagram and monitoring screen for message DDDWMC…………………………………………..1253
DKWHMA – R lever right-left redu pot abnorm(VLV/S1)………………………………………………….1254
Wiring Diagram – right lever redundant right-left potentiometer input (DKWHMA)………………………1255
DKWFL4 – R lever right-left sig. mismatch(VALVE/S1)………………………………………………….1256
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1………………………………1258
DKWLMA – R lever front-back redu pot abnorm(VLV/S1)………………………………………………….1259
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA)………………………1260
DKWJL4 – R lever front-back sig. mismatch(VALVE/S1)………………………………………………….1261
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1………………………………1263
DKWPMA – L lever right-left redu pot abnorm(VLV/S1)………………………………………………….1264
Wiring Diagram – left lever redundant right-left potentiometer input (DKWPMA)……………………….1265
DKWML4 – L lever right-left sig. mismatch(VALVE/S1)………………………………………………….1266
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1………………………………1268
DKWSMA – L lever front-back redu pot abnorm(VLV/S1)………………………………………………….1269
Wiring Diagram – L lever front-back redu pot abnorm(VLV/S1) for DKWSMA……………………………..1270
DKWQL4 – L lever front-back sig. mismatch(VALVE/S1)………………………………………………….1271
Wiring Diagram – L lever front-back sig. mismatch(VALVE/S1) for DKWQL4……………………………..1273
DKWVMA – R pedal red pot abnormality(VALVE/S1)………………………………………………………1274
Wiring Diagram – R pedal red pot abnormality(VALVE/S1) for DKWVMA………………………………….1275
DKWTL4 – R pedal signal mismatch(VALVE/S1 Con)………………………………………………………1276
Wiring Diagram – R pedal signal mismatch(VALVE/S1 Con) for DKWTL4………………………………….1278
DKWYMA – L pedal red pot abnormality(VALVE/S1)………………………………………………………1279
Wiring Diagram – L pedal red pot abnormality(VALVE/S1) for DKWYMA………………………………….1280
DKWWL4 – L pedal signal mismatch(VALVE/S1 Con)………………………………………………………1281
Wiring Diagram – L pedal signal mismatch(VALVE/S1 Con) for DKWWL4………………………………….1283
DKX2MA – Clam open redu pot abnormality(VALVE/S1)……………………………………………………1284
Wiring Diagram – Clam open redu pot abnormality(VALVE/S1)) for DKX2MA………………………………1285
DKX0L4 – Clam open signal mismatch(VALVE/S1 Con)…………………………………………………….1286
Wiring Diagram – Clam open signal mismatch(VALVE/S1 Con) for DKX0L4………………………………..1288
DKX5MA – Clam close redu pot abnormality(VALVE/S1)…………………………………………………..1289
Wiring Diagram – Clam close redu pot abnormality(VALVE/S1) for DKX5MA………………………………1290
DKX3L4 – Clam close signal mismatch(VALVE/S1 Con)……………………………………………………1291
Wiring Diagram – Clam close signal mismatch(VALVE/S1 Con) for DKX3L4……………………………….1293
DKX8MA – Hyd. slew brake redu pot abnorm(VALVE/S1)…………………………………………………..1294
Wiring Diagram – Hyd. slew brake redu pot abnorm(VALVE/S1) for DKX8MA………………………………1295
DKX6L4 – Hyd. slew brake signal mismatch(VALVE/S1)…………………………………………………..1296
Wiring Diagram – Hyd. slew brake signal mismatch(VALVE/S1) for DKWCL4………………………………1298
DWNRKA – Ladder up solenoid open circuit……………………………………………………………1300
Wiring Diagram and monitoring screen for message DWNRKA…………………………………………..1301
DWNRKB – Ladder up solenoid short circuit…………………………………………………………..1302
Wiring Diagram and monitoring screen for message DWNRKB…………………………………………..1303
DWNRKY – Ladder up solenoid hot short circuit……………………………………………………….1304
Wiring Diagram – Ladder up solenoid hot short circuit (DWNRKY)…………………………………….1305
DW7RKA – Hydraulic slew brake solenoid open circuit………………………………………………….1306
Wiring Diagram and monitoring screen for message DW7RKA…………………………………………..1307
DW7RKB – Hydraulic slew brake sol. short circuit…………………………………………………….1308
Wiring Diagram and monitoring screen for message DW7RKB…………………………………………..1309
DW7RKY – Hyd. slew brake sol. hot short circuit……………………………………………………..1310
Wiring Diagram – Hyd. slew brake sol. hot short circuit (DW7RKY)…………………………………..1311
DWANKA – Slew1 right solenoid open circuit………………………………………………………….1312
Wiring Diagram and monitoring screen for message DWANKA…………………………………………..1313
DWANKB – Slew1 right solenoid short circuit…………………………………………………………1314
Wiring Diagram and monitoring screen for message DWANKB…………………………………………..1315
DWANKY – Slew1 right solenoid hot short circuit……………………………………………………..1316
Wiring Diagram and monitoring screen for message DWANKY…………………………………………..1317
DWAJKA – Slew1 left solenoid open circuit…………………………………………………………..1318
Wiring Diagram and monitoring screen for message DWAJKA…………………………………………..1319
DWAJKB – Slew1 left solenoid short circuit………………………………………………………….1320
Wiring Diagram and monitoring screen for message DWAJKB…………………………………………..1321
DWAJKY – Slew1 left solenoid hot short circuit………………………………………………………1322
Wiring Diagram and monitoring screen for message DWAJKY…………………………………………..1323
DWASKA – Bucket1 fill solenoid open circuit…………………………………………………………1324
Wiring Diagram and monitoring screen for message DWASKA…………………………………………..1325
DWASKB – Bucket1 fill solenoid short circuit………………………………………………………..1326
Wiring Diagram and monitoring screen for message DWASKB…………………………………………..1327
DWASKY – Bucket1 fill solenoid hot short circuit…………………………………………………….1328
Wiring Diagram and monitoring screen for message DWASKY…………………………………………..1329
DWBEKA – Boom1 down solenoid open circuit…………………………………………………………..1330
Wiring Diagram and monitoring screen for message DWBEKA…………………………………………..1331
DWBEKB – Boom1 down solenoid short circuit………………………………………………………….1332
Wiring Diagram and monitoring screen for message DWBEKB…………………………………………..1333
DWBEKY – Boom1 down solenoid hot short circuit………………………………………………………1334
Wiring Diagram and monitoring screen for message DWBEKY…………………………………………..1335
DWBAKA – Boom1 up solenoid open circuit…………………………………………………………….1336
Wiring Diagram and monitoring screen for message DWBAKA…………………………………………..1337
DWBAKB – Boom1 up solenoid short circuit……………………………………………………………1338
Wiring Diagram and monitoring screen for message DWBAKB…………………………………………..1339
DWBAKY – Boom1 up solenoid hot short circuit………………………………………………………..1340
Wiring Diagram and monitoring screen for message DWBAKY…………………………………………..1341
DWBJKA – Stick1 out solenoid open circuit…………………………………………………………..1342
Wiring Diagram and monitoring screen for message DWBJKA…………………………………………..1343
DWBJKB – Stick1 out solenoid short circuit………………………………………………………….1344
Wiring Diagram and monitoring screen for message DWBJKB…………………………………………..1345
DWBJKY – Stick1 out solenoid hot short circuit………………………………………………………1346
Wiring Diagram and monitoring screen for message DWBJKY…………………………………………..1347
DWBNKA – Stick1 in solenoid open circuit……………………………………………………………1348
Wiring Diagram and monitoring screen for message DWBNKA…………………………………………..1349
DWBNKB – Stick1 in solenoid short circuit…………………………………………………………..1350
Wiring Diagram and monitoring screen for message DWBNKB…………………………………………..1351
DWBNKY – Stick1 in solenoid hot short circuit……………………………………………………….1352
Wiring Diagram and monitoring screen for message DWBNKY…………………………………………..1353
DWBBKA – Boom2 up solenoid open circuit…………………………………………………………….1354
Wiring Diagram and monitoring screen for message DWBBKA…………………………………………..1355
DWBBKB – Boom2 up solenoid short circuit……………………………………………………………1356
Wiring Diagram and monitoring screen for message DWBBKB…………………………………………..1357
DWBBKY – Boom2 up solenoid hot short circuit………………………………………………………..1358
Wiring Diagram and monitoring screen for message DWBBKY…………………………………………..1359
DWBFKA – Boom2 down solenoid open circuit…………………………………………………………..1360
Wiring Diagram and monitoring screen for message DWBFKA…………………………………………..1361
DWBFKB – Boom2 down solenoid short circuit………………………………………………………….1362
Wiring Diagram and monitoring screen for message DWBFKB…………………………………………..1363
DWBFKY – Boom2 down solenoid hot short circuit………………………………………………………1364
Wiring Diagram and monitoring screen for message DWBFKY…………………………………………..1365
DWBXKA – Clam2 close solenoid open circuit………………………………………………………….1366
Wiring Diagram and monitoring screen for message DWBXKA…………………………………………..1367
DWBXKB – Clam2 close solenoid short circuit…………………………………………………………1368
Wiring Diagram and monitoring screen for message DWBXKB…………………………………………..1369
DWBXKY – Clam2 close solenoid hot short circuit……………………………………………………..1370
Wiring Diagram and monitoring screen for message DWBXKY…………………………………………..1371
DWBKKA – Stick2 out solenoid open circuit…………………………………………………………..1372
Wiring Diagram and monitoring screen for message DWBKKA…………………………………………..1373
DWBKKB – Stick2 out solenoid short circuit………………………………………………………….1374
Wiring Diagram and monitoring screen for message DWBKKB…………………………………………..1375
DWBKKY – Stick2 out solenoid hot short circuit………………………………………………………1376
Wiring Diagram and monitoring screen for message DWBKKY…………………………………………..1377
DWBTKA – Clam2 open solenoid open circuit…………………………………………………………..1378
Wiring Diagram and monitoring screen for message DWBTKA…………………………………………..1379
DWBTKB – Clam2 open solenoid short circuit………………………………………………………….1380
Wiring Diagram and monitoring screen for message DWBTKB…………………………………………..1381
DWBTKY – Clam2 open solenoid hot short circuit………………………………………………………1382
Wiring Diagram and monitoring screen for message DWBTKY…………………………………………..1383
DWBPKA – Stick2 in solenoid open circuit……………………………………………………………1384
Wiring Diagram and monitoring screen for message DWBPKA…………………………………………..1385
DWBPKB – Stick2 in solenoid short circuit…………………………………………………………..1386
Wiring Diagram and monitoring screen for message DWBPKB…………………………………………..1387
DWBPKY – Stick2 in solenoid hot short circuit……………………………………………………….1388
Wiring Diagram and monitoring screen for message DWBPKY…………………………………………..1389
DWATKA – Bucket2 fill solenoid open circuit…………………………………………………………1390
Wiring Diagram and monitoring screen for message DWATKA…………………………………………..1391
DWATKB – Bucket2 fill solenoid short circuit………………………………………………………..1392
Wiring Diagram and monitoring screen for message DWATKB…………………………………………..1393
DWATKY – Bucket2 fill solenoid hot short circuit…………………………………………………….1394
Wiring Diagram and monitoring screen for message DWATKY…………………………………………..1395
DWAXKA – Bucket2 dump solenoid open circuit…………………………………………………………1396
Wiring Diagram and monitoring screen for message DWAXKA…………………………………………..1397
DWAXKB – Bucket2 dump solenoid short circuit………………………………………………………..1398
Wiring Diagram and monitoring screen for message DWAXKB…………………………………………..1399
DWAXKY – Bucket2 dump solenoid hot short circuit…………………………………………………….1400
Wiring Diagram and monitoring screen for message DWAXKY…………………………………………..1401
DWKFKA – Travel2 left backward sol. open circuit…………………………………………………….1402
Wiring Diagram and monitoring screen for message DWKFKA…………………………………………..1403
DWKFKB – Travel2 left backward sol. short circuit……………………………………………………1404
Wiring Diagram and monitoring screen for message DWKFKB…………………………………………..1405
DWKFKY – Travel2 left backward sol. hot short circuit………………………………………………..1406
Wiring Diagram and monitoring screen for message DWKFKY…………………………………………..1407
DWKBKA – Travel2 left forward sol. open circuit……………………………………………………..1408
Wiring Diagram and monitoring screen for message DWKBKA…………………………………………..1409
DWKBKB – Travel2 left forward sol. short circuit…………………………………………………….1410
Wiring Diagram and monitoring screen for message DWKBKB…………………………………………..1411
DWKBKY – Travel2 left forward sol. hot short………………………………………………………..1412
Wiring Diagram and monitoring screen for message DWKBKY…………………………………………..1413
D5ZWKA – Travel hour meter open circuit…………………………………………………………….1414
Wiring Diagram and monitoring screen for message D5ZWKA…………………………………………..1415
D5ZWKB – Travel hour meter short circuit……………………………………………………………1416
Wiring Diagram and monitoring screen for message D5ZWKB…………………………………………..1417
D1EUKA – Travel alarm relay open circuit……………………………………………………………1418
Wiring Diagram and monitoring screen for message D1EUKA…………………………………………..1419
D1EUKB – Travel alarm relay short circuit…………………………………………………………..1420
Wiring Diagram and monitoring screen for message D1EUKB…………………………………………..1421
DBX9KQ – Model Selection Abnormality……………………………………………………………….1422
Wiring Diagram and monitoring screen for message DBX9KQ…………………………………………..1423
DBXZKQ – Lever Control Selection Abnormality………………………………………………………..1424
Wiring Diagram and monitoring screen for message DBXZKQ…………………………………………..1425
DBXYKQ – Attachment selection abnormality…………………………………………………………..1426
Wiring Diagram – Attachment selection abnormality (DBXYKQ)………………………………………..1427
D561MA – Lock lever sol. power cut abnorm(VALVE/S1)………………………………………………….1428
Wiring Diagram 1 for message D561MA…………………………………………………………….1429
Wiring Diagram 2 for message D561MA…………………………………………………………….1430
Wiring Diagram 3 for message D561MA…………………………………………………………….1431
D563MA – Ladder up sensor sol cut abnorm(VLV/S1)…………………………………………………….1432
Wiring Diagram 1 for message D563MA…………………………………………………………….1433
Wiring Diagram 2 for message D563MA…………………………………………………………….1434
Wiring Diagram 3 for message D563MA…………………………………………………………….1435
DBX2KK – Solenoid Power Low Error(VALVE/S1 Con)……………………………………………………..1436
Wiring Diagram 1 for message DBX2KK…………………………………………………………….1437
Wiring Diagram 2 for message DBX2KK…………………………………………………………….1438
Wiring Diagram 3 for message DBX2KK…………………………………………………………….1439
DBX0KQ – VALVE/S1 Con Selection Abnormality…………………………………………………………1440
Wiring Diagram and monitoring screen for message DBX0KQ…………………………………………..1441
DBX0MA – VALVE/S1 Con Error……………………………………………………………………….1442
DWAQKA – Slew3 right solenoid open circuit………………………………………………………….1444
Wiring Diagram and monitoring screen for message DWAQKA…………………………………………..1445
DWAQKB – Slew3 right solenoid short circuit…………………………………………………………1446
Wiring Diagram and monitoring screen for message DWAQKB…………………………………………..1447
DWAQKY – Slew3 right solenoid hot short circuit……………………………………………………..1448
Wiring Diagram and monitoring screen for message DWAQKY…………………………………………..1449
DWALKA – Slew3 left solenoid open circuit…………………………………………………………..1450
Wiring Diagram and monitoring screen for message DWALKA…………………………………………..1451
DWALKB – Slew3 left solenoid short circuit………………………………………………………….1452
Wiring Diagram and monitoring screen for message DWALKB…………………………………………..1453
DWALKY – Slew3 left solenoid hot short circuit………………………………………………………1454
Wiring Diagram and monitoring screen for message DWALKY…………………………………………..1455
DWAUKA – Bucket3 fill solenoid open circuit…………………………………………………………1456
Wiring Diagram and monitoring screen for message DWAUKA…………………………………………..1457
DWAUKB – Bucket3 fill solenoid short circuit………………………………………………………..1458
Wiring Diagram and monitoring screen for message DWAUKB…………………………………………..1459
DWAUKY – Bucket3 fill solenoid hot short circuit…………………………………………………….1460
Wiring Diagram and monitoring screen for message DWAUKY…………………………………………..1461
DWAYKA – Bucket3 dump solenoid open circuit…………………………………………………………1462
Wiring Diagram and monitoring screen for message DWAYKA…………………………………………..1463
DWAYKB – Bucket3 dump solenoid short circuit………………………………………………………..1464
Wiring Diagram and monitoring screen for message DWAYKB…………………………………………..1465
DWAYKY – Bucket3 dump solenoid hot short circuit…………………………………………………….1466
Wiring Diagram and monitoring screen for message DWAYKY…………………………………………..1467
DWBGKA – Boom3 down solenoid open circuit…………………………………………………………..1468
Wiring Diagram and monitoring screen for message DWBGKA…………………………………………..1469
DWBGKB – Boom3 down solenoid short circuit………………………………………………………….1470
Wiring Diagram and monitoring screen for message DWBGKB…………………………………………..1471
DWBGKY – Boom3 down solenoid hot short circuit………………………………………………………1472
Wiring Diagram and monitoring screen for message DWBGKY…………………………………………..1473
DWBDKA – Boom4 up solenoid open circuit…………………………………………………………….1474
Wiring Diagram and monitoring screen for message DWBDKA…………………………………………..1475
DWBDKB – Boom4 up solenoid short circuit……………………………………………………………1476
Wiring Diagram and monitoring screen for message DWBDKB…………………………………………..1477
DWBDKY – Boom4 up solenoid hot short circuit………………………………………………………..1478
Wiring Diagram and monitoring screen for message DWBDKY…………………………………………..1479
DWBHKA – Boom4 down solenoid open circuit…………………………………………………………..1480
Wiring Diagram and monitoring screen for message DWBHKA…………………………………………..1481
DWBHKB – Boom4 down solenoid short circuit………………………………………………………….1482
Wiring Diagram and monitoring screen for message DWBHKB…………………………………………..1483
DWBHKY – Boom4 down solenoid hot short circuit………………………………………………………1484
Wiring Diagram and monitoring screen for message DWBHKY…………………………………………..1485
DWAVKA – Bucket4 fill solenoid open circuit…………………………………………………………1486
Wiring Diagram and monitoring screen for message DWAVKA…………………………………………..1487
DWAVKB – Bucket4 fill solenoid short circuit………………………………………………………..1488
Wiring Diagram and monitoring screen for message DWAVKB…………………………………………..1489
DWAVKY – Bucket4 fill solenoid hot short circuit…………………………………………………….1490
Wiring Diagram and monitoring screen for message DWAVKY…………………………………………..1491
DWAZKA – Bucket4 dump solenoid open circuit…………………………………………………………1492
Wiring Diagram and monitoring screen for message DWAZKA…………………………………………..1493
DWAZKB – Bucket4 dump solenoid short circuit………………………………………………………..1494
Wiring Diagram and monitoring screen for message DWAZKB…………………………………………..1495
DWAZKY – Bucket4 dump solenoid hot short circuit…………………………………………………….1496
Wiring Diagram and monitoring screen for message DWAZKY…………………………………………..1497
DWBMKA – Stick4 out solenoid open circuit…………………………………………………………..1498
Wiring Diagram and monitoring screen for message DWBMKA…………………………………………..1499
DWBMKB – Stick4 out solenoid short circuit………………………………………………………….1500
Wiring Diagram and monitoring screen for message DWBMKB…………………………………………..1501
DWBMKY – Stick4 out solenoid hot short circuit………………………………………………………1502
Wiring Diagram and monitoring screen for message DWBMKY…………………………………………..1503
DWBRKA – Stick4 in solenoid open circuit……………………………………………………………1504
Wiring Diagram and monitoring screen for message DWBRKA…………………………………………..1505
DWBRKB – Stick4 in solenoid short circuit…………………………………………………………..1506
Wiring Diagram and monitoring screen for message DWBRKB…………………………………………..1507
DWBRKY – Stick4 in solenoid hot short circuit……………………………………………………….1508
Wiring Diagram and monitoring screen for message DWBRKY…………………………………………..1509
DWKRKA – Travel4 right backward sol. open circuit……………………………………………………1510
Wiring Diagram and monitoring screen for message DWKRKA…………………………………………..1511
DWKRKB – Travel4 right backward sol. short circuit…………………………………………………..1512
Wiring Diagram and monitoring screen for message DWKRKB…………………………………………..1513
DWKRKY – Travel4 right backward sol. hot short………………………………………………………1514
Wiring Diagram and monitoring screen for message DWKRKY…………………………………………..1515
DWKMKA – Travel4 right forward sol. open circuit…………………………………………………….1516
Wiring Diagram and monitoring screen for message DWKMKA…………………………………………..1517
DWKMKB – Travel4 right forward sol. short circuit……………………………………………………1518
Wiring Diagram and monitoring screen for message DWKMKB…………………………………………..1519
DWKMKY – Travel4 right forward sol. hot short……………………………………………………….1520
Wiring Diagram and monitoring screen for message DWKMKY…………………………………………..1521
DXEDKA – Hydraulic slew brake epc sol. open circuit………………………………………………….1522
Wiring Diagram and monitoring screen for message DXEDKA…………………………………………..1523
DXEDKB – Hyd. slew brake epc sol. short circuit……………………………………………………..1524
Wiring Diagram and monitoring screen for message DXEDKB…………………………………………..1525
DXEDKY – Hyd. slew brake epc sol. hot short circuit………………………………………………….1526
Wiring Diagram and monitoring screen for message DXEDKY…………………………………………..1527
DWKVKA – Boom4 float solenoid open circuit………………………………………………………….1528
Wiring Diagram and monitoring screen for message DWKVKA…………………………………………..1529
DWKVKB – Boom4 float solenoid short circuit…………………………………………………………1530
Wiring Diagram and monitoring screen for message DWKVKB…………………………………………..1531
DWKVKY – Boom4 float solenoid hot short circuit……………………………………………………..1532
Wiring Diagram and monitoring screen for message DWKVKY…………………………………………..1533
DWKWKA – Stick1 float solenoid open circuit…………………………………………………………1534
Wiring Diagram and monitoring screen for message DWKWKA…………………………………………..1535
DWKWKB – Stick1 float solenoid short circuit………………………………………………………..1536
Wiring Diagram and monitoring screen for message DWKWKB…………………………………………..1537
DWKWKY – Stick1 float solenoid hot short circuit…………………………………………………….1538
Wiring Diagram and monitoring screen for message DWKWKY…………………………………………..1539
DWKZKA – Stick4 float solenoid open circuit…………………………………………………………1540
Wiring Diagram and monitoring screen for message DWKZKA…………………………………………..1541
DWKZKB – Stick4 float solenoid short circuit………………………………………………………..1542
Wiring Diagram and monitoring screen for message DWKZKB…………………………………………..1543
DWKZKY – Stick4 float solenoid hot short circuit…………………………………………………….1544
Wiring Diagram and monitoring screen for message DWKZKY…………………………………………..1545
DBY9KQ – Model Selection Abnormality……………………………………………………………….1546
Wiring Diagram and monitoring screen for message DBY9KQ…………………………………………..1547
DBYZKQ – Lever Control Selection Abnormality………………………………………………………..1548
Wiring Diagram and monitoring screen for message DBYZKQ…………………………………………..1549
DBYYKQ – Attachment selection abnormality…………………………………………………………..1550
Wiring Diagram – Attachment selection abnormality (DBYYKQ)………………………………………..1551
D562MA – Lock lever sol power cut abnorm(VALVE/S2)…………………………………………………..1552
Wiring Diagram 1 and monitoring screen for message D562MA…………………………………………1553
Wiring Diagram 2 for message D562MA…………………………………………………………….1554
Wiring Diagram 3 for message D562MA…………………………………………………………….1555
D564MA – Ladder up sensor sol cut abnorm(VLV/S2)…………………………………………………….1556
Wiring Diagram 1 for message D564MA…………………………………………………………….1557
Wiring Diagram 2 for message D564MA…………………………………………………………….1558
Wiring Diagram 3 for message D564MA…………………………………………………………….1559
DBY2KK – Solenoid Power Low Error(VALVE/S2 Con)……………………………………………………..1560
Wiring Diagram 1 for message DBY2KK…………………………………………………………….1561
Wiring Diagram 2 for message DBY2KK…………………………………………………………….1562
Wiring Diagram 3 for message DBY2KK…………………………………………………………….1563
DBY0KQ – VALVE/S2 Con Selection Abnormality…………………………………………………………1564
Wiring Diagram and monitoring screen for message DBY0KQ…………………………………………..1565
DBY0MA – VALVE/S2 Con Error……………………………………………………………………….1566
DGB0MA – Motor1 bearing D end temp sensor abnormal…………………………………………………..1568
Wiring Diagram and monitoring screen for message DGB0MA…………………………………………..1569
DGB1MA – Motor1 bearing no D E temp sensor abnormal………………………………………………….1570
Wiring Diagram and monitoring screen for message DGB1MA…………………………………………..1571
DGB6MA – Motor1 winding temp sensor1 abnormality…………………………………………………….1572
DGB7MA – Motor1 winding temp sensor2 abnormality…………………………………………………….1572
DGB8MA – Motor1 winding temp sensor3 abnormality…………………………………………………….1572
Wiring Diagram and monitoring screen for message DGB6MA…………………………………………..1574
D552KK – Batt. volt emergency power supply abnormal………………………………………………….1576
Emergency voltage monitoring screen for message D552KK……………………………………………1576
Wiring Diagram for message D552KK………………………………………………………………1577
D1HEKA – Heating cab contactor1 open circuit………………………………………………………..1578
Wiring Diagram and monitoring screen for message D1HEKA…………………………………………..1579
D1HEKB – Heating cab contactor1 short circuit……………………………………………………….1580
Wiring Diagram and monitoring screen for message D1HEKB…………………………………………..1581
D1HFKA – Heating cab contactor2 open circuit………………………………………………………..1582
Wiring Diagram and monitoring screen for message D1HFKA…………………………………………..1583
D1HFKB – Heating cab contactor2 short circuit……………………………………………………….1584
Wiring Diagram and monitoring screen for message D1HFKB…………………………………………..1585
D1HGKA – Heating cab contactor3 open circuit………………………………………………………..1586
Wiring Diagram and monitoring screen for message D1HGKA…………………………………………..1587
D1HGKB – Heating cab contactor3 short circuit……………………………………………………….1588
Wiring Diagram and monitoring screen for message D1HGKB…………………………………………..1589
D1HHKA – Electric heating error reset line open……………………………………………………..1590
Wiring Diagram and monitoring screen for message D1HHKA…………………………………………..1591
D1HHKB – Electric heating error reset line short…………………………………………………….1592
Wiring Diagram and monitoring screen for message D1HHKB…………………………………………..1593
D1HJKA – Motor1 standstill heating contactor open……………………………………………………1594
Wiring Diagram and monitoring screen for message D1HJKA…………………………………………..1595
D1HJKB – Motor1 standstill heating contactor short…………………………………………………..1596
Wiring Diagram and monitoring screen for message D1HJKB…………………………………………..1597
D1HLKA – Blower cabinet wall relay open circuit……………………………………………………..1598
Wiring Diagram and monitoring screen for message D1HLKA…………………………………………..1599
D1HLKB – Blower cabinet wall relay short circuit…………………………………………………….1600
Wiring Diagram and monitoring screen for message D1HLKB…………………………………………..1601
D1HMKA – Blower operator seat relay open circuit…………………………………………………….1602
Wiring Diagram and monitoring screen for message D1HMKA…………………………………………..1603
D1HMKB – Blower operator seat relay short circuit……………………………………………………1604
Wiring Diagram and monitoring screen for message D1HMKB…………………………………………..1605
K@3AMA – Fire supp. switch cabinet circuit abnormal………………………………………………….1606
Wiring Diagram and monitoring screen for message K@3AMA…………………………………………..1607
DCP9KQ – Model Selection Abnormality……………………………………………………………….1608
Wiring Diagram and monitoring screen for message DCP9KQ…………………………………………..1609
DCP2KK – Solenoid Power Low Error(ELEC Con)…………………………………………………………1610
Wiring Diagram and monitoring screen for message DCP2KK…………………………………………..1611
DAP0KQ – ELECTRIC Con Selection Abnormality…………………………………………………………1612
Wiring Diagram and monitoring screen for message DAP0KQ…………………………………………..1613
DCP0MA – ELECTRIC Con Error……………………………………………………………………….1614
DJH2L5 – Hydraulic oil level signal mismatch………………………………………………………..1616
Wiring Diagram and monitoring screen for message DJH2L5…………………………………………..1617
DJH2KX – Hydraulic oil level sensor abnormality……………………………………………………..1618
Wiring Diagram and monitoring screen for message DJH2KX…………………………………………..1619
DH2GKX – Suction tank pressure sensor abnormality……………………………………………………1620
Wiring Diagram and monitoring screen for message DH2GKX…………………………………………..1621
DH2HKX – Oil cooler pressure sensor abnormality……………………………………………………..1622
Wiring Diagram and monitoring screen for message DH2HKX…………………………………………..1623
DH2JKX – Preload valve return oil press abnormality………………………………………………….1624
Wiring Diagram and monitoring screen for message DH2JKX…………………………………………..1625
DHSUKX – X2 pressure sensor abnormality…………………………………………………………….1626
Wiring Diagram and monitoring screen for message DHSUKX…………………………………………..1627
DGE5MA – Ambient air temp sensor abnormality………………………………………………………..1628
Wiring Diagram and monitoring screen for message DGE5MA…………………………………………..1629
DH2KKX – Return oil chamber press. sensor abnormal…………………………………………………..1630
Wiring Diagram and monitoring screen for message DH2KKX…………………………………………..1631
DH2LKX – Leak oil chamber press. sensor abnormality………………………………………………….1632
Wiring Diagram and monitoring screen for message DH2LKX…………………………………………..1633
D5ZXMA – Impulse kWh-meter signal abnormality……………………………………………………….1634
Wiring Diagram and monitoring screen for message D5ZXMA…………………………………………..1635
DJE5L4 – SLS sensor system abnormality……………………………………………………………..1636
Wiring Diagram and monitoring screen for message DJE5L4…………………………………………..1637
DJE6L4 – CLS sensor system abnormality……………………………………………………………..1638
Wiring Diagram and monitoring screen for message DJE6L4…………………………………………..1639
DBB3KK – Abnormality in VBAT voltage……………………………………………………………….1640
Wiring Diagram for message DBB3KK………………………………………………………………1641
DBB0KK – KOMTRAX Plus source voltage Error………………………………………………………….1642
Wiring Diagram for message DBB0KK………………………………………………………………1643
DBB0KQ – KOMTRAX Plus Connector Mismatch……………………………………………………………1644
Wiring Diagram for message DBB0KQ………………………………………………………………1645
DBB5KP – 5V sensor1 power abnormality………………………………………………………………1646
Wiring Diagram – 5V sensor1 power abnormality (DBB5KP)……………………………………………1647
DBB6KP – 24V Sensor Power Abnormality………………………………………………………………1648
Wiring Diagram – 24V sensor power abnormality (DBB6KP)……………………………………………1649
DA2RKR – CAN1 Discon (Pump Con)……………………………………………………………………1650
Wiring Diagram for message DA2RKR………………………………………………………………1651
DBWRKR – CAN1 Discon (Valve/M Con)…………………………………………………………………1652
Wiring Diagram for message DBWRKR………………………………………………………………1653
DBXRKR – CAN1 Discon (Valve/S1 Con)………………………………………………………………..1654
Wiring Diagram for message DBXRKR………………………………………………………………1655
DBYRKR – CAN1 Discon (Valve/S2 Con)………………………………………………………………..1656
Wiring Diagram for message DBYRKR………………………………………………………………1657
DCPRKR – CAN1 Discon (Electric Con)………………………………………………………………..1658
Wiring Diagram for message DCPRKR………………………………………………………………1659
DA2QKR – CAN2 Discon (Pump Con)……………………………………………………………………1660
Wiring Diagram for message DA2QKR………………………………………………………………1661
DBWQKR – CAN2 Discon (Valve/M Con)…………………………………………………………………1662
Wiring Diagram for message DBWQKR………………………………………………………………1663
DBXQKR – CAN2 Discon (Valve/S1 Con)………………………………………………………………..1664
Wiring Diagram for message DBXQKR………………………………………………………………1665
DBYQKR – CAN2 Discon (Valve/S2 Con)………………………………………………………………..1666
Wiring Diagram for message DBYQKR………………………………………………………………1667
DCPQKR – CAN2 Discon (Electric Con)………………………………………………………………..1668
Wiring Diagram for message DCPQKR………………………………………………………………1669
DBBQKR – CAN2 Discon (KOMTRAX Plus)………………………………………………………………..1670
Wiring Diagram for message DBBQKR………………………………………………………………1671
D19YKB – Emergency Lighting Ladder Relay Short Circuit……………………………………………….1672
Wiring Diagram and monitoring screen for message D19YKB…………………………………………..1673
DV00KB – Shutdown Buzzer Short Circuit……………………………………………………………..1674
Wiring Diagram and monitoring screen for message DV00KB…………………………………………..1675
7 Troubleshooting by Symptoms…………………………………………………………………………1677
7.1 Symptoms of the E-motor(s) and related parts…………………………………………………….1678
SEM001 – Starting the E-motor(s) is not possible…………………………………………………….1678
SEM002 – Stopping the E-motor(s) is not possible…………………………………………………….1679
SEM003 – E-motor has excessive vibration……………………………………………………………1680
View onto the coupling for SEM003………………………………………………………………1681
SEM004 – Abnormal noise coming from the E-motor(s)…………………………………………………..1682
SEM005 – E-motor lacks output (low power)…………………………………………………………..1684
View onto the PM CLINIC sheet (power check) for SEM005……………………………………………1685
SEM006 – Air-to-Air motor cooling system not sufficient………………………………………………1686
Exemplary view onto the Air-to-Air motor cooling system for SEM006…………………………………1687
SEM007 – Motor shuts down during start……………………………………………………………..1688
Signal wiring for the phases (SEM007)…………………………………………………………..1689
SEM008 – Substation main circuit breaker tripped…………………………………………………….1690
Net-line supply overview (SEM008)………………………………………………………………1691
Electric energy consumption (SEM008)……………………………………………………………1692
Motor current overview (SEM008)………………………………………………………………..1693
7.2 Symptoms of the Hydraulic System……………………………………………………………….1694
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function)…..1694
SHY002 – No work equipment, travel, or swing movement………………………………………………..1696
SHY003 – Work equipment has too much hydraulic drift…………………………………………………1697
SHY004 – Work equipment has big time lag……………………………………………………………1698
SHY005 – Machine deviates during travel movement…………………………………………………….1699
SHY006 – Machine does not swing (or it swings very low)………………………………………………1700
Slew brake block (SHY006)……………………………………………………………………..1701
SHY007 – Swing acceleration is poor………………………………………………………………..1702
SHY008 – Excessive overrun when stopping swing………………………………………………………1704
SHY009 – Floating system without function…………………………………………………………..1706
SHY010 – Abnormal noise coming from SRV or MRV………………………………………………………1707
SHY011 – Track tensioning system without function……………………………………………………1708
Track tensioning – overview (SHY011)……………………………………………………………1709
SHY012 – Ladder does not move, or slow movement……………………………………………………..1710
SHY013 – The hydraulic driven grease pump does not move………………………………………………1712
SHY014 – Abnormal track chain movement during digging………………………………………………..1714
SHY015 – Swing parking brake without function……………………………………………………….1715
SHY016 – Travel parking brake without function………………………………………………………1716
7.3 Symptoms of the Mechanical System………………………………………………………………1718
SME001 – Abnormal noise around the PTO / hydraulic pumps……………………………………………..1718
SME002 – There is a big shock when stopping swing……………………………………………………1719
SME003 – There is a big abnormal noise when moving/stopping swing……………………………………..1720
SME004 – Abnormal noise coming from a travel gearbox…………………………………………………1722
SME005 – Abnormal noise coming from the work equipment (lack of grease)………………………………..1724
SME006 – Abnormal idler movement…………………………………………………………………..1726
SME007 – Leak at the PTO shaft seal………………………………………………………………..1728
7.4 Symptoms of Additional Systems…………………………………………………………………1730
SAD001 – Air conditioner for the cabin does not work…………………………………………………1730
Exemplary view onto A/C test tools & A/C filling and service station……………………………….1731
SAD002 – Air conditioner LV cabinet does not work……………………………………………………1732
Exemplary view onto A/C test tools & A/C filling and service station……………………………….1733
SAD003 – Air conditioner HV cabinet does not work……………………………………………………1734
Exemplary view onto A/C test tools & A/C filling and service station……………………………….1735
50 DISASSEMBLY & ASSEMBLY
……………………………………………………………………………….1737
TOC………………………………………………………………………………………………..1739
1 Superstructure…………………………………………………………………………………….1747
1.1 Superstructure / machine house overview…………………………………………………………1748
1.2 Batteries……………………………………………………………………………………1750
1.2.1 Removal of the batteries…………………………………………………………………1750
1.2.2 Replacement of the batteries……………………………………………………………..1752
1.3 Electric motor……………………………………………………………………………….1753
1.3.1 Removal of the electric motor…………………………………………………………….1753
1.3.2 Replacement of the electric motor…………………………………………………………1758
1.3.3 Final alignment of the electric motor……………………………………………………..1761
1.3.4 Capacitor assembly………………………………………………………………………1762
1.3.4.1 Removal of the capacitor assembly……………………………………………………1763
1.3.4.2 Replacement of the capacitor assembly………………………………………………..1765
1.4 Coupling assembly…………………………………………………………………………….1766
1.4.1 Vulkan coupling…………………………………………………………………………1766
1.4.1.1 Removal of the Vulkan coupling………………………………………………………1768
1.4.1.2 Replacement of the Vulkan coupling…………………………………………………..1770
1.5 PTO…………………………………………………………………………………………1772
1.5.1 Overview of the PTO and the mounting of the pumps…………………………………………..1772
1.5.2 Main pumps……………………………………………………………………………..1774
1.5.2.1 Preparatory works for main pump removal………………………………………………1774
1.5.2.2 Removal of main pump 1……………………………………………………………..1777
1.5.2.3 Replacement of main pump 1………………………………………………………….1779
1.5.2.4 Removal of main pump 2……………………………………………………………..1780
1.5.2.5 Replacement of main pump 2………………………………………………………….1782
1.5.2.6 Removal of main pump 3……………………………………………………………..1783
1.5.2.7 Replacement of main pump 3………………………………………………………….1783
1.5.2.8 Removal of main pump 4……………………………………………………………..1783
1.5.2.9 Replacement of main pump 4………………………………………………………….1783
1.5.3 PTO oil circulation pump (auxiliary pump)………………………………………………….1784
1.5.3.1 Removal of the oil circulation pump (auxiliary pump)…………………………………..1784
1.5.3.2 Replacement of the oil circulation pump (auxiliary pump)……………………………….1786
1.5.4 Pilot oil pump………………………………………………………………………….1787
1.5.4.1 Removal of the pilot oil pump……………………………………………………….1787
1.5.4.2 Replacement of the pilot oil pump……………………………………………………1787
1.5.5 Hydraulic oil cooler fan drive pump……………………………………………………….1789
1.5.5.1 Removal of the hydraulic oil cooler fan drive pump…………………………………….1789
1.5.5.2 Replacement of the hydraulic oil cooler fan drive pump…………………………………1791
1.5.6 Pump distributor gearbox (PTO)……………………………………………………………1792
1.5.6.1 Removal of the pump distributor gearbox (PTO)…………………………………………1794
1.5.6.2 Replacement of the pump distributor gearbox (PTO)……………………………………..1796
1.6 Hydraulics…………………………………………………………………………………..1798
1.6.1 Hydraulic oil cooler assembly…………………………………………………………….1798
1.6.1.1 Removal of hydraulic cooler fan……………………………………………………..1799
1.6.1.2 Replacement of hydraulic cooler fan………………………………………………….1800
1.6.1.3 Removal of hydraulic cooler fan bearings and motors……………………………………1801
1.6.1.4 Replacement of hydraulic cooler fan bearings and motors………………………………..1803
1.6.1.5 Removal of the hydraulic oil coolers…………………………………………………1804
1.6.1.6 Replacement of the hydraulic oil coolers……………………………………………..1807
1.6.1.7 Removal of the hydraulic oil cooler assembly………………………………………….1808
1.6.1.8 Replacement of the hydraulic oil cooler assembly………………………………………1813
1.6.2 Main gate valve…………………………………………………………………………1814
1.6.2.1 Removal of the main gate valve………………………………………………………1814
1.6.2.2 Replacement of the main gate valve…………………………………………………..1815
1.6.3 Hydraulic oil reservoir………………………………………………………………….1816
1.6.3.1 Removal of the hydraulic oil reservoir……………………………………………….1817
1.6.3.2 Replacement of the hydraulic oil reservoir……………………………………………1823
1.6.4 Main control valve blocks………………………………………………………………..1826
1.6.4.1 General information………………………………………………………………..1826
1.6.4.2 Removal of the main control valve blocks……………………………………………..1834
1.6.4.3 Replacement of the main control valve blocks………………………………………….1838
1.6.5 Main relief valves (MRV)…………………………………………………………………1839
1.6.5.1 Removal of the MRV at the main control valve blocks……………………………………1839
1.6.5.2 Replacement of the MRV at the main control valve blocks………………………………..1840
1.6.6 Service line relief valves (SRV)………………………………………………………….1842
1.6.6.1 Removal of SRV on main control valve block……………………………………………1843
1.6.6.2 Replacement of SRV on main control valve blocks……………………………………….1844
1.6.7 Anti-cavitation valves (ACV)……………………………………………………………..1845
1.6.7.1 Removal of single ACV at the manifold………………………………………………..1847
1.6.7.2 Replacement of single ACV at the manifold…………………………………………….1850
1.6.7.3 Removal of ACV with attached check valve at the manifold……………………………….1851
1.6.7.4 Replacement of ACV with attached check valve at the manifold……………………………1853
1.6.7.5 Removal of ACV on main control valve blocks…………………………………………..1855
1.6.7.6 Replacement of ACV on main control valve blocks……………………………………….1856
1.6.8 Throttle check valves……………………………………………………………………1858
1.6.8.1 Removal of throttle check valves…………………………………………………….1861
1.6.8.2 Replacement of throttle check valves…………………………………………………1863
1.6.9 Diffuser block (FSA only)………………………………………………………………..1864
1.6.9.1 Removal of the Diffuser block at the manifold…………………………………………1864
1.6.9.2 Replacement of the Diffuser block at the manifold……………………………………..1866
1.6.10 Manifold………………………………………………………………………………1867
1.6.10.1 Removal of the manifold……………………………………………………………1867
1.6.10.2 Replacement of the manifold………………………………………………………..1870
1.7 Slew system………………………………………………………………………………….1871
1.7.1 Slew gear………………………………………………………………………………1871
1.7.1.1 Removal of the slew gear……………………………………………………………1873
1.7.1.2 Replacement of the slew gear………………………………………………………..1876
1.7.2 Swing motor…………………………………………………………………………….1878
1.7.2.1 Removal of the swing motor………………………………………………………….1879
1.7.2.2 Replacement of the swing motor………………………………………………………1881
1.7.3 Slew parking brake………………………………………………………………………1882
1.7.3.1 Removal/disassembly of the slew parking brake (L&S)……………………………………1883
1.7.3.2 Replacement/assembly of the slew parking brake (L&S)…………………………………..1886
1.7.3.3 Removal of the slew parking brake (siebenhaar)………………………………………..1889
1.7.3.4 Replacement of the slew parking brake (Siebenhaar)…………………………………….1892
1.7.4 Dynamic slew brake………………………………………………………………………1896
1.7.4.1 Removal of the slew brake valve……………………………………………………..1899
1.7.4.2 Replacement of the slew brake valve………………………………………………….1901
1.7.5 Swing circle……………………………………………………………………………1902
1.7.5.1 Removal of the swing circle…………………………………………………………1903
1.7.5.2 Replacement of the swing circle……………………………………………………..1906
1.7.6 Swing circle lubrication pinion (dummy wheel)………………………………………………1910
1.7.6.1 Removal of the lubrication pinion assembly……………………………………………1911
1.7.6.2 Replacement of the lubrication pinion assembly………………………………………..1913
1.8 Lubrication pumps…………………………………………………………………………….1914
1.8.1 Removal of the lubrication pump…………………………………………………………..1914
1.8.2 Replacement of the lubricating pump……………………………………………………….1916
1.9 Operator’s cab……………………………………………………………………………….1918
1.9.1 Removal of the operator’s cab…………………………………………………………….1920
1.9.2 Replacement of the operator’s cab…………………………………………………………1925
1.9.3 Cab-mounts……………………………………………………………………………..1926
1.9.3.1 Removal of the cab-mounts…………………………………………………………..1926
1.9.3.2 replacement of the cab-mounts……………………………………………………….1928
1.9.4 Front window……………………………………………………………………………1930
1.9.4.1 Removal of the front window…………………………………………………………1930
1.9.4.2 Replacement of the front window……………………………………………………..1931
1.9.5 Operator’s seat…………………………………………………………………………1932
1.9.5.1 Removal of the operator’s seat………………………………………………………1932
1.9.5.2 Replacement of the operator’s seat…………………………………………………..1933
1.10 Cab base (medium voltage switch cabinet)……………………………………………………….1934
1.10.1 Removal of the cab base…………………………………………………………………1934
1.10.2 Replacement of the cab base……………………………………………………………..1937
1.10.3 Pump controller………………………………………………………………………..1939
1.10.3.1 Removal of the pump controller……………………………………………………..1939
1.10.3.2 Replacement of the pump controller………………………………………………….1940
1.11 Access ladder……………………………………………………………………………….1942
1.11.1 Removal of the access ladder…………………………………………………………….1943
1.11.2 Replacement of the access ladder…………………………………………………………1945
1.11.3 Removal of the access ladder cylinder…………………………………………………….1947
1.11.4 Replacement of the access ladder cylinder…………………………………………………1949
1.12 Counterweight……………………………………………………………………………….1950
1.12.1 Removal of the counterweight…………………………………………………………….1951
1.12.2 Replacement of the counterweight…………………………………………………………1953
1.13 Superstructure Lifting……………………………………………………………………….1954
1.13.1 Remove the superstructure from the undercarriage…………………………………………..1954
1.13.2 Install the superstructure onto the undercarriage………………………………………….1959
1.14 High voltage switch cabinet…………………………………………………………………..1962
1.14.1 Removal of the high voltage switch cabinet………………………………………………..1962
1.14.2 Replacement of the high voltage switch cabinet…………………………………………….1967
1.15 Slip ring unit………………………………………………………………………………1968
1.15.1 Removal of the slip ring unit……………………………………………………………1969
1.15.2 Replacement of the slip ring unit………………………………………………………..1972
2 Undercarriage……………………………………………………………………………………..1973
2.1 Undercarriage overview………………………………………………………………………..1974
2.2 Travel system………………………………………………………………………………..1976
2.2.1 Track group…………………………………………………………………………….1976
2.2.1.1 Changing of the track group…………………………………………………………1976
2.2.2 Sprocket……………………………………………………………………………….1981
2.2.2.1 Removal of the sprocket…………………………………………………………….1981
2.2.2.2 Replacement of the sprocket…………………………………………………………1986
2.2.3 Guide wheels……………………………………………………………………………1988
2.2.3.1 Removal of the guide wheel assembly………………………………………………….1988
2.2.3.2 Replacement of the guide wheel assembly………………………………………………1990
2.2.4 Track tensioning accumulators…………………………………………………………….1992
2.2.4.1 Removal of the low pressure accumulators……………………………………………..1992
2.2.4.2 Replacement of the low pressure accumulators………………………………………….1993
2.2.4.3 Removal of the high pressure accumulators…………………………………………….1995
2.2.4.4 Replacement of the high pressure accumulators…………………………………………1996
2.2.5 Track tension valve block………………………………………………………………..1997
2.2.5.1 Removal of the track tensioning valve block…………………………………………..1997
2.2.5.2 Replacement of the track tensioning valve block……………………………………….1999
2.2.6 Track tensioning cylinders……………………………………………………………….2000
2.2.6.1 Removal of the track tensioning cylinders…………………………………………….2000
2.2.6.2 Replacement of the track tensioning cylinders…………………………………………2002
2.2.7 Hydraulic hoses of the track tensioning system……………………………………………..2003
2.2.7.1 Precursory work……………………………………………………………………2003
2.2.7.2 Substitute the hydraulic hoses inside the car body…………………………………….2005
2.2.7.3 Substitute the hydraulic hoses between car body and crawler frame……………………….2005
2.2.7.4 Substitute the hydraulic hoses inside the crawler frame………………………………..2007
2.2.7.5 Subsequent work……………………………………………………………………2007
2.2.8 Travel brake valve block (overspeed valve)…………………………………………………2009
2.2.8.1 Removal of the travel brake valve block………………………………………………2012
2.2.8.2 Replacement of the travel brake valve block…………………………………………..2013
2.2.9 Travel motors…………………………………………………………………………..2014
2.2.9.1 Removal of the travel motors………………………………………………………..2014
2.2.9.2 Replacement of the travel motors…………………………………………………….2016
2.2.10 Travel parking brake……………………………………………………………………2018
2.2.10.1 Travel parking brake overview………………………………………………………2018
2.2.10.2 Removal/disassembly of the travel parking brake (L&S)…………………………………2023
2.2.10.3 Replacement/assembly of the travel parking brake (L&S)………………………………..2026
2.2.10.4 Removal/disassembly of the travel parking brake (Zollern)……………………………..2029
2.2.10.5 Replacement/assembly of the travel parking brake (Zollern)…………………………….2032
2.2.11 Travel gear box………………………………………………………………………..2034
2.2.11.1 Removal of the travel gear box……………………………………………………..2035
2.2.11.2 Replacement of the travel gear box………………………………………………….2037
2.2.12 Carrier roller…………………………………………………………………………2039
2.2.12.1 Removal of the carrier roller assembly………………………………………………2039
2.2.12.2 Replacement of the carrier roller assembly…………………………………………..2042
2.2.13 Track roller…………………………………………………………………………..2043
2.2.13.1 Removal of the track roller assembly………………………………………………..2043
2.2.13.2 Replacement of the track roller assembly…………………………………………….2045
2.3 Car body…………………………………………………………………………………….2046
2.3.1 Removal of the car body and the crawler carriers (type with mounting pins)…………………….2046
2.3.2 Replacement of the car body and the crawler carriers (type with mounting pins)…………………2050
2.3.3 Removal of the car Body and the crawler carriers (type with bolted connection)…………………2054
2.3.4 Replacement of the car body and the crawler carriers (type with bolted connection)……………..2060
2.3.5 Rotary joint……………………………………………………………………………2068
2.3.5.1 Removal of the rotary joint…………………………………………………………2068
2.3.5.2 Replacement of the rotary joint……………………………………………………..2071
2.4 Cable drum (optional)…………………………………………………………………………2072
2.4.1 Preparatory work for the removal and replacement of the cable drum assembly……………………2073
2.4.2 Removal of the cable drum assembly………………………………………………………..2074
2.4.3 Replacement of the cable drum assembly…………………………………………………….2075
2.5 Cable supply…………………………………………………………………………………2078
2.5.1 Preparatory work for the removal and replacement of the cable supply………………………….2079
2.5.2 Removal of the cable supply………………………………………………………………2080
2.5.3 Replacement of the cable supply assembly…………………………………………………..2082
3 Attachment………………………………………………………………………………………..2085
3.1 Backhoe……………………………………………………………………………………..2086
3.1.1 Boom…………………………………………………………………………………..2087
3.1.1.1 Removal of the Boom………………………………………………………………..2087
3.1.1.2 Replacement of the boom…………………………………………………………….2090
3.1.1.3 Removal of the boom cylinders……………………………………………………….2092
3.1.1.4 Replacement of the boom cylinders……………………………………………………2097
3.1.2 Stick………………………………………………………………………………….2102
3.1.2.1 Removal of the Stick……………………………………………………………….2102
3.1.2.2 Replacement of the Stick……………………………………………………………2106
3.1.2.3 Removal of the Stick Cylinders………………………………………………………2108
3.1.2.4 Replacement of the Stick cylinders…………………………………………………..2113
3.1.3 Bucket…………………………………………………………………………………2118
3.1.3.1 Removal of the bucket………………………………………………………………2118
3.1.3.2 Replacement of the bucket…………………………………………………………..2121
3.1.3.3 Removal of the Bucket Cylinders……………………………………………………..2122
3.1.3.4 Replacement of the Bucket Cylinders………………………………………………….2128
3.1.4 Bucket link rod and steering rods…………………………………………………………2131
3.1.4.1 Removal of the bucket link rod………………………………………………………2131
3.1.4.2 Replacement of the bucket link rod…………………………………………………..2133
3.1.4.3 Removal of the steering rods………………………………………………………..2134
3.1.4.4 Replacement of the steering rods…………………………………………………….2137
3.1.5 Ground engaging tools (GET)………………………………………………………………2138
3.1.5.1 Removal and replacement of the GET…………………………………………………..2138
3.1.6 Hydraulic hoses at the backhoe attachment………………………………………………….2140
3.1.6.1 Substitute the boom arc hoses……………………………………………………….2140
3.1.6.2 Substitute the boom cylinder hoses…………………………………………………..2146
3.1.6.3 Substitute the stick cylinder hoses………………………………………………….2150
3.1.6.4 Substitute the bucket cylinder hoses…………………………………………………2154
3.2 Faceshovel…………………………………………………………………………………..2158
3.2.1 Using the installation tools for hydraulic cylinders………………………………………..2159
3.2.2 Boom…………………………………………………………………………………..2160
3.2.2.1 Removal of the boom………………………………………………………………..2160
3.2.2.2 Replacement of the boom…………………………………………………………….2167
3.2.2.3 Removal of the boom cylinders……………………………………………………….2172
3.2.2.4 Replacement of the boom cylinders……………………………………………………2176
3.2.3 Stick………………………………………………………………………………….2180
3.2.3.1 Removal of the stick……………………………………………………………….2180
3.2.3.2 Replacement of the stick……………………………………………………………2184
3.2.3.3 Removal of the stick cylinders………………………………………………………2188
3.2.3.4 Replacement of the stick cylinders…………………………………………………..2192
3.2.4 Bull Clam bucket………………………………………………………………………..2196
3.2.4.1 Removal of the bull clam bucket……………………………………………………..2196
3.2.4.2 Replacement of the bull clam bucket………………………………………………….2202
3.2.4.3 Removal of the bucket cylinders……………………………………………………..2204
3.2.4.4 Replacement of the bucket cylinders………………………………………………….2208
3.2.4.5 Removal of the clam cylinders……………………………………………………….2212
3.2.4.6 Replacement of the clam cylinders……………………………………………………2216
3.2.5 Ground engaging tools (GET)………………………………………………………………2219
3.2.5.1 Removal and replacement of the GET…………………………………………………..2219
3.2.6 Hydraulic hoses at the Faceshovel attachment……………………………………………….2220
3.2.6.1 Substitute the boom arc hoses……………………………………………………….2220
3.2.6.2 Substitute the boom cylinder hoses…………………………………………………..2226
3.2.6.3 Substitute the stick arc hoses………………………………………………………2230
3.2.6.4 Substitute the stick cylinder hoses………………………………………………….2234
3.2.6.5 Substitute the bucket cylinder hoses…………………………………………………2238
3.2.6.6 Substitute the clam cylinder hoses…………………………………………………..2242
3.3 Metering valves (grease injectors) at the attachment……………………………………………..2250
3.3.1 Operation test of the metering valves (grease injectors)…………………………………….2251
3.3.2 Removal of the metering valves (grease injectors)…………………………………………..2252
3.3.3 Replacement of the metering valves (grease injectors)……………………………………….2254
3.4 Cylinder bypass test………………………………………………………………………….2255
4 Service Information………………………………………………………………………………..2257
4.1 Classification of Voltages for KMG Electric Shovels………………………………………………2258
4.2 Fluids and lubricants…………………………………………………………………………2258
4.3 Lifting Gears………………………………………………………………………………..2259
4.4 Safety hints for sling accessory……………………………………………………………….2261
4.5 Filling capacities……………………………………………………………………………2262
4.6 Work instructions…………………………………………………………………………….2263
4.6.1 Remove / install the crawler carrier………………………………………………………2263
4.7 Weight tables………………………………………………………………………………..2264
4.7.1 Superstructure………………………………………………………………………….2264
4.7.2 Undercarriage…………………………………………………………………………..2266
4.7.3 Backhoe attachment (BHA)…………………………………………………………………2267
4.7.4 Face shovel attachment (FSA)……………………………………………………………..2268
4.8 Torque charts according to KOMATSU company standard………………………………………………2269
4.8.1 Metric standard thread…………………………………………………………………..2269
4.8.2 Metric fine thread………………………………………………………………………2270
4.8.3 Cummins motor torques – metric……………………………………………………………2271
4.8.4 Cummins motor torques – U.S. customary…………………………………………………….2271
4.8.5 Flange connections………………………………………………………………………2272
4.9 Blind plugs………………………………………………………………………………….2273
4.9.1 Dummy plates for SAE–flanges……………………………………………………………..2273
4.9.2 Classification of threads to the nominal width……………………………………………..2275
4.9.3 Plugs and fittings according to DIN 2353…………………………………………………..2276
4.10 Conversion table…………………………………………………………………………….2277
4.10.1 Method of using the conversion table……………………………………………………..2277
4.10.2 Millimeter – inch & kilogram – pound……………………………………………………..2278
4.10.3 Liter – U.S. gallon & liter – U.K. gallon…………………………………………………2279
4.10.4 Nm- ft.lb……………………………………………………………………………..2280
4.10.5 Bar – PSI – kPa – MPa…………………………………………………………………..2281
4.10.6 Temperature……………………………………………………………………………2282
4.11 Tools………………………………………………………………………………………2283
4.11.1 Standard tool case……………………………………………………………………..2283
4.11.2 Used special tools (Overview)……………………………………………………………2285
5 Tools catalogue……………………………………………………………………………………2289
6 Parts & Service News……………………………………………………………………………….2291
6.1 List of the PARTS AND SERVICE NEWS……………………………………………………………..2292
7 Supplier’s documentation……………………………………………………………………………2295

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