Komatsu Hydraulic Mining Excavator PC7000-11 T4 Shop Manual – PDF DOWNLOAD

Komatsu Hydraulic Mining Excavator PC7000-11 T4 Shop Manual – PDF DOWNLOAD

DESCRIPTION:

Komatsu Hydraulic Mining Excavator PC7000-11 T4 Shop Manual – PDF DOWNLOAD

SERIAL NUMBER 35013 and up

BEFORE READING THIS MANUAL
This manual gives details of the methods of inspection, maintenance and troubleshooting for this excavator
that must be obeyed in order to use the excavator safely. Most accidents are caused by the failure to follow
fundamental safety rules for the inspection, maintenance and troubleshooting of excavators.
Read, understand and follow all precautions and warnings in this manual and on the excavator 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 excavator is used.
Therefore, the safety messages in this manual and on the excavator 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 excavator can be hazardous and could result in
serious injury or death.
If you sell the excavator, be sure to give this manual to the new owner together with the excavator.
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 excavatore 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 excavator or with questions regarding information contained in this
manual.
Komatsu delivers excavators that comply with all applicable regulations and standards of the country to which
it has been shipped. If the excavator 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 excavator.
TABLE OF CONTENTS:

Komatsu Hydraulic Mining Excavator PC7000-11 T4 Shop Manual – PDF DOWNLOAD

SHOP MANUAL PC7000-11 T4…………………………………………………………………………………………….. 1
00 FOREWORD & SAFETY………………………………………………………………………………………………… 3
1 Foreword……………………………………………………………………………………………………… 5
1.1 BEFORE READING THIS MANUAL………………………………………………………………………………… 6
1.1.1 CSA (Canadian Standards Association)………………………………………………………………….. 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………………………………………………………………………… 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 excavator………………………………………………………………………….. 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 excavator……………………………………………………………………….. 13
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT………………………………………………… 14
2.4.3.4 KEEP excavator 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 ON PC3000…………………………………………………………………. 16
2.4.4.3 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000……………………………………………. 17
2.4.4.4 EMERGENCY EXIT FROM OPERATOR’S CAB………………………………………………………………. 17
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR……………………………………………………….. 18
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE excavator……………………………………….. 18
2.4.5.2 NO JUMPING ON OR OFF THE excavator………………………………………………………………. 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 excavator………………………………………………………………………….. 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
2.4.9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS…………………………………………………….. 21
2.4.9.1 UNAUTHORIZED MODIFICATION………………………………………………………………………. 21
2.4.9.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS……………………………………………………. 21
2.4.10 ELECTROMAGNETIC COMPATIBILITY (EMC)………………………………………………………………….. 21
2.4.11 PRECAUTIONS AT JOBSITE……………………………………………………………………………… 22
2.4.11.1 VISIBILITY FROM OPERATOR’S SEAT………………………………………………………………… 23
2.4.11.2 CAMERA SYSTEM WITH MONITORS……………………………………………………………………. 23
2.4.11.3 ENSURE GOOD VISIBILITY………………………………………………………………………… 23
2.4.11.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS………………………………………………………….. 23
2.4.11.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS………………………………………………………. 24
2.4.11.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES………………………………………………………….. 24
2.4.11.7 Lightning Strikes…………………………………………………………………………….. 25
2.4.11.8 WORKING ON LOOSE GROUND……………………………………………………………………….. 25
2.4.11.9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES……………………………………………………….. 26
2.4.11.10 VENTILATION OF ENCLOSED AREAS…………………………………………………………………. 27
2.4.12 STARTING motor…………………………………………………………………………………….. 28
2.4.12.1 WARNING TAG………………………………………………………………………………….. 28
2.4.12.2 CHECKS BEFORE STARTING motor…………………………………………………………………… 28
2.4.12.3 PRECAUTION WHEN STARTING motor…………………………………………………………………. 28
2.4.12.4 PRECAUTION IN COLD AREAS………………………………………………………………………. 29
2.4.13 OPERATION…………………………………………………………………………………………. 29
2.4.13.1 CHECKS BEFORE OPERATION……………………………………………………………………….. 29
2.4.13.2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE…………………………………………………. 30
2.4.13.3 PRECAUTIONS WHEN traveling…………………………………………………………………….. 31
2.4.13.4 TRAVELING ON SLOPES…………………………………………………………………………… 32
2.4.13.5 OPERATIONS ON SLOPES………………………………………………………………………….. 33
2.4.13.6 PROHIBITED OPERATIONS…………………………………………………………………………. 33
2.4.13.7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES…………………………………………………….. 34
2.4.13.8 PARKING THE excavator…………………………………………………………………………. 34
2.4.13.9 TRANSPORTATION……………………………………………………………………………….. 34
2.5 PRECAUTION FOR MAINTENANCE………………………………………………………………………………… 35
2.5.1 GENERAL PRECAUTIONS…………………………………………………………………………………. 35
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…………………………………… 36
2.5.1.2 STOP motor FOR MAINTENANCE……………………………………………………………………… 37
2.5.1.3 WARNING TAG…………………………………………………………………………………… 37
2.5.1.4 Maintenance safety Switch………………………………………………………………………. 37
2.5.1.5 KEEP WORKPLACE CLEAN AND TIDY…………………………………………………………………… 38
2.5.1.6 APPOINT LEADER WHEN WORKING WITH OTHERS………………………………………………………….. 39
2.5.1.7 TWO WORKERS FOR MAINTENANCE WHEN THE excavator IS RUNNING………………………………………….. 39
2.5.1.8 INSTALLING, REMOVING OR STORING ATTACHMENTS………………………………………………………. 39
2.5.1.9 PRECAUTIONS WHEN WORKING UNDER THE excavator OR EQUIPMENT………………………………………….. 40
2.5.1.10 NOISE……………………………………………………………………………………….. 40
2.5.1.11 WHEN USING A HAMMER…………………………………………………………………………… 40
2.5.1.12 PROPER TOOLS…………………………………………………………………………………. 41
2.5.1.13 ACCUMULATOR………………………………………………………………………………….. 41
2.5.1.14 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……………………………………………………………… 44
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…………………………………………………………… 45
2.5.3.3 REPLACEMENT OF HOSE LINES………………………………………………………………………. 45
2.5.3.4 INSPECTION OF HOSE LINES……………………………………………………………………….. 45
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………………………………………………….. 46
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE……………………………………………………………………. 46
2.5.3.7 AIR CONDITIONING MAINTENANCE……………………………………………………………………. 46
2.5.3.8 COMPRESSED AIR………………………………………………………………………………… 47
2.5.3.9 WASTE MATERIALS……………………………………………………………………………….. 47
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS……………………………………………… 48
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM……………………………………………………………………. 48
2.6.2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS………………………………………… 48
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…………………………………………………………. 48
2.7 SPECIAL SAFETY EQUIPMENT………………………………………………………………………………….. 50
2.7.1 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’S CAB………………………………………………. 51
2.7.2 OBJECT HANDLING…………………………………………………………………………………….. 51
2.7.3 LIGHTING…………………………………………………………………………………………… 51
2.7.4 WARNING BEACON……………………………………………………………………………………… 51
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…………………………………………….. 51
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)……………………………………….. 51
2.7.5.2 INSTRUCTIONS FOR USE…………………………………………………………………………… 52
2.7.5.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS……………….. 53
2.7.5.4 INSTRUCTIONS FOR USE…………………………………………………………………………… 53
01 SPECIFICATION……………………………………………………………………………………………………. 55
PC7000-11………………………………………………………………………………………………………. 57
10 STRUCTURE & FUNCTION……………………………………………………………………………………………… 65
TOC……………………………………………………………………………………………………………. 67
1 Introduction………………………………………………………………………………………………….. 79
1.1 Foreword………………………………………………………………………………………………… 80
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining excavators……………… 81
1.3 Explanation of abbreviations………………………………………………………………………………. 82
1.4 Diagrams and illustrations in this manual…………………………………………………………………… 83
2 Specifications………………………………………………………………………………………………… 85
2.1 Lifting Gears……………………………………………………………………………………………. 86
2.2 Safety hints for sling accessory…………………………………………………………………………… 88
2.3 Standard Tightening Torque Chart…………………………………………………………………………… 89
2.4 Conversion Table…………………………………………………………………………………………. 90
2.5 Blind plugs……………………………………………………………………………………………… 96
2.6 Classification of threads to the nominal width………………………………………………………………. 98
2.7 Plugs & fittings according to ISO 8434-1 / DIN 2353………………………………………………………….. 99
3 Main assembly groups…………………………………………………………………………………………… 101
3.1 General layout…………………………………………………………………………………………… 102
3.2 Superstructure…………………………………………………………………………………………… 104
3.2.1 Side view………………………………………………………………………………………….. 104
3.2.2 Superstructure top view……………………………………………………………………………… 106
3.3 Machinery house………………………………………………………………………………………….. 108
3.4 Hydraulic oil tank……………………………………………………………………………………….. 110
3.5 Hydraulic oil cooler……………………………………………………………………………………… 112
3.6 Fuel tank with Wiggins service system VR300…………………………………………………………………. 114
3.7 Cab support……………………………………………………………………………………………… 116
3.8 Operator’s cab…………………………………………………………………………………………… 118
3.9 Main control blocks (FSA)…………………………………………………………………………………. 120
3.10 Slew machinery………………………………………………………………………………………….. 122
3.10.1 Slew gear type 2063………………………………………………………………………………… 122
3.10.2 Slew gear type 632770………………………………………………………………………………. 124
3.11 Undercarriage…………………………………………………………………………………………… 126
3.12 Slew ring………………………………………………………………………………………………. 128
3.13 Attachment……………………………………………………………………………………………… 130
3.13.1 Front Shovel Attachment (FSA)……………………………………………………………………….. 130
3.13.2 Backhoe Attachment (BHA)……………………………………………………………………………. 132
3.14 Counterweight…………………………………………………………………………………………… 134
3.15 PPC safety circuit………………………………………………………………………………………. 136
3.16 KomVision camera system………………………………………………………………………………….. 139
4 Drive………………………………………………………………………………………………………… 141
4.1 Prime drive assembly……………………………………………………………………………………… 142
4.2 Engine and PTO mounts…………………………………………………………………………………….. 144
4.2.1 Checks and adjustments………………………………………………………………………………. 145
4.3 Flexible coupling………………………………………………………………………………………… 146
4.3.1 Information for maintenance………………………………………………………………………….. 148
4.3.2 Coupling elements…………………………………………………………………………………… 149
4.3.3 Separation and assembly of the coupling inner and outer part…………………………………………….. 150
4.3.4 Operation troubles, causes, and rectification………………………………………………………….. 151
4.4 Radiator assembly and fan drive……………………………………………………………………………. 152
4.4.1 Radiator assembly…………………………………………………………………………………… 152
4.4.2 Fan motor………………………………………………………………………………………….. 154
4.4.3 Expansion tanks…………………………………………………………………………………….. 155
4.4.4 Radiator fan drive………………………………………………………………………………….. 156
4.4.4.1 Hydraulic schematic of radiator fan drive………………………………………………………… 158
4.4.5 Fan pump type HPV190………………………………………………………………………………… 160
4.4.6 Radiator fan speed testing & adjustment……………………………………………………………….. 162
4.4.6.1 Testing & readjustment procedure………………………………………………………………… 164
4.4.6.2 Basic adjustment procedure……………………………………………………………………… 165
4.5 Fuel cooling (T4 equipment)……………………………………………………………………………….. 166
4.6 Pump distributor gearbox (PTO)…………………………………………………………………………….. 168
4.6.1 PTO oil filling, oil level, and ventilation……………………………………………………………. 170
4.6.2 Pump spline lubrication……………………………………………………………………………… 172
4.6.2.1 Oil level in main pump & gear oil pump drive shaft housing…………………………………………. 173
4.6.3 PTO lubrication and cooling………………………………………………………………………….. 174
4.6.3.1 Hydraulic components and schematic of cooling circuit-1……………………………………………. 174
4.6.3.2 Schematic overview – PTO gear oil cooling circuit-1……………………………………………….. 176
4.6.3.3 Checks and adjustments…………………………………………………………………………. 178
4.7 Hydraulic pumps – location, drive speed and flow rates……………………………………………………….. 180
4.8 Air cleaner……………………………………………………………………………………………… 184
4.9 Fuel filtration system stage 1 (HYDAC)……………………………………………………………………… 186
4.9.1 Status light & flash lights for fuel filtration………………………………………………………… 188
5 Hydraulic oil tank…………………………………………………………………………………………….. 191
5.1 General layout…………………………………………………………………………………………… 192
5.1.1 Hydraulic oil level definition……………………………………………………………………….. 194
5.2 Hydraulic oil tank, location of the electric equipment……………………………………………………….. 196
5.3 Suction oil tank with strainers……………………………………………………………………………. 198
5.4 Return oil collector pipe with strainer…………………………………………………………………….. 200
5.5 Back pressure valve………………………………………………………………………………………. 202
5.6 Transfer pump……………………………………………………………………………………………. 204
5.7 Return and leak oil filter………………………………………………………………………………… 206
5.8 Breather filter………………………………………………………………………………………….. 208
6 Hydraulic oil cooling………………………………………………………………………………………….. 211
6.1 Overall view on the hydraulic oil cooling…………………………………………………………………… 212
6.2 Function of the hydraulic oil cooling circuit……………………………………………………………….. 214
6.3 Adjustment of the back pressure valve………………………………………………………………………. 216
6.4 Stepless cooler fan RPM control……………………………………………………………………………. 218
6.4.1 Pressure limiting valves…………………………………………………………………………….. 220
6.4.2 Components of the fan drive circuits………………………………………………………………….. 222
6.4.3 Fan pump type HPV190………………………………………………………………………………… 224
6.5 Oil cooler fan speed……………………………………………………………………………………… 226
6.6 OC fan resonance speed……………………………………………………………………………………. 228
6.6.1 Hydraulic oil temperature charts……………………………………………………………………… 230
7 Controlling…………………………………………………………………………………………………… 233
7.1 General layout…………………………………………………………………………………………… 234
7.2 Control and filter panels – location of components…………………………………………………………… 236
7.2.1 Control and filter panel engine 1 (rear)………………………………………………………………. 236
7.2.2 Valve cartridge block engine 1 (rear)…………………………………………………………………. 238
7.2.3 Control and filter panel engine 2 (front)……………………………………………………………… 240
7.3 Pilot pressure supply and adjustments………………………………………………………………………. 242
7.3.1 Pilot pressure control (PPC) circuit………………………………………………………………….. 242
7.3.2 Pilot pressure operating the main block spools…………………………………………………………. 244
7.3.3 Checks and adjustment of pilot pressure……………………………………………………………….. 246
7.3.4 Remote control valves arrangement…………………………………………………………………….. 248
7.4 Function of the electro hydraulic control system…………………………………………………………….. 250
7.4.1 Illustration of the joystick signal flow (example)……………………………………………………… 252
7.5 Hand lever (joystick) control……………………………………………………………………………… 254
7.5.1 Voltage supply of LH hand lever 20S020………………………………………………………………… 255
7.5.2 Direction signal course from hand lever to controllers………………………………………………….. 256
7.5.3 Double ratiometric* output diagram……………………………………………………………………. 257
7.6 Foot pedal control……………………………………………………………………………………….. 258
7.6.1 Voltage supply of foot pedal 20S021a………………………………………………………………….. 260
7.6.2 Direction signal course from foot pedal to controllers………………………………………………….. 261
7.6.3 Double ratiometric* output diagram for 2 direction pedal………………………………………………… 262
7.6.4 Single ratiometric* output diagram for 1 direction pedal………………………………………………… 263
7.7 Hand lever & foot pedal monitoring…………………………………………………………………………. 264
7.7.1 Lever monitoring screens (example)……………………………………………………………………. 266
7.7.2 Valve monitoring screen (example)…………………………………………………………………….. 268
7.8 Valve solenoid adjustment…………………………………………………………………………………. 270
7.8.1 Overview sol min/max current & adjustment range………………………………………………………… 271
7.9 ACCEL & DECEL time adjustment……………………………………………………………………………… 272
7.9.1 Accel & Decel times…………………………………………………………………………………. 272
8 Components……………………………………………………………………………………………………. 275
8.1 Main control blocks and high pressure screens (FSA)………………………………………………………….. 276
8.2 Main control blocks with valves and hp screens (FSA)…………………………………………………………. 278
8.3 Main control blocks with valves and hp screens (BHA)…………………………………………………………. 280
8.4 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA)……………………………. 282
8.5 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA)……………………………. 284
8.6 Restrictor block with secondary relief valve………………………………………………………………… 286
8.7 Anti-cavitation valve (ACV) block………………………………………………………………………….. 288
8.7.1 Single ACV block on the manifold……………………………………………………………………… 288
8.7.2 Double ACV block on the manifold……………………………………………………………………… 290
8.8 Remote control valves…………………………………………………………………………………….. 292
8.9 4/3 Directional solenoid valves……………………………………………………………………………. 294
8.10 Proportional solenoid valves……………………………………………………………………………… 296
8.11 High-pressure screen…………………………………………………………………………………….. 298
8.12 Control blocks and valves………………………………………………………………………………… 300
8.12.1 Main control blocks I, II, III (4 spool blocks)……………………………………………………….. 300
8.12.1.1 Spin lock for valve blocks (ND52)………………………………………………………………. 301
8.12.2 Hydraulic diagram of a 4-spool valve block……………………………………………………………. 302
8.12.3 Spool types……………………………………………………………………………………….. 303
8.12.4 Spool positions (control block)……………………………………………………………………… 306
8.12.5 MRV, SRV, and ACV………………………………………………………………………………….. 308
8.12.6 Load holding valve…………………………………………………………………………………. 310
8.12.7 Main control block IV (slew)………………………………………………………………………… 312
8.13 Travel brake valve………………………………………………………………………………………. 314
8.14 Pressure reducing valve………………………………………………………………………………….. 316
8.15 4/2 Directional valves…………………………………………………………………………………… 318
8.16 Pressure double stage valve………………………………………………………………………………. 320
8.17 Hydraulic cylinder………………………………………………………………………………………. 322
8.17.1 Hydraulic cylinder – Chevron® sealing………………………………………………………………… 322
8.17.2 Hydraulic cylinder – Chesterton® 11KE sealing…………………………………………………………. 324
8.17.3 Cylinder data markings……………………………………………………………………………… 326
9 Main hydraulic pumps, pump regulation, valve control & monitoring system…………………………………………….. 327
9.1 General…………………………………………………………………………………………………. 328
9.1.1 Pump data………………………………………………………………………………………….. 330
9.2 Main pumps………………………………………………………………………………………………. 334
9.2.1 Hydraulic pump type HPV375+375……………………………………………………………………….. 334
9.2.1.1 Main pump sectional drawings……………………………………………………………………. 336
9.2.2 Servo valve………………………………………………………………………………………… 338
9.2.2.1 VC valve  servo piston………………………………………………………………………… 339
9.2.3 EPC valve………………………………………………………………………………………….. 344
9.3 Electronic pump regulation system………………………………………………………………………….. 346
9.3.1 Cut-off function……………………………………………………………………………………. 348
9.3.2 Slew control……………………………………………………………………………………….. 348
9.3.3 Temperature control…………………………………………………………………………………. 348
9.3.3.1 Hydraulic oil temperature charts………………………………………………………………… 349
9.4 Pump & valve controllers………………………………………………………………………………….. 352
9.4.1 Service menu screen…………………………………………………………………………………. 354
9.4.2 Service ID…………………………………………………………………………………………. 354
9.4.3 Service menu – 01 Monitoring…………………………………………………………………………. 354
9.5 Monitoring PUMP 1 controller………………………………………………………………………………. 355
9.5.1 Monitoring PUMP 2 controller…………………………………………………………………………. 356
9.6 Monitoring VALVE 0 controller……………………………………………………………………………… 357
9.7 Monitoring VALVE 1 controller……………………………………………………………………………… 358
9.8 Monitoring VALVE 2 controller……………………………………………………………………………… 359
9.9 Using machine monitor functions for monitoring………………………………………………………………. 360
9.10 Error indication of pump controllers………………………………………………………………………. 360
9.11 Adjustments for pump controllers………………………………………………………………………….. 361
9.11.1 Adjustments for PUMP 1 controller……………………………………………………………………. 361
9.11.2 Adjustments for PUMP 2 controller……………………………………………………………………. 362
9.12 Details on adjustable parameters………………………………………………………………………….. 363
9.12.1 PUMP1 controller…………………………………………………………………………………… 363
9.12.2 PUMP2 controller…………………………………………………………………………………… 365
9.12.3 Description of the primary p-factor………………………………………………………………….. 367
9.12.4 Pump sol min current values according to pump type plate……………………………………………….. 368
9.12.5 Pump sol max current values according to pump type plate……………………………………………….. 369
9.13 Checks and adjustments…………………………………………………………………………………… 370
9.13.1 Engine power check…………………………………………………………………………………. 370
9.13.2 Cut-off function check……………………………………………………………………………… 372
9.13.2.1 Cut-off for clam close (FSA only)………………………………………………………………. 373
9.14 Engine speed sensors (pick-up)……………………………………………………………………………. 374
9.14.1 General…………………………………………………………………………………………… 375
9.14.2 Engine speed sensor (pick-up) adjustment……………………………………………………………… 375
9.14.3 In case of problems – when correct speed sensor adjustment is guaranteed…………………………………. 376
10 Operating hydraulics………………………………………………………………………………………….. 379
10.1 General………………………………………………………………………………………………… 380
10.1.1 Allocation of pumps and main valve blocks…………………………………………………………….. 382
10.2 Spool functions (FSA)……………………………………………………………………………………. 384
10.2.1 Floating function for boom and stick cylinders………………………………………………………… 384
10.2.2 Spool functions (BHA)………………………………………………………………………………. 386
10.3 Hydraulics for the attachment cylinders……………………………………………………………………. 388
10.3.1 Electric / hydraulic flowchart “Boom UP” (FSA)………………………………………………………… 388
10.3.2 Electric / hydraulic flowchart “boom up” (BHA)………………………………………………………… 390
10.3.3 Electric / hydraulic flowchart “boom down” (FSA), single movement and Auto-float ON……………………….. 392
10.3.4 Electric / hydraulic flowchart “boom down” (FSA), Auto-float OFF – button 20S095 pressed and single movement…. 394
10.3.5 Electric / hydraulic flowchart “Boom down” (BHA)………………………………………………………. 396
10.3.6 Electric / hydraulic flowchart “Stick out” (FSA)………………………………………………………. 398
10.3.7 Electric / hydraulic flowchart “Stick out” (BHA)………………………………………………………. 400
10.3.8 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float ON and single movement………………………… 402
10.3.9 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float OFF – 20S098 pressed & single movement………….. 404
10.3.10 Electric / hydraulic flowchart “Stick in” (BHA)………………………………………………………. 406
10.3.11 Electric / hydraulic flowchart “Bucket fill” (FSA)……………………………………………………. 408
10.3.12 Electric / hydraulic flowchart “Bucket fill” (BHA)……………………………………………………. 410
10.3.13 Electric / hydraulic flowchart “Bucket dump” (FSA)……………………………………………………. 412
10.3.14 Electric / hydraulic flowchart “Bucket dump” (BHA)……………………………………………………. 414
10.3.15 Electric / hydraulic flowchart “Clam open” (FSA)……………………………………………………… 416
10.3.16 Electric / hydraulic flowchart “Clam close” (FSA)…………………………………………………….. 418
10.3.17 Checks & adjustments of main relief valve (MRV)………………………………………………………. 420
10.3.18 Checks and adjustments of the secondary relief valves (SRV)……………………………………………. 422
10.3.18.1 Boom cylinders, piston side (BHA & FSA), boom up………………………………………………… 422
10.3.18.2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down……………………………………………. 426
10.3.18.3 Stick cylinders, piston side (FSA), stick out…………………………………………………… 430
10.3.18.4 Stick cylinders, piston side (BHA), stick in……………………………………………………. 434
10.3.18.5 Stick cylinders, piston rod side (FSA), stick in………………………………………………… 438
10.3.18.6 Stick cylinders, piston rod side (BHA), stick out……………………………………………….. 442
10.3.18.7 Bucket cylinders, piston side (FSA), bucket fill………………………………………………… 446
10.3.18.8 Bucket cylinders, piston side (BHA), bucket fill………………………………………………… 450
10.3.18.9 Bucket cylinders, piston rod side (FSA), bucket dump…………………………………………….. 454
10.3.18.10 Bucket cylinders, piston rod side (BHA), bucket dump……………………………………………. 458
10.3.18.11 Clam cylinders, piston rod side (FSA), clam open……………………………………………….. 462
10.3.18.12 Clam cylinders, piston side (FSA), clam close………………………………………………….. 466
10.3.19 Checks and adjustments of cycle times……………………………………………………………….. 470
10.3.19.1 Checks and adjustments of boom lowering speed (FSA)……………………………………………… 470
10.3.19.2 Checks and adjustments of boom lowering speed (BHA)……………………………………………… 474
10.3.19.3 Checks and adjustments of stick retract speed (FSA)……………………………………………… 478
10.3.19.4 Checks and adjustments of stick retract speed (BHA)……………………………………………… 482
10.3.19.5 Checks and adjustments of bucket dump speed (FSA)……………………………………………….. 486
10.3.19.6 Checks and adjustments of bucket dump speed (BHA)……………………………………………….. 490
10.3.19.7 Checks and Adjustment of bucket Curl Speed (BHA)………………………………………………… 494
10.3.19.8 Checks and adjustments of clam close speed (FSA)………………………………………………… 498
10.4 Hydraulics for the slew circuit…………………………………………………………………………… 500
10.4.1 Slew circuit with variable slew motors……………………………………………………………….. 500
10.4.2 Slew motor (variable displacement)…………………………………………………………………… 504
10.4.2.1 Hydraulic slew motor – displacement control……………………………………………………… 506
10.4.3 Slew gearbox type 2063……………………………………………………………………………… 508
10.4.4 Slew gearbox type 632770……………………………………………………………………………. 510
10.4.5 Slew parking brake (on slew gear type 2063)…………………………………………………………… 512
10.4.6 Slew parking brake (on slew gear type 632770)…………………………………………………………. 514
10.4.7 Slew brake valve…………………………………………………………………………………… 516
10.4.8 Flushing circuit…………………………………………………………………………………… 520
10.4.9 Electric / hydraulic flowchart “Slew left” FSA………………………………………………………… 522
10.4.10 Electric / hydraulic flowchart “Slew left” BHA……………………………………………………….. 524
10.4.11 Electric / hydraulic flowchart “Slew right” FSA………………………………………………………. 526
10.4.12 Electric / hydraulic flowchart “Slew right” BHA………………………………………………………. 528
10.4.13 Checks and adjustments for the slew circuit………………………………………………………….. 530
10.4.13.1 Pressure checks & adjustments – double stage valve (DSV)…………………………………………. 531
10.4.13.2 Checks & adjustments – brake pilot pressure…………………………………………………….. 533
10.4.13.3 Checks & adjustments – slew speed……………………………………………………………… 534
10.4.14 Function check for hydraulic slew brake……………………………………………………………… 536
10.4.15 Function check for slew parking brake……………………………………………………………….. 538
10.4.15.1 Slew parking brake release pressure check………………………………………………………. 538
10.5 Hydraulics for the travel circuit…………………………………………………………………………. 540
10.5.1 Travel circuit…………………………………………………………………………………….. 540
10.5.2 Travel motor………………………………………………………………………………………. 544
10.5.3 Rotary joint………………………………………………………………………………………. 546
10.5.4 Travel gearbox…………………………………………………………………………………….. 548
10.5.4.1 Travel gearbox type 2063………………………………………………………………………. 548
10.5.4.2 Travel gearbox type 631053…………………………………………………………………….. 550
10.5.5 Travel parking brake……………………………………………………………………………….. 552
10.5.5.1 Travel parking brake on travel gear type 2063……………………………………………………. 552
10.5.5.2 Travel parking brake on travel gear type 631053………………………………………………….. 553
10.5.5.3 Travel brake valve……………………………………………………………………………. 554
10.5.6 Electric / hydraulic flowchart “travel forward”……………………………………………………….. 556
10.5.7 Electric / hydraulic flowchart “travel backwards”……………………………………………………… 558
10.5.8 Checks and adjustments……………………………………………………………………………… 560
10.5.8.1 Checks and adjustments for travel circuit……………………………………………………….. 560
10.5.8.2 Function check for the travel parking brake……………………………………………………… 563
11 Hydraulic track tensioning system………………………………………………………………………………. 565
11.1 General………………………………………………………………………………………………… 566
11.2 Functional description…………………………………………………………………………………… 570
11.3 Double stage valve………………………………………………………………………………………. 572
11.4 Tensioning cylinder……………………………………………………………………………………… 574
11.5 Adjustments / checks…………………………………………………………………………………….. 576
12 Access stairway, hydraulically operated…………………………………………………………………………. 579
12.1 Overview……………………………………………………………………………………………….. 580
12.2 Function of the hydraulically operated access stairway………………………………………………………. 582
12.3 Adjustments / checks…………………………………………………………………………………….. 586
13 Central refilling system (Service arm)………………………………………………………………………….. 589
13.1 Refilling arm location…………………………………………………………………………………… 590
13.2 Function……………………………………………………………………………………………….. 592
14 Hints for reading the Hydraulic Diagram…………………………………………………………………………. 595
14.1 General………………………………………………………………………………………………… 596
14.2 Hydraulic symbols……………………………………………………………………………………….. 598
14.2.1 Lines, unions……………………………………………………………………………………… 599
14.2.2 Components, valves…………………………………………………………………………………. 601
14.2.3 Sensors…………………………………………………………………………………………… 601
14.2.4 Valves, valve components……………………………………………………………………………. 602
14.2.5 Pump, motor, cylinder………………………………………………………………………………. 606
15 Hints for reading the electric Wiring Diagram……………………………………………………………………. 609
15.1 General………………………………………………………………………………………………… 610
15.2 Reference code of the electrical components………………………………………………………………… 611
15.2.1 Area code…………………………………………………………………………………………. 611
15.2.2 Component identifying letter………………………………………………………………………… 612
15.3 Graphical symbols……………………………………………………………………………………….. 613
15.4 Concept of the Wiring Diagram…………………………………………………………………………….. 618
15.4.1 Cover page of the Komatsu W/D……………………………………………………………………….. 618
15.4.2 Example 1 from the schematics in the W/D……………………………………………………………… 620
15.4.3 Example 2 from the schematics in the W/D……………………………………………………………… 622
15.4.4 Table of contents in the W/D (page 1 of 2)……………………………………………………………. 624
15.4.5 Location list……………………………………………………………………………………… 626
15.4.6 Cross reference list for electr. components in the W/D…………………………………………………. 628
15.4.7 Cross reference list for terminals in the W/D…………………………………………………………. 630
15.4.8 Cross reference list for connectors in the W/D………………………………………………………… 632
15.4.9 Cross reference list for terminal boards in the W/D……………………………………………………. 634
15.4.10 Connection table………………………………………………………………………………….. 636
15.5 Cable and connector marking………………………………………………………………………………. 638
15.6 Cable color identification……………………………………………………………………………….. 640
16 Monitoring & Control System……………………………………………………………………………………. 641
16.1 Controller system overview……………………………………………………………………………….. 642
16.2 System layout…………………………………………………………………………………………… 644
16.2.1 CAN #1 overview……………………………………………………………………………………. 644
16.2.2 CAN #2 overview……………………………………………………………………………………. 645
16.2.3 CAN #0 overview……………………………………………………………………………………. 646
16.2.4 CAN #0 at 52K014-1/-2………………………………………………………………………………. 646
16.2.5 CAN #3 overview……………………………………………………………………………………. 646
16.3 Interface connection…………………………………………………………………………………….. 647
16.3.1 General description………………………………………………………………………………… 648
16.4 Machine monitor – Operator level………………………………………………………………………….. 649
16.5 Main gauge screens………………………………………………………………………………………. 650
16.6 Operator menu / Tabs / Function of keys F1…F6…………………………………………………………….. 654
16.6.1 Operator menu → Shovel payload………………………………………………………………………. 656
16.6.2 Operator menu → ECO Guidance – Operation Records………………………………………………………. 658
16.6.3 Operator menu → ECO Guidance – Average Fuel Consumption Logs……………………………………………. 660
16.6.4 Operator menu → Machine Setting……………………………………………………………………… 662
16.6.5 Operator menu → Aftertreatment cleaning………………………………………………………………. 664
16.6.6 Operator menu → SCR Information……………………………………………………………………… 670
16.6.7 Operator menu → Maintenance…………………………………………………………………………. 674
16.6.7.1 Reset of ’remaining time’ till next maintenance interval………………………………………….. 676
16.6.7.2 Usage limitation……………………………………………………………………………… 677
16.6.8 Operator menu → Monitor Setting – Screen Adjustment……………………………………………………. 679
16.6.9 Operator menu → Monitor Setting – Clock Adjustment – Calender…………………………………………… 680
16.6.10 Operator menu → Monitor Setting – Clock Adjustment – Time……………………………………………… 681
16.6.11 Operator menu → Monitor Setting – Clock Adjustment – 12h/24h Mode………………………………………. 682
16.6.12 Operator menu → Monitor Setting – Clock Adjustment – Daylight Saving Time……………………………….. 683
16.6.13 Operator menu → Monitor Setting – Language…………………………………………………………… 684
16.6.14 Operator menu → Monitor Setting – ID Key Information………………………………………………….. 685
16.7 Status indication and errors on the operator level………………………………………………………….. 686
16.7.1 Prompts (status indication)…………………………………………………………………………. 686
16.7.2 Cautions………………………………………………………………………………………….. 687
16.7.3 Emergency shutdown screen…………………………………………………………………………… 688
16.7.4 Fault levels for error messages……………………………………………………………………… 690
16.7.5 Action code level L01………………………………………………………………………………. 691
16.7.6 Action code level L02………………………………………………………………………………. 692
16.7.7 Action code level L03………………………………………………………………………………. 693
16.7.8 Action code level L04………………………………………………………………………………. 694
16.7.9 Error list………………………………………………………………………………………… 695
16.8 Table of failure codes…………………………………………………………………………………… 696
16.8.1 Table of failure codes for Mechanical Systems PC7000-11 T4……………………………………………… 696
16.8.2 Table of failure codes for Electrical Systems PC7000-11 T4……………………………………………… 698
16.8.3 Failure codes without monitor indication……………………………………………………………… 712
16.8.4 Additional text information for action codes………………………………………………………….. 712
16.9 Table of C-codes – Diesel engines QSK50 T4…………………………………………………………………. 714
16.10 Flow charts of machine monitor screens……………………………………………………………………. 732
16.10.1 Flow chart Operator Level………………………………………………………………………….. 732
16.10.2 Flow chart Service Level…………………………………………………………………………… 733
16.11 Machine monitor – Service level………………………………………………………………………….. 734
16.11.1 Entering the Service Level…………………………………………………………………………. 734
16.11.2 Key symbols (F1…F6) on the Service Level…………………………………………………………… 736
16.11.3 Service Menu selection screens……………………………………………………………………… 737
16.12 Service Menu – item 01 Monitoring / Custom………………………………………………………………… 738
16.12.1 Monitoring list for: ENG1 controller………………………………………………………………… 738
16.12.2 Monitoring list for: ENG2 controller………………………………………………………………… 740
16.12.3 Monitoring list for: PUMP1 controller……………………………………………………………….. 742
16.12.4 Monitoring list for: PUMP2 controller……………………………………………………………….. 745
16.12.5 Monitoring list for: VALVE0 controller………………………………………………………………. 748
16.12.6 Monitoring list for: VALVE1 controller………………………………………………………………. 751
16.12.7 Monitoring list for: VALVE2 controller………………………………………………………………. 754
16.12.8 Monitoring list for: MON (monitor)………………………………………………………………….. 756
16.12.9 Monitoring list for: KOM PLS (K+ controller)…………………………………………………………. 758
16.12.10 How to perform the monitoring function……………………………………………………………… 760
16.13 Service Menu – item 02 PM Clinic…………………………………………………………………………. 762
16.13.1 PM Clinic (General)……………………………………………………………………………….. 762
16.13.2 PM Clinic (Power Check)……………………………………………………………………………. 763
16.13.3 Functions of PM CLINIC (POWER CHECK)………………………………………………………………… 764
16.14 Service Menu – item 03 Abnormality record…………………………………………………………………. 766
16.14.1 Reset error messages………………………………………………………………………………. 767
16.15 Service Menu – item 04 Maintenance record…………………………………………………………………. 768
16.16 Service Menu – item 05 Maintenance Mode Setting……………………………………………………………. 769
16.17 Service Menu – item 06 Snap Shot…………………………………………………………………………. 770
16.18 Service Menu – item 07 Phone Number Entry…………………………………………………………………. 771
16.19 Service menu – item 08 Default…………………………………………………………………………… 772
16.20 Service Menu – item 09 Unit……………………………………………………………………………… 774
16.21 Service Menu – item 10 Adjustment………………………………………………………………………… 776
16.21.1 Adjustments for: PUMP1 controller…………………………………………………………………… 776
16.21.2 Adjustments for: PUMP2 controller…………………………………………………………………… 780
16.21.3 Pump sol ’min’ current values according to pump type plate…………………………………………….. 783
16.21.4 Pump sol ’max’ current values according to pump type plate…………………………………………….. 784
16.21.5 Adjustments for: VALVE0 controller………………………………………………………………….. 785
16.21.6 Accel & Decel times……………………………………………………………………………….. 791
16.21.7 Adjustments for: VALVE2 controller………………………………………………………………….. 792
16.21.8 Adjustments for: KOM PLS controller…………………………………………………………………. 793
16.21.9 Adjustments for: MON (Monitor)……………………………………………………………………… 794
16.21.9.1 Using the Idling Stop Timer…………………………………………………………………… 795
16.22 Service Menu – item 11 Machine Configuration………………………………………………………………. 796
16.22.1 Details of Machine Configuration for PC7000-11 T4…………………………………………………….. 797
16.22.2 Changing lever control from EURO to KMG……………………………………………………………… 798
16.22.2.1 Changing lever control from KMG to EURO………………………………………………………… 798
16.22.3 Changing attachment type from FSA to BHA…………………………………………………………….. 800
16.22.3.1 Changing attachment type from BHA to FSA……………………………………………………….. 800
16.22.4 In case of problems during changing procedure for lever control or attachment type……………………….. 801
16.22.5 Hydraulic Oil & PTO Gear Oil Definition Tables……………………………………………………….. 802
16.22.5.1 Hydraulic oil temperature charts………………………………………………………………. 802
16.22.5.2 PTO gear oil temperature charts……………………………………………………………….. 803
16.23 Service Menu – item 12 Abuse function setting……………………………………………………………… 804
16.24 Automatic engine speed control…………………………………………………………………………… 805
16.24.1 Auto-Deceleration mode…………………………………………………………………………….. 805
16.24.2 Auto Low Idle mode………………………………………………………………………………… 805
16.24.3 Idling Stop Timer…………………………………………………………………………………. 806
16.25 KOMTRAX Plus controller (UM600)………………………………………………………………………….. 807
16.26 CR720 controller……………………………………………………………………………………….. 811
16.26.1 Location of CR720 controllers………………………………………………………………………. 811
16.27 Controller replacement procedure…………………………………………………………………………. 813
16.27.1 Sequence of the controller replacement procedure……………………………………………………… 813
16.27.2 After controller replacement……………………………………………………………………….. 814
17 Lubrication system……………………………………………………………………………………………. 815
17.1 General overview SLS & CLS1 / 2…………………………………………………………………………… 816
17.1.1 General description………………………………………………………………………………… 817
17.2 Basic function of lubrication systems……………………………………………………………………… 818
17.3 Lubrication systems (SLS & CLS1/2)………………………………………………………………………… 820
17.3.1 Lubrication pump station……………………………………………………………………………. 822
17.3.2 General Information on CLS1/2……………………………………………………………………….. 824
17.3.3 General information on SLS………………………………………………………………………….. 824
17.3.4 Manual lube activation……………………………………………………………………………… 824
17.4 Lubrication cycle……………………………………………………………………………………….. 825
17.4.1 Operation and control………………………………………………………………………………. 825
17.4.2 Lubrication cycle – processing………………………………………………………………………. 826
17.4.3 Time segments & switch points of a lubrication cycle…………………………………………………… 827
17.4.4 Lubrication modes………………………………………………………………………………….. 828
17.4.4.1 Automatic lubrication mode…………………………………………………………………….. 828
17.4.4.2 Manual lubrication mode……………………………………………………………………….. 828
17.4.4.3 Reduced pause time for service…………………………………………………………………. 828
17.5 Hydraulically driven lube pump……………………………………………………………………………. 830
17.5.1 Adjustment of lube pump speed……………………………………………………………………….. 832
17.5.1.1 Stroke speed adjustment……………………………………………………………………….. 833
17.5.1.2 Working pressure……………………………………………………………………………… 833
17.6 Lubricant injectors……………………………………………………………………………………… 834
17.6.1 Tightening torques for fittings at grease injectors……………………………………………………. 835
17.6.2 Description……………………………………………………………………………………….. 835
17.6.3 Adjustment of lubricant output………………………………………………………………………. 836
17.6.4 Operation principle of lubricant injectors……………………………………………………………. 838
17.6.4.1 Function description………………………………………………………………………….. 839
17.6.5 Connection of two or more injectors………………………………………………………………….. 840
17.7 Vent valve & grease outlet filter…………………………………………………………………………. 842
17.7.1 Vent valve description……………………………………………………………………………… 843
17.8 End-line switch…………………………………………………………………………………………. 844
17.8.1 Description……………………………………………………………………………………….. 845
17.8.2 CLS1/2 end-line switch adjustment……………………………………………………………………. 846
17.8.3 SLS end-line switch adjustment………………………………………………………………………. 848
17.9 Lubricant level sensors………………………………………………………………………………….. 850
17.9.1 Description……………………………………………………………………………………….. 851
17.9.2 Checks……………………………………………………………………………………………. 851
17.10 Commissioning………………………………………………………………………………………….. 852
17.10.1 Commissioning of CLS 1/2 lubrication system………………………………………………………….. 852
17.10.2 Fine adjustment…………………………………………………………………………………… 853
17.10.3 Commissioning of SLS lubrication system……………………………………………………………… 854
18 Deep temperature equipment (option)…………………………………………………………………………….. 857
18.1 General information……………………………………………………………………………………… 858
18.1.1 Introduction………………………………………………………………………………………. 858
18.1.2 Deep temperature components overview…………………………………………………………………. 858
18.1.3 Power supply preconditions for preheating…………………………………………………………….. 859
18.1.4 Power requirements for preheating systems…………………………………………………………….. 860
18.2 Preheating procedure…………………………………………………………………………………….. 861
18.2.1 Global flow chart of the preheating procedure…………………………………………………………. 861
18.2.2 Starting the preheating procedure……………………………………………………………………. 862
18.2.3 Preheating of operator’s cab and Diesel engine [coolant system]…………………………………………. 863
18.2.4 Preheating of lubricants and superstructure (Diesel) [electric system]…………………………………… 864
18.3 Constant heating of travel motors (TTT equipment below-40°C only)…………………………………………….. 865
18.4 Component location………………………………………………………………………………………. 866
18.4.1 Electric heating elements for hydraulic & batteries [electric excavator]…………………………………. 866
18.4.2 Electric heating elements for hydraulics [Diesel excavator]…………………………………………….. 868
18.4.3 Electric heating elements for engines & batteries [Diesel excavator]…………………………………….. 870
18.5 Components of TT equipment……………………………………………………………………………….. 872
18.5.1 Preheating components on a Diesel excavator…………………………………………………………… 872
18.5.2 Preheating components on an electric excavator………………………………………………………… 873
18.5.3 Wiring Diagrams for preheating systems……………………………………………………………….. 874
18.5.3.1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3………………………………………… 874
18.5.3.2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3………………………………………… 875
18.5.3.3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3………………………………………… 876
18.5.3.4 Wiring diagram “Suction Oil Manifold Preheating”…………………………………………………. 877
18.5.3.5 Wiring diagram “PTO Preheating”………………………………………………………………… 878
18.5.3.6 Wiring diagram “Battery heater pads”……………………………………………………………. 879
40 TROUBLESHOOTING………………………………………………………………………………………………….. 881
TOC……………………………………………………………………………………………………………. 883
1 Introduction………………………………………………………………………………………………….. 911
1.1 Overview………………………………………………………………………………………………… 912
1.1.1 General advice when using troubleshooting charts……………………………………………………….. 912
1.2 General precautions………………………………………………………………………………………. 913
2 General Information for Troubleshooting………………………………………………………………………….. 915
2.1 Preparations For Work…………………………………………………………………………………….. 916
2.2 Precautions During Work…………………………………………………………………………………… 916
2.3 Precautions When Carrying Out Any Operation…………………………………………………………………. 917
2.3.1 Precautions when carrying out removal work…………………………………………………………….. 917
2.3.2 Precautions when carrying out installation work………………………………………………………… 917
2.3.3 Precautions when completing the operation……………………………………………………………… 918
2.4 Fundamental Requirements for Trouble shooting……………………………………………………………….. 919
2.4.1 Technical documentation……………………………………………………………………………… 919
2.4.2 Tools……………………………………………………………………………………………… 919
2.4.2.1 Reference Guide for Deutsch Removal Tools………………………………………………………… 922
2.4.3 Personnel………………………………………………………………………………………….. 923
2.5 Points To Remember When Trouble- shooting…………………………………………………………………… 923
2.6 Sequence Of Events In Troubleshooting………………………………………………………………………. 925
2.7 Checks Before Troubleshooting……………………………………………………………………………… 926
2.8 Handling Of Electric Equipment And Hydraulic Components………………………………………………………. 927
2.8.1 Points to remember when handling electric equipment…………………………………………………….. 927
2.8.2 Points To Remember When Handling Hydraulic Equipment……………………………………………………. 929
2.9 General working procedures………………………………………………………………………………… 932
2.9.1 Air Bleeding of Various Hydraulic Parts……………………………………………………………….. 932
2.9.2 Air bleeding from hydraulic pumps…………………………………………………………………….. 932
2.9.3 Air bleeding from hydraulic cylinders…………………………………………………………………. 932
2.10 Cylinder bypass test…………………………………………………………………………………….. 933
2.11 Basics about “How to crimp” (with strain relief)……………………………………………………………. 934
2.11.1 Crimp tool & repair kit…………………………………………………………………………….. 934
2.11.2 General…………………………………………………………………………………………… 935
2.11.3 Select the required connector components……………………………………………………………… 935
2.11.4 Stripping a wire…………………………………………………………………………………… 936
2.11.5 Crimping………………………………………………………………………………………….. 937
2.11.6 Connector assembly after crimping……………………………………………………………………. 938
2.12 Cable Shielding…………………………………………………………………………………………. 939
3 Mounting Locations and Connector Types…………………………………………………………………………… 941
3.1 Superstructure…………………………………………………………………………………………… 942
3.1.1 Superstructure side view…………………………………………………………………………….. 942
3.1.2 Superstructure top view……………………………………………………………………………… 944
3.2 Location of engine electrical parts………………………………………………………………………… 946
3.2.1 Engine side view……………………………………………………………………………………. 946
3.2.2 Engine top view…………………………………………………………………………………….. 947
3.2.3 Location of engine remote oil tank sensors…………………………………………………………….. 949
3.3 Location of hydraulic components…………………………………………………………………………… 950
3.3.1 Control and filter panel engine 1 (rear)………………………………………………………………. 950
3.3.2 Valve cartridge block engine 1 (rear)…………………………………………………………………. 952
3.3.3 Control and filter panel engine 2 (front)……………………………………………………………… 954
3.3.4 Remote control valves arrangement…………………………………………………………………….. 956
3.4 View onto SLS or CLS1/2 grease container and lubrication cycle components………………………………………. 958
3.5 Hydraulic oil tank & suction oil tank – Location of electrical components………………………………………. 960
3.6 Hydraulically operated access stairway……………………………………………………………………… 962
3.7 Refilling arm……………………………………………………………………………………………. 964
3.8 Connector Types Overview………………………………………………………………………………….. 966
4 Standard Value Table for Electrical Components……………………………………………………………………. 971
5 Tables for Testing and Troubleshooting…………………………………………………………………………… 985
5.1 Test Value Tables for Transducers………………………………………………………………………….. 986
5.1.1 Pump press. transducers……………………………………………………………………………… 986
5.1.2 Hydraulic oil pressure transducers……………………………………………………………………. 987
5.1.3 Miscellaneous Pressure Transducers……………………………………………………………………. 988
5.1.4 Temperature Transducers……………………………………………………………………………… 989
5.2 Hydraulic oil temperature charts…………………………………………………………………………… 990
5.3 PTO gear oil temperature charts……………………………………………………………………………. 991
5.4 Table of failure codes……………………………………………………………………………………. 992
5.4.1 Table of failure codes for Mechanical Systems PC7000-11 T4………………………………………………. 992
5.4.2 Table of failure codes for Electrical Systems PC7000-11 T4………………………………………………. 994
5.5 Table of C-codes – Diesel engines QSK50 T4…………………………………………………………………..1008
5.6 Tables of Symptom Codes……………………………………………………………………………………1028
5.6.1 Symptoms of engines and Related electrical systems………………………………………………………1028
5.6.2 Symptoms of Hydraulic System………………………………………………………………………….1028
5.6.3 Symptoms of Mechanical System…………………………………………………………………………1029
5.6.4 Symptoms of Additional Systems………………………………………………………………………..1029
5.7 Cable colour identification………………………………………………………………………………..1030
6 Troubleshooting by Trouble Code………………………………………………………………………………….1031
B@HANS – Hyd Oil Overheat……………………………………………………………………………………..1032
Monitoring hydraulic oil temperature………………………………………………………………………..1033
Hydraulic oil temperature charts for message B@HANS…………………………………………………………..1034
6A1BMA – Trouble Shut-Off (gate) valve not open error…………………………………………………………….1036
View onto gap of proximity switch 40B031…………………………………………………………………….1037
Wiring Diagram (40B031) for message 6A1BMA…………………………………………………………………..1038
AA10NX – Air Cleaner1 Clogging…………………………………………………………………………………1040
AA1FNX – Air Cleaner2 Clogging…………………………………………………………………………………1040
View onto engine air cleaner (AA10NX & AA1FNX)……………………………………………………………….1041
AB00KE – Charge Voltage Low……………………………………………………………………………………1042
AB0MKE – Charge Voltage2 Low…………………………………………………………………………………..1042
Wiring Diagram (alternator) for message AB00KE or AB0MKE………………………………………………………1043
B@F0MA – CLS1 Lubrication System Error………………………………………………………………………….1044
B@CPMA – SLS Lubrication System Error…………………………………………………………………………..1045
B@CNMA – CLS2 Lubrication System Error………………………………………………………………………….1046
B@F0N9 – CLS1 pressure increase time too long……………………………………………………………………1048
B@CNN9 – CLS2 pressure increase time too long……………………………………………………………………1048
B@CPN9 – SLS pressure increase time too long…………………………………………………………………….1048
Allocation of vent valves and end-of-line switches……………………………………………………………1049
Vent valve (62Q507a & 62Q509a & 62Q642a)…………………………………………………………………….1050
Wiring Diagram – lube pump solenoid & vent valve (CLS1/2 & SLS)………………………………………………..1051
B@F0N0 – CLS1 pressure decrease time too long……………………………………………………………………1052
B@CNN0 – CLS2 pressure decrease time too long……………………………………………………………………1052
B@CPN0 – SLS pressure decrease time too long…………………………………………………………………….1052
Vent valve (62Q507a & 62Q509a & 62Q642a)…………………………………………………………………….1053
B@F0ZK – CLS1 grease level too low……………………………………………………………………………..1054
B@CPZK – SLS grease level too low………………………………………………………………………………1054
Wiring Diagram – grease level sensors (CLS1/2 & SLS)………………………………………………………….1055
B@HAZK – Hydraulic oil level too low……………………………………………………………………………1056
Hydraulic oil level in defined excavator position…………………………………………………………….1057
Wiring Diagram – hydraulic oil level sensor 40B004……………………………………………………………1058
B@CBNS – PTO1 Gear Oil Temp High……………………………………………………………………………….1059
B@KCNS – PTO2 Gear Oil Temp High……………………………………………………………………………….1059
B@CBNS – PTO1 Gear Oil Temp High……………………………………………………………………………….1060
View onto the universal pump distributor gearbox (PTO1/2)……………………………………………………..1061
B@CBZG – PTO1 Gear Lubrication Error……………………………………………………………………………1062
B@KCZG – PTO2 Gear Lubrication Error……………………………………………………………………………1062
Monitoring PTO1/2 lube oil pressure…………………………………………………………………………1063
Shutdown adjustment for PTO1/2 lube oil pressure……………………………………………………………..1063
B@H2NX – Breather Filter Clogging………………………………………………………………………………1064
Location of 40B024 and hydraulic oil level definitions………………………………………………………..1065
B@M9NX – PTO1 Gear Oil Filter Clogging………………………………………………………………………….1066
B@N8NX – PTO2 Gear Oil Filter Clogging………………………………………………………………………….1066
View onto PTO1/2 gear oil filter with pressure sensor 57B027-1/-2………………………………………………1067
B@HBNX – Return Oil Filter Clogging…………………………………………………………………………….1068
B@L4NX – Leak Oil Filter Clogging………………………………………………………………………………1069
B@L5N9 – Pilot Press X2 Too Low………………………………………………………………………………..1070
Valve cartridge block, location of components………………………………………………………………..1071
B@L5N0 – Pilot Press X2 Too High……………………………………………………………………………….1072
Valve cartridge block, location of components………………………………………………………………..1073
B@BKPQ – Eng Remote Oil Tank1 Empty…………………………………………………………………………….1074
B@BLPQ – Eng Remote Oil Tank2 Empty…………………………………………………………………………….1074
B@HANX – Screen At Hyd Cooler Entry Clogging…………………………………………………………………….1076
Monitoring screens for 40B165 and 40B166…………………………………………………………………….1076
Hydraulic oil tank & return oil collector pipe with strainer, location of components……………………………..1077
AB30MA – Starter Circuit Abnormality……………………………………………………………………………1078
Wiring Diagram for AB30MA………………………………………………………………………………….1079
989HMA – Emergency stop line abnormality………………………………………………………………………..1080
Monitoring screens and Wiring Diagram for 989HMA……………………………………………………………..1081
DGT3MA – PTO1 oil temperature sensor abnormality…………………………………………………………………1082
Wiring Diagram, monitoring screen, and location of 57B049-1……………………………………………………1083
DGH2MA – Hydraulic oil temp sensor abnormality…………………………………………………………………..1084
Wiring Diagram, monitoring screen, and location of 59B015……………………………………………………..1085
DHQ7MA – PTO1 lube pressure sensor abnormality…………………………………………………………………..1086
Monitoring screen, Wiring Diagram, and location of 57B017-1……………………………………………………1087
D1E7KB – Starter cut relay short circuit………………………………………………………………………..1088
Wiring Diagram and monitoring screen – Starter cut relay for message D1E7KB……………………………………..1089
D1E7KY – Starter cut relay hot short circuit…………………………………………………………………….1090
Wiring Diagram – Starter cut relay for message D1E7KY…………………………………………………………1091
DHPEMA – Pump-1 pressure sensor abnormality……………………………………………………………………..1092
DHPGMA – Pump-2 pressure sensor abnormality……………………………………………………………………..1092
DHPJMA – Pump-3 pressure sensor abnormality……………………………………………………………………..1092
Monitoring screen & Wiring Diagram – PWR & GND supply for pump pressure transducers (main pumps 1…3)……………..1094
DLE2MA – Engine speed sensor abnormality………………………………………………………………………..1096
Monitoring screen and Wiring Diagram – 52B064 -1 for message DLE2MA…………………………………………….1097
DA27KP – 24V sensor power abnormality…………………………………………………………………………..1098
Wiring Diagram – 24V sensor power supply for DA27KP…………………………………………………………..1099
DA26KP – 5V sensor2 power abnormality…………………………………………………………………………..1100
Wiring Diagram – 5V sensor power supply for DA26KP……………………………………………………………1101
DA2LKA – Operating Lamp Open Circuit(Pump Con)…………………………………………………………………..1102
Wiring Diagram – Operating Lamp Open Circuit(Pump Con)………………………………………………………..1103
DA2LKB – Operating Lamp Short Circuit(Pump Con)………………………………………………………………….1104
Wiring Diagram – Operating Lamp Short Circuit(Pump Con)……………………………………………………….1105
DA22KK – Solenoid Power Low Error(Pump Con)……………………………………………………………………..1106
DA22MA – Solenoid Power Circuit Abnormality……………………………………………………………………..1107
Wiring Diagram 1 – monitoring safety power line for DA22MA…………………………………………………….1108
Wiring Diagram 2 – 11Q044d for DA22MA……………………………………………………………………….1109
DXAAKA – Pump1 Front Solenoid open circuit………………………………………………………………………1110
DXABKA – Pump1 Rear Solenoid open circuit……………………………………………………………………….1110
DXACKA – Pump2 Front Solenoid open circuit………………………………………………………………………1110
DXADKA – Pump2 Rear Solenoid open circuit……………………………………………………………………….1110
DXAEKA – Pump3 Front Solenoid open circuit………………………………………………………………………1110
DXAFKA – Pump3 Rear Solenoid open circuit……………………………………………………………………….1110
Wiring Diagram – EPC valve control (PUMP1)…………………………………………………………………..1111
DXAAKB – Pump1 Front Solenoid short circuit……………………………………………………………………..1112
DXABKB – Pump1 Rear Solenoid short circuit………………………………………………………………………1112
DXACKB – Pump2 Front Solenoid short circuit……………………………………………………………………..1112
DXADKB – Pump2 Rear Solenoid short circuit………………………………………………………………………1112
DXAEKB – Pump3 Front Solenoid short circuit……………………………………………………………………..1112
DXAFKB – Pump3 Rear Solenoid short circuit………………………………………………………………………1112
Wiring Diagram – EPC valve control (PUMP1)…………………………………………………………………..1113
DWA5KA – CLS pump solenoid open circuit…………………………………………………………………………1114
DWA8KA – SLS pump solenoid open circuit…………………………………………………………………………1114
Wiring Diagram – CLS1/SLS pump solenoid control………………………………………………………………1115
DWA5KB – CLS pump solenoid short circuit………………………………………………………………………..1116
DWA8KB – SLS pump solenoid short circuit………………………………………………………………………..1116
Wiring Diagram – CLS1/SLS pump solenoid control………………………………………………………………1117
DWA5KY – CLS pump solenoid hot short circuit…………………………………………………………………….1118
DWA8KY – SLS pump solenoid hot short circuit…………………………………………………………………….1118
Wiring Diagram – CLS/SLS pump solenoid / hot short circuit…………………………………………………….1119
DWA7KA – CLS line release solenoid open circuit………………………………………………………………….1120
DWA9KA – SLS lube line release sol. open circuit…………………………………………………………………1120
Wiring Diagram – CLS1/SLS lube line release solenoid control…………………………………………………..1121
DWA7KB – CLS line release solenoid short circuit…………………………………………………………………1122
DWA9KB – SLS lube line release solenoid short circuit…………………………………………………………….1122
Wiring Diagram – CLS/SLS lube line release solenoid control……………………………………………………1123
DWA7KY – CLS line release sol. hot short circuit…………………………………………………………………1124
DWA9KY – SLS lube line release sol hot short circuit……………………………………………………………..1124
Wiring Diagram – CLS/SLS lube line release solenoid / hot short circuit…………………………………………1125
DWAAKA – PTO lube preload solenoid open circuit………………………………………………………………….1126
Wiring Diagram and monitoring screen for message DWAAKA……………………………………………………….1127
DWAAKB – PTO lube preload solenoid short circuit…………………………………………………………………1128
Wiring Diagram and monitoring screen for message DWAAKB……………………………………………………….1129
DWAAKY – PTO lube preload sol. hot short circuit…………………………………………………………………1130
Wiring Diagram for message DWAAKY…………………………………………………………………………..1131
D168KB – Oil cooler preload sol relay short circuit………………………………………………………………1132
Wiring Diagram and monitoring screen – Relay 11K070 (D168KB)…………………………………………………..1133
D1E9KB – Wiper fast relay short circuit…………………………………………………………………………1134
D1ETKB – Wiper slow relay short circuit…………………………………………………………………………1134
D1EBKB – Wiper stop relay short circuit…………………………………………………………………………1134
Wiring Diagram – wiper motor control………………………………………………………………………..1135
D162KB – Horn relay short circuit………………………………………………………………………………1136
Wiring Diagram and monitoring screen – signal horn control…………………………………………………….1137
D1F0KB – Engine1/motor1 shutdown relay short circuit……………………………………………………………..1138
D1F4KB – Engine2/motor2 shutdown relay short circuit……………………………………………………………..1138
Wiring Diagram and monitoring screen – engine1/2 shutdown relay 11K064-1/2………………………………………1139
D1F0KY – Engine1/motor1 shutdown relay hot short…………………………………………………………………1140
D1F4KY – Engine2/motor2 shutdown relay hot short…………………………………………………………………1140
Wiring Diagram for D1F0KY / D1F4KY………………………………………………………………………….1141
DWNCKA – Hyd. Oil Cooler fan pump1 Sol. open circuit……………………………………………………………..1142
DWNUKA – Hyd. Oil Cooler fan pump2 Sol. open circuit……………………………………………………………..1142
Wiring Diagram – Hyd. oil cooler fan pump1/2 solenoid…………………………………………………………1143
DWNCKB – Hyd. Oil Cooler fan pump1 Sol. short circuit…………………………………………………………….1144
DWNUKB – Hyd. Oil Cooler fan pump2 Sol. short circuit…………………………………………………………….1144
Wiring Diagram – Hyd. oil cooler fan pump1/2 solenoid…………………………………………………………1145
DXQ0KA – X1 pilot pressure pump1 Sol. open circuit……………………………………………………………….1146
DXQ1KA – X1 pilot pressure pump2 Sol. open circuit……………………………………………………………….1146
Wiring Diagram – X1 pilot pressure pump1/2 solenoid…………………………………………………………..1147
DXQ0KB – X1 pilot pressure pump1 Sol. short circuit………………………………………………………………1148
DXQ1KB – X1 pilot pressure pump2 Sol. short circuit………………………………………………………………1148
Wiring Diagram – X1 pilot pressure pump1/2 solenoid…………………………………………………………..1149
DWN5KA – Radiator fan pump1 Sol. open circuit……………………………………………………………………1150
DWNTKA – Radiator fan pump2 Sol. open circuit……………………………………………………………………1150
Wiring Diagram – Radiator fan pump1/2 solenoid……………………………………………………………….1151
DWN5KB – Radiator fan pump1 Sol. short circuit…………………………………………………………………..1152
DWNTKB – Radiator fan pump2 Sol. short circuit…………………………………………………………………..1152
Wiring Diagram – Radiator fan pump1/2 solenoid……………………………………………………………….1153
D110KA – Battery relay open circuit…………………………………………………………………………….1154
Wiring Diagram – battery relay 11Q044d………………………………………………………………………1155
D110KB – Battery relay short circuit……………………………………………………………………………1156
Wiring Diagram – Battery relay 11Q044d………………………………………………………………………1157
DA29KQ – Model Selection Abnormality……………………………………………………………………………1158
Wiring Diagram and monitoring screen – machine selection PUMP1 (DA29KQ)…………………………………………1159
DA2YKQ – Motor/Engine Selection Abnormality……………………………………………………………………..1160
Monitoring screen for motor/engine selection PUMP1……………………………………………………………1160
DA20KQ – Pump Con Selection Abnormality…………………………………………………………………………1161
Monitoring screen for PUMP1 controller selection……………………………………………………………..1161
DA20MC – Pump Con Error……………………………………………………………………………………….1162
DLM8MA – Oil cooler fan1 speed sensor abnormality………………………………………………………………..1164
Wiring Diagram and monitoring screen – Oil cooler fan1 speed sensor (DLM8MA)…………………………………….1165
DXAGKA – Pump4 Front Solenoid open circuit………………………………………………………………………1166
DXAHKA – Pump4 Rear Solenoid open circuit……………………………………………………………………….1166
DXAJKA – Pump5 Front Solenoid open circuit………………………………………………………………………1166
DXAKKA – Pump5 Rear Solenoid open circuit……………………………………………………………………….1166
DXALKA – Pump6 Front Solenoid open circuit………………………………………………………………………1166
DXAMKA – Pump6 Rear Solenoid open circuit……………………………………………………………………….1166
Wiring Diagram – EPC valve control (PUMP2)…………………………………………………………………..1167
DXAGKB – Pump4 Front Solenoid short circuit……………………………………………………………………..1168
DXAHKB – Pump4 Rear Solenoid short circuit………………………………………………………………………1168
DXAJKB – Pump5 Front Solenoid short circuit……………………………………………………………………..1168
DXAKKB – Pump5 Rear Solenoid short circuit………………………………………………………………………1168
DXALKB – Pump6 Front Solenoid short circuit……………………………………………………………………..1168
DXAMKB – Pump6 Rear Solenoid short circuit………………………………………………………………………1168
Wiring Diagram – EPC valve control (PUMP2)…………………………………………………………………..1169
DWAEKA – CLS2 pump solenoid open circuit………………………………………………………………………..1170
Wiring Diagram and monitoring screen – CLS2 pump solenoid control………………………………………………1171
DWAEKB – CLS2 pump solenoid short circuit……………………………………………………………………….1172
Wiring Diagram and monitoring screen – CLS2 pump solenoid control………………………………………………1173
DWAEKY – CLS2 pump solenoid hot short circuit……………………………………………………………………1174
Wiring Diagram – CLS2 pump solenoid / hot short circuit……………………………………………………….1175
DWAFKA – CLS2 line release solenoid open circuit…………………………………………………………………1176
Wiring Diagram – CLS2 lube line release solenoid control………………………………………………………1177
DWAFKB – CLS2 line release solenoid short circuit………………………………………………………………..1178
Wiring Diagram – CLS2 lube line release solenoid control………………………………………………………1179
DWAFKY – CLS2 line release sol. hot short circuit………………………………………………………………..1180
Wiring Diagram – CLS2 lube line release solenoid / hot short circuit……………………………………………1181
DWABKA – PTO2 lube preload solenoid open circuit…………………………………………………………………1182
Wiring Diagram and monitoring screen for message DWABKA……………………………………………………….1183
DWABKB – PTO2 lube preload solenoid short circuit………………………………………………………………..1184
Wiring Diagram and monitoring screen for message DWABKB……………………………………………………….1185
DWABKY – PTO lube preload sol. hot short circuit…………………………………………………………………1186
Wiring Diagram for message DWABKY…………………………………………………………………………..1187
DGT8MA – PTO2 oil temperature sensor abnormality…………………………………………………………………1188
Wiring Diagram, monitoring screen, and location of 57B049-2……………………………………………………1189
DGE5MA – Ambient air temp sensor abnormality…………………………………………………………………….1190
Wiring Diagram and monitoring screen for message DGE5MA……………………………………………………….1191
DHQ8MA – PTO2 lube pressure sensor abnormality…………………………………………………………………..1192
Monitoring screen, Wiring Diagram, and location of 57B017-2……………………………………………………1193
DCH3KB – Fuel filter heating short circuit………………………………………………………………………1194
Wiring Diagram and monitoring screen for message DCH3KB……………………………………………………….1195
DCH3KY – Fuel filter heating hot short circuit…………………………………………………………………..1196
Wiring Diagram for message DCH3KY…………………………………………………………………………..1197
DCH4KB – Fuel filter drain pipe heating short……………………………………………………………………1198
Wiring Diagram and monitoring screen for message DCH4KB……………………………………………………….1199
DCH4KY – Fuel filter drain pipe heating hot short………………………………………………………………..1200
Wiring Diagram for message DCH4KY…………………………………………………………………………..1201
AB3EMA – Starter Circuit Abnormality……………………………………………………………………………1202
Wiring Diagram for AB3EMA………………………………………………………………………………….1203
D1EEKB – Starter cut relay short circuit………………………………………………………………………..1204
Wiring Diagram and monitoring screen – Starter cut relay for message D1EEKB……………………………………..1205
D1EEKY – Starter cut relay hot short circuit…………………………………………………………………….1206
Wiring Diagram – Starter cut relay for message D1EEKY…………………………………………………………1207
FF11KB – Starter power cut relay1 short circuit………………………………………………………………….1208
Wiring Diagram and monitoring screen – Starter power cut relay for message FF11KB………………………………..1209
FF11KY – Starter power cut relay1 hot short circuit………………………………………………………………1210
Wiring Diagram – Starter power cut relay1 hot short circuit for message FF11KY…………………………………..1211
FF11LK – Starter power cut relay1 abnormality……………………………………………………………………1212
FF12LK – Starter power cut relay2 abnormality……………………………………………………………………1214
DBZ7KP – 24V sensor power abnormality…………………………………………………………………………..1216
Wiring Diagram – 24V sensor power supply for DBZ7KP…………………………………………………………..1217
DBZ6KP – 5V sensor2 power abnormality…………………………………………………………………………..1218
Wiring Diagram – 5V sensor power supply for DBZ6KP……………………………………………………………1219
DBZLKA – Operating Lamp Open Circuit(Pump2 Con)………………………………………………………………….1220
Wiring Diagram – Operating Lamp Open Circuit(Pump2 Con)……………………………………………………….1221
DBZLKB – Operating Lamp Short Circuit(Pump2 Con)…………………………………………………………………1222
Wiring Diagram – Operating Lamp Short Circuit(Pump2 Con)………………………………………………………1223
DHPLMA – Pump-4 pressure sensor abnormality……………………………………………………………………..1224
DHPNMA – Pump-5 pressure sensor abnormality……………………………………………………………………..1224
DHPQMA – Pump-6 pressure sensor abnormality……………………………………………………………………..1224
Monitoring screen & Wiring Diagram – PWR & GND supply for pump pressure transducers (main pumps 4…6)……………..1226
DBZ2KK – Solenoid Power Low Error(Pump2 Con)…………………………………………………………………….1227
DLE6MA – Engine2 speed sensor abnormality……………………………………………………………………….1228
Monitoring screen and Wiring Diagram – 52B064-2 for message DLE6MA……………………………………………..1229
DBZ9KQ – Model Selection Abnormality……………………………………………………………………………1230
Wiring Diagram and monitoring screen – machine selection PUMP2 (DBZ9KQ)…………………………………………1231
DBZWKQ – Motor/Engine Selection Abnormality……………………………………………………………………..1232
Monitoring screen for motor/engine selection PUMP2……………………………………………………………1232
DBZ0KQ – Pump2 Con Selection Abnormality………………………………………………………………………..1233
Monitoring screen for PUMP2 controller selection……………………………………………………………..1233
DBZ0MC – Pump2 Con Error………………………………………………………………………………………1234
DLMAMA – Oil cooler fan2 speed sensor abnormality………………………………………………………………..1236
Wiring Diagram and monitoring screen – Oil cooler fan2 speed sensor (DLMAMA)…………………………………….1237
DDABL4 – Lock lever switch mismatch…………………………………………………………………………….1238
DDXAL4 – Ladder up position proximity switch mismatch…………………………………………………………….1239
DDXBL4 – Service arm upper position proximity switch mismatch……………………………………………………..1240
DKURMA – R lever right-left potentio abnormality…………………………………………………………………1242
Wiring Diagram – right lever right-left potentiometer input (DKURMA)……………………………………………1243
DKUSMA – R lever right-left redu pot abnorm(VALVE/M)……………………………………………………………..1244
Wiring Diagram – right lever redundant right-left potentiometer input (DKUSMA)…………………………………..1245
DKUQL8 – R lever right-left potentio error………………………………………………………………………1246
Wiring Diagram – right lever main + redundant right-left signal voltage (DKUQL8)…………………………………1247
DKUQL4 – R lever right-left sig. mismatch(VALVE/M)……………………………………………………………….1248
Wiring Diagram – R lever right-left redundant signal input at VALVE0 and VALVE1………………………………….1249
DKUNMA – R lever front-back potentio abnormality…………………………………………………………………1250
Wiring Diagram – right lever front-back potentiometer input (DKUNMA)……………………………………………1251
DKUPMA – R lever front-back redu pot abnorm(VALVE/M)……………………………………………………………..1252
Wiring Diagram – right lever redundant front-back potentiometer input (DKUPMA)…………………………………..1253
DKUML8 – R lever front-back potentio error………………………………………………………………………1254
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8)…………………………………….1255
DKUML4 – R lever front-back sig. mismatch(VALVE/M)……………………………………………………………….1256
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1…………………………………………..1257
DKUXMA – Left lever right-left potentio abnormality………………………………………………………………1258
Wiring Diagram – left lever right-left potentiometer input (DKUXMA)…………………………………………….1259
DKUYMA – L lever right-left redu pot abnorm(VALVE/M)……………………………………………………………..1260
Wiring Diagram – left lever redundant right-left potentiometer input (DKUYMA)……………………………………1261
DKUWL8 – L lever right-left potentio error………………………………………………………………………1262
Wiring Diagram – left lever main + redundant right-left signal voltage (DKUWL8)………………………………….1263
DKUWL4 – L lever right-left sig. mismatch(VALVE/M)……………………………………………………………….1264
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1…………………………………………..1265
DKUUMA – L lever front-back potentio abnormality…………………………………………………………………1266
Wiring Diagram – left lever front-back potentiometer input (DKUUMA)…………………………………………….1267
DKUVMA – L lever front-back redu pot abnorm(VALVE/M)……………………………………………………………..1268
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/M) for DKUVMA…………………………………………1269
DKUTL8 – L lever front-back potentio error………………………………………………………………………1270
Wiring Diagram – L lever front-back potentio error (DKUTL8)……………………………………………………1271
DKUTL4 – L lever front-back sig. mismatch(VALVE/M)……………………………………………………………….1272
Wiring Diagram – L lever front-back sig. mismatch(VALVE/M) for DKUTL4…………………………………………..1273
DKW1MA – R pedal potentio abnormality…………………………………………………………………………..1274
Wiring Diagram – R pedal potentio abnormality (DKW1MA)………………………………………………………..1275
DKW2MA – R pedal redundant pot abnormality(VALVE/M)………………………………………………………………1276
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA………………………………………….1277
DKW0L8 – R pedal potentio error………………………………………………………………………………..1278
Wiring Diagram – R pedal potentio error (DKW0L8)……………………………………………………………..1279
DKW0L4 – R pedal signal mismatch(VALVE/M Con)……………………………………………………………………1280
Wiring Diagram – R pedal signal mismatch(VALVE/M Con) for DKW0L4……………………………………………….1281
DKW4MA – L pedal potentio abnormality…………………………………………………………………………..1282
Wiring Diagram – L pedal potentio abnormality (DKW4MA)………………………………………………………..1283
DKW5MA – L pedal redundant pot abnormality(VALVE/M)………………………………………………………………1284
Wiring Diagram – L pedal redundant pot abnormality(VALVE/M) for DKW5MA………………………………………….1285
DKW3L8 – L pedal potentio error………………………………………………………………………………..1286
Wiring Diagram – L pedal potentio error (DKW3L8)……………………………………………………………..1287
DKW3L4 – L pedal signal mismatch(VALVE/M Con)……………………………………………………………………1288
Wiring Diagram – L pedal signal mismatch(VALVE/M Con) for DKW3L4……………………………………………….1289
DKW7MA – Clam open potentio abnormality…………………………………………………………………………1290
Wiring Diagram – Clam open potentio abnormality (DKW7MA)………………………………………………………1291
DKW8MA – Clam open redu pot abnormality(VALVE/M)…………………………………………………………………1292
Wiring Diagram – Clam open redu pot abnormality(VALVE/M) for DKW8MA…………………………………………….1293
DKW6L8 – Clam open potentio error………………………………………………………………………………1294
Wiring Diagram – Clam open potentio error (DKW6L8)……………………………………………………………1295
DKW6L4 – Clam open signal mismatch(VALVE/M Con)………………………………………………………………….1296
Wiring Diagram – Clam open signal mismatch(VALVE/M Con) for DKW6L4……………………………………………..1297
DKWAMA – Clam close potentio abnormality………………………………………………………………………..1298
Wiring Diagram – Clam close potentio abnormality (DKWAMA)……………………………………………………..1299
DKWBMA – Clam close redundant pot abnorm(VALVE/M)………………………………………………………………..1300
Wiring Diagram – Clam close redundant pot abnorm(VALVE/M) for DKWBMA……………………………………………1301
DKW9L8 – Clam close potentio error……………………………………………………………………………..1302
Wiring Diagram – Clam close potentio error (DKW9L8)…………………………………………………………..1303
DKW9L4 – Clam close signal mismatch(VALVE/M Con)…………………………………………………………………1304
Wiring Diagram – Clam close signal mismatch(VALVE/M Con) for DKW9L4…………………………………………….1305
DKWDMA – Hydraulic slew brake potentio abnormality……………………………………………………………….1306
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA)…………………………………………….1307
DKWEMA – Hyd. slew brake redu pot abnorm(VALVE/M)………………………………………………………………..1308
Wiring Diagram – Hyd. slew brake redu pot abnorm(VALVE/M) for DKWEMA……………………………………………1309
DKWCL8 – Hydraulic slew brake potentio error…………………………………………………………………….1310
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8)………………………………………………….1311
DKWCL4 – Hyd. slew brake sig. mismatch(VALVE/M)………………………………………………………………….1312
Wiring Diagram – Hyd. slew brake sig. mismatch(VALVE/M) for DKWCL4……………………………………………..1313
DBWLKA – Operating Lamp Open Circuit(VALVE/M Con)………………………………………………………………..1314
Wiring Diagram – Operating Lamp Open Circuit(VALVE/M Con)……………………………………………………..1315
DBWLKB – Operating Lamp Short Circuit(VALVE/M Con)……………………………………………………………….1316
Wiring Diagram – Operating Lamp Short Circuit(VALVE/M Con)…………………………………………………….1317
DWNPKA – Service arm up solenoid open circuit……………………………………………………………………1318
Wiring Diagram and monitoring screen for message DWNPKA……………………………………………………….1319
DWNPKB – Service arm up solenoid short circuit…………………………………………………………………..1320
Wiring Diagram and monitoring screen for message DWNPKB……………………………………………………….1321
DWNPKY – Service arm up solenoid hot short circuit……………………………………………………………….1322
Wiring Diagram and monitoring screen for message DWNPKY……………………………………………………….1323
DWNQKA – Service arm down solenoid open circuit………………………………………………………………….1324
Wiring Diagram and monitoring screen for message DWNQKA……………………………………………………….1325
DWNQKB – Service arm down solenoid short circuit…………………………………………………………………1326
Wiring Diagram and monitoring screen for message DWNQKB……………………………………………………….1327
DWNQKY – Service arm down solenoid hot short circuit……………………………………………………………..1328
Wiring Diagram and monitoring screen for message DWNQKY……………………………………………………….1329
DW4BKA – Travel parking brake solenoid open circuit………………………………………………………………1330
Wiring Diagram and monitoring screen for message DW4BKA……………………………………………………….1331
DW4BKB – Travel parking brake sol. short circuit…………………………………………………………………1332
Wiring Diagram and monitoring screen for message DW4BKB……………………………………………………….1333
DW4BKY – Travel parking brake sol. hot short circuit……………………………………………………………..1334
Wiring Diagram and monitoring screen for message DW4BKY……………………………………………………….1335
DW4BMA – Travel parking brake solenoid circuit abnormality………………………………………………………..1336
Wiring Diagram and monitoring screen for DW4BMA………………………………………………………………1337
DW45KA – Slew parking brake solenoid open circuit………………………………………………………………..1338
Wiring Diagram and monitoring screen for message DW45KA……………………………………………………….1339
DW45KB – Slew parking brake solenoid short circuit……………………………………………………………….1340
Wiring Diagram and monitoring screen for message DW45KB……………………………………………………….1341
DW45KY – Slew parking brake sol. hot short circuit……………………………………………………………….1342
Wiring Diagram and monitoring screen for message DW45KY……………………………………………………….1343
DW45MA – Slew parking brake solenoid circuit abnormality………………………………………………………….1344
Wiring Diagram and monitoring screen for DW45MA………………………………………………………………1345
DXN2KA – Boom1 epc solenoid open circuit (BHA)…………………………………………………………………..1346
DXN3KA – Stick1 epc solenoid open circuit……………………………………………………………………….1346
DXNJKA – Bucket1 epc solenoid open circuit………………………………………………………………………1346
DXNHKA – Travel1 left epc solenoid open circuit………………………………………………………………….1346
DXN4KA – Boom2 epc solenoid open circuit………………………………………………………………………..1346
DXN5KA – Clam2 epc solenoid open circuit (FSA)…………………………………………………………………..1346
DXN6KA – Stick2 epc solenoid open circuit (BHA)………………………………………………………………….1346
DXN8KA – Bucket2 epc solenoid open circuit………………………………………………………………………1346
DXNBKA – Bucket3 epc solenoid open circuit………………………………………………………………………1346
DXNCKA – Boom3 epc solenoid open circuit………………………………………………………………………..1346
DXNLKA – Stick3 epc solenoid open circuit……………………………………………………………………….1346
DXNKKA – Travel3 right epc solenoid open circuit…………………………………………………………………1346
DXNMKA – Slew4 epc solenoid open circuit………………………………………………………………………..1346
Details of above 6-digit failure codes (FSA & BHA)……………………………………………………………1347
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623………………………………………………………1348
Wiring Diagram for EPC 61K624 – 61K625………………………………………………………………………1349
Wiring Diagram for EPC 61K626 – 61K627 – 61K628 – 61K629………………………………………………………1350
Wiring Diagram for EPC 61K630 – 61K631 – 61K632………………………………………………………………1351
Monitoring screens as an example……………………………………………………………………………1352
DXN2KB – Boom1 epc solenoid short circuit (BHA)………………………………………………………………….1354
DXN3KB – Stick1 epc solenoid short circuit………………………………………………………………………1354
DXNJKB – Bucket1 epc solenoid short circuit……………………………………………………………………..1354
DXNHKB – Travel1 left epc solenoid short circuit…………………………………………………………………1354
DXN4KB – Boom2 epc solenoid short circuit……………………………………………………………………….1354
DXN5KB – Clam2 epc solenoid short circuit (FSA)………………………………………………………………….1354
DXN6KB – Stick2 epc solenoid short circuit (BHA)…………………………………………………………………1354
DXN8KB – Bucket2 epc solenoid short circuit……………………………………………………………………..1354
DXNBKB – Bucket3 epc solenoid short circuit……………………………………………………………………..1354
DXNCKB – Boom3 epc solenoid short circuit……………………………………………………………………….1354
DXNLKB – Stick3 epc solenoid short circuit………………………………………………………………………1354
DXNKKB – Travel3 right epc solenoid short circuit………………………………………………………………..1354
DXNMKB – Slew4 epc solenoid short circuit……………………………………………………………………….1354
Details of above 6-digit failure codes (FSA & BHA)……………………………………………………………1355
DXN2KY – Boom1 epc solenoid hot short circuit (BHA)………………………………………………………………1356
DXN3KY – Stick1 epc solenoid hot short circuit…………………………………………………………………..1356
DXNJKY – Bucket1 epc solenoid hot short circuit………………………………………………………………….1356
DXNHKY – Travel1 left epc solenoid hot short circuit……………………………………………………………..1356
DXN4KY – Boom2 epc solenoid hot short circuit……………………………………………………………………1356
DXN5KY – Clam2 epc solenoid hot short circuit (FSA)………………………………………………………………1356
DXN6KY – Stick2 epc solenoid hot short circuit (BHA)……………………………………………………………..1356
DXN8KY – Bucket2 epc solenoid hot short circuit………………………………………………………………….1356
DXNBKY – Bucket3 epc solenoid hot short circuit………………………………………………………………….1356
DXNCKY – Boom3 epc solenoid hot short circuit……………………………………………………………………1356
DXNLKY – Stick3 epc solenoid hot short circuit…………………………………………………………………..1356
DXNKKY – Travel3 right epc solenoid hot short circuit…………………………………………………………….1356
DXNMKY – Slew4 epc solenoid hot short circuit……………………………………………………………………1356
Details of above 6-digit failure codes (FSA & BHA)……………………………………………………………1357
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623………………………………………………………1358
Wiring Diagram for EPC 61K624 – 61K625………………………………………………………………………1359
Wiring Diagram for EPC 61K626 – 61K627 – 61K628 – 61K629………………………………………………………1360
Wiring Diagram for EPC 61K630 – 61K631 – 61K632………………………………………………………………1361
DWACKA – Service arm check valve sol. open circuit……………………………………………………………….1362
Wiring Diagram and monitoring screen for message DWACKA……………………………………………………….1363
DWACKB – Service arm check valve sol. short circuit………………………………………………………………1364
Wiring Diagram and monitoring screen for message DWACKB……………………………………………………….1365
DWACKY – Service arm check valveSol hotShortCircuit………………………………………………………………1366
Wiring Diagram and monitoring screen for message DWACKY……………………………………………………….1367
DWADKA – Ladder speed control solenoid open circuit………………………………………………………………1368
Wiring Diagram and monitoring screen for message DWADKA……………………………………………………….1369
DWADKB – Ladder speed control sol. short circuit…………………………………………………………………1370
Wiring Diagram and monitoring screen for message DWADKB……………………………………………………….1371
DWADKY – Ladder speed control sol. hot short circuit……………………………………………………………..1372
Wiring Diagram – Ladder speed control sol. hot short circuit (DWADKY)…………………………………………..1373
DBW5MA – 5V sensor1 power abnormality…………………………………………………………………………..1374
DBW6MA – 5V sensor2 power abnormality…………………………………………………………………………..1374
Wiring Diagram – 5V power supply and GND output at VALVE0……………………………………………………..1378
DBW9KQ – Model Selection Abnormality……………………………………………………………………………1380
Monitoring screen and Wiring Diagram – model selection abnormality (DBW9KQ)……………………………………..1381
DBWZKQ – Lever control selection abnormality…………………………………………………………………….1382
Monitoring screen & Wiring Diagram – Lever control selection abnormality (DBWZKQ)………………………………..1383
DBWYKQ – Attachment selection abnormality……………………………………………………………………….1384
Monitoring screen & Wiring Diagram – Attachment selection abnormality (DBWYKQ)…………………………………..1385
DBW2KK – Solenoid Power Low Error(VALVE/M Con)…………………………………………………………………..1386
Wiring Diagram 1 for message DBW2KK…………………………………………………………………………1388
Wiring Diagram 2 for message DBW2KK…………………………………………………………………………1389
DBW0KQ – VALVE/M Con Selection Abnormality………………………………………………………………………1390
Monitoring screen and Wiring Diagram for message DBW0KQ……………………………………………………….1391
DBW0MA – VALVE/M Con Error…………………………………………………………………………………….1392
DDDWMC – Ladder operation switch abnormality…………………………………………………………………….1394
Wiring Diagram and monitoring screen for message DDDWMC……………………………………………………….1395
DKWHMA – R lever right-left redu pot abnorm(VLV/S1)………………………………………………………………1396
Wiring Diagram – right lever redundant right-left potentiometer input (DKWHMA)…………………………………..1397
DKWFL4 – R lever right-left sig. mismatch(VALVE/S1)………………………………………………………………1398
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1…………………………………………..1399
DKWLMA – R lever front-back redu pot abnorm(VLV/S1)………………………………………………………………1400
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA)…………………………………..1401
DKWJL4 – R lever front-back sig. mismatch(VALVE/S1)………………………………………………………………1402
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1…………………………………………..1403
DKWPMA – L lever right-left redu pot abnorm(VLV/S1)………………………………………………………………1404
Wiring Diagram – left lever redundant right-left potentiometer input (DKWPMA)……………………………………1405
DKWML4 – L lever right-left sig. mismatch(VALVE/S1)………………………………………………………………1406
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1…………………………………………..1407
DKWSMA – L lever front-back redu pot abnorm(VLV/S1)………………………………………………………………1408
Wiring Diagram – L lever front-back redu pot abnorm(VLV/S1) for DKWSMA………………………………………….1409
DKWQL4 – L lever front-back sig. mismatch(VALVE/S1)………………………………………………………………1410
Wiring Diagram – L lever front-back sig. mismatch(VALVE/S1) for DKWQL4………………………………………….1411
DKWVMA – R pedal red pot abnormality(VALVE/S1)…………………………………………………………………..1412
Wiring Diagram – R pedal red pot abnormality(VALVE/S1) for DKWVMA………………………………………………1413
DKWTL4 – R pedal signal mismatch(VALVE/S1 Con)…………………………………………………………………..1414
Wiring Diagram – R pedal signal mismatch(VALVE/S1 Con) for DKWTL4………………………………………………1415
DKWYMA – L pedal red pot abnormality(VALVE/S1)…………………………………………………………………..1416
Wiring Diagram – L pedal red pot abnormality(VALVE/S1) for DKWYMA………………………………………………1417
DKWWL4 – L pedal signal mismatch(VALVE/S1 Con)…………………………………………………………………..1418
Wiring Diagram – L pedal signal mismatch(VALVE/S1 Con) for DKWWL4………………………………………………1419
DKX2MA – Clam open redu pot abnormality(VALVE/S1)………………………………………………………………..1420
Wiring Diagram – Clam open redu pot abnormality(VALVE/S1) for DKX2MA……………………………………………1421
DKX0L4 – Clam open signal mismatch(VALVE/S1 Con)…………………………………………………………………1422
Wiring Diagram – Clam open signal mismatch(VALVE/S1 Con) for DKX0L4…………………………………………….1423
DKX5MA – Clam close redu pot abnormality(VALVE/S1)……………………………………………………………….1424
Wiring Diagram – Clam close redu pot abnormality(VALVE/S1) for DKX5MA…………………………………………..1425
DKX3L4 – Clam close signal mismatch(VALVE/S1 Con)………………………………………………………………..1426
Wiring Diagram – Clam close signal mismatch(VALVE/S1 Con) for DKX3L4……………………………………………1427
DKX8MA – Hyd. slew brake redu pot abnorm(VALVE/S1)……………………………………………………………….1428
Wiring Diagram – Hyd. slew brake redu pot abnorm(VALVE/S1) for DKX8MA…………………………………………..1429
DKX6L4 – Hyd. slew brake signal mismatch(VALVE/S1)……………………………………………………………….1430
Wiring Diagram – Hyd. slew brake signal mismatch(VALVE/S1) for DKX6L4…………………………………………..1431
DBXLKA – Operating Lamp Open Circuit(VALVE/S1 Con)……………………………………………………………….1432
Wiring Diagram – Operating Lamp Open Circuit((VALVE/S1 Con)……………………………………………………1433
DBXLKB – Operating Lamp Short Circuit(VALVE/S1 Con)………………………………………………………………1434
Wiring Diagram – Operating Lamp Short Circuit(VALVE/S1 Con)……………………………………………………1435
DWNRKB – Ladder up solenoid short circuit……………………………………………………………………….1436
Wiring Diagram and monitoring screen for message DWNRKB……………………………………………………….1437
DWNRKY – Ladder up solenoid hot short circuit……………………………………………………………………1438
Wiring Diagram – Ladder up solenoid hot short circuit (DWNRKY)…………………………………………………1439
DWNRMA – Ladder up solenoid circuit abnormality………………………………………………………………….1440
Wiring Diagram and monitoring screen for DWNRMA………………………………………………………………1441
DW7RKA – Hydraulic slew brake solenoid open circuit………………………………………………………………1442
Wiring Diagram and monitoring screen for message DW7RKA……………………………………………………….1443
DW7RKB – Hydraulic slew brake sol. short circuit…………………………………………………………………1444
Wiring Diagram and monitoring screen for message DW7RKB……………………………………………………….1445
DW7RKY – Hyd. slew brake sol. hot short circuit………………………………………………………………….1446
Wiring Diagram – Hyd. slew brake sol. hot short circuit (DW7RKY)……………………………………………….1447
DWASKA – Bucket1 fill solenoid open circuit……………………………………………………………………..1448
Wiring Diagram and monitoring screen for message DWASKA……………………………………………………….1449
DWASKB – Bucket1 fill solenoid short circuit…………………………………………………………………….1450
Wiring Diagram and monitoring screen for message DWASKB……………………………………………………….1451
DWASKY – Bucket1 fill solenoid hot short circuit…………………………………………………………………1452
Wiring Diagram and monitoring screen for message DWASKY……………………………………………………….1453
DWAWKA – Bucket1 dump solenoid open circuit……………………………………………………………………..1454
Wiring Diagram and monitoring screen for message DWAWKA……………………………………………………….1455
DWAWKB – Bucket1 dump solenoid short circuit…………………………………………………………………….1456
Wiring Diagram and monitoring screen for message DWAWKB……………………………………………………….1457
DWAWKY – Bucket1 dump solenoid hot short circuit…………………………………………………………………1458
Wiring Diagram and monitoring screen for message DWAWKY……………………………………………………….1459
DWKAKA – Travel1 left forward sol. open circuit………………………………………………………………….1460
Wiring Diagram and monitoring screen for message DWKAKA……………………………………………………….1461
DWKAKB – Travel1 left forward sol. short circuit…………………………………………………………………1462
Wiring Diagram and monitoring screen for message DWKAKB……………………………………………………….1463
DWKAKY – Travel1 left forward sol. hot short circuit……………………………………………………………..1464
Wiring Diagram and monitoring screen for message DWKAKY……………………………………………………….1465
DWKEKA – Travel1 left backward sol. open circuit…………………………………………………………………1466
Wiring Diagram and monitoring screen for message DWKEKA……………………………………………………….1467
DWKEKB – Travel1 left backward sol. short circuit………………………………………………………………..1468
Wiring Diagram and monitoring screen for message DWKEKB……………………………………………………….1469
DWKEKY – Travel1 left backward sol. hot short circuit…………………………………………………………….1470
Wiring Diagram and monitoring screen for message DWKEKY……………………………………………………….1471
DWBEKA – Boom1 down solenoid open circuit……………………………………………………………………….1472
Wiring Diagram and monitoring screen for message DWBEKA……………………………………………………….1473
DWBEKB – Boom1 down solenoid short circuit………………………………………………………………………1474
Wiring Diagram and monitoring screen for message DWBEKB……………………………………………………….1475
DWBEKY – Boom1 down solenoid hot short circuit…………………………………………………………………..1476
Wiring Diagram and monitoring screen for message DWBEKY……………………………………………………….1477
DWBAKA – Boom1 up solenoid open circuit…………………………………………………………………………1478
Wiring Diagram and monitoring screen for message DWBAKA……………………………………………………….1479
DWBAKB – Boom1 up solenoid short circuit………………………………………………………………………..1480
Wiring Diagram and monitoring screen for message DWBAKB……………………………………………………….1481
DWBAKY – Boom1 up solenoid hot short circuit…………………………………………………………………….1482
Wiring Diagram and monitoring screen for message DWBAKY……………………………………………………….1483
DWBJKA – Stick1 out solenoid open circuit……………………………………………………………………….1484
Wiring Diagram and monitoring screen for message DWBJKA……………………………………………………….1485
DWBJKB – Stick1 out solenoid short circuit………………………………………………………………………1486
Wiring Diagram and monitoring screen for message DWBJKB……………………………………………………….1487
DWBJKY – Stick1 out solenoid hot short circuit…………………………………………………………………..1488
Wiring Diagram and monitoring screen for message DWBJKY……………………………………………………….1489
DWBNKA – Stick1 in solenoid open circuit………………………………………………………………………..1490
Wiring Diagram and monitoring screen for message DWBNKA……………………………………………………….1491
DWBNKB – Stick1 in solenoid short circuit……………………………………………………………………….1492
Wiring Diagram and monitoring screen for message DWBNKB……………………………………………………….1493
DWBNKY – Stick1 in solenoid hot short circuit……………………………………………………………………1494
Wiring Diagram and monitoring screen for message DWBNKY……………………………………………………….1495
DWBBKA – Boom2 up solenoid open circuit…………………………………………………………………………1496
Wiring Diagram (BHA) and monitoring screen for message DWBBKA………………………………………………….1497
Wiring Diagram (FSA) and monitoring screen for message DWBBKA………………………………………………….1498
DWBBKB – Boom2 up solenoid short circuit………………………………………………………………………..1499
Wiring Diagram (BHA) and monitoring screen for message DWBBKB………………………………………………….1500
Wiring Diagram (FSA) and monitoring screen for message DWBBKA………………………………………………….1501
DWBBKY – Boom2 up solenoid hot short circuit…………………………………………………………………….1502
Wiring Diagram for message DWBBKY…………………………………………………………………………..1503
DWBFKA – Boom2 down solenoid open circuit……………………………………………………………………….1504
Wiring Diagram (BHA) and monitoring screen for message DWBFKA………………………………………………….1505
Wiring Diagram (FSA) and monitoring screen for message DWBFKA………………………………………………….1506
DWBFKB – Boom2 down solenoid short circuit………………………………………………………………………1507
Wiring Diagram (BHA) and monitoring screen for message DWBFKB………………………………………………….1508
Wiring Diagram (FSA) and monitoring screen for message DWBFKB………………………………………………….1509
DWBFKY – Boom2 down solenoid hot short circuit…………………………………………………………………..1510
Wiring Diagram for message DWBFKY…………………………………………………………………………..1511
DWBXKA – Clam2 close solenoid open circuit………………………………………………………………………1512
Wiring Diagram and monitoring screen for message DWBXKA……………………………………………………….1513
DWBXKB – Clam2 close solenoid short circuit……………………………………………………………………..1514
Wiring Diagram and monitoring screen for message DWBXKB……………………………………………………….1515
DWBXKY – Clam2 close solenoid hot short circuit………………………………………………………………….1516
Wiring Diagram and monitoring screen for message DWBXKY……………………………………………………….1517
DWBKKA – Stick2 out solenoid open circuit……………………………………………………………………….1518
Wiring Diagram and monitoring screen for message DWBKKA……………………………………………………….1519
DWBKKB – Stick2 out solenoid short circuit………………………………………………………………………1520
Wiring Diagram and monitoring screen for message DWBKKB……………………………………………………….1521
DWBKKY – Stick2 out solenoid hot short circuit…………………………………………………………………..1522
Wiring Diagram and monitoring screen for message DWBKKY……………………………………………………….1523
DWBTKA – Clam2 open solenoid open circuit……………………………………………………………………….1524
Wiring Diagram and monitoring screen for message DWBTKA……………………………………………………….1525
DWBTKB – Clam2 open solenoid short circuit………………………………………………………………………1526
Wiring Diagram and monitoring screen for message DWBTKB……………………………………………………….1527
DWBTKY – Clam2 open solenoid hot short circuit…………………………………………………………………..1528
Wiring Diagram and monitoring screen for message DWBTKY……………………………………………………….1529
DWBPKA – Stick2 in solenoid open circuit………………………………………………………………………..1530
Wiring Diagram and monitoring screen for message DWBPKA……………………………………………………….1531
DWBPKB – Stick2 in solenoid short circuit……………………………………………………………………….1532
Wiring Diagram and monitoring screen for message DWBPKB……………………………………………………….1533
DWBPKY – Stick2 in solenoid hot short circuit……………………………………………………………………1534
Wiring Diagram and monitoring screen for message DWBPKY……………………………………………………….1535
DWATKA – Bucket2 fill solenoid open circuit……………………………………………………………………..1536
Wiring Diagram (BHA) and monitoring screen for message DWATKA………………………………………………….1537
Wiring Diagram (FSA) and monitoring screen for message DWATKA………………………………………………….1538
DWATKB – Bucket2 fill solenoid short circuit…………………………………………………………………….1539
Wiring Diagram (BHA) and monitoring screen for message DWATKB………………………………………………….1540
Wiring Diagram (FSA) and monitoring screen for message DWATKB………………………………………………….1541
DWATKY – Bucket2 fill solenoid hot short circuit…………………………………………………………………1542
Wiring Diagram for message DWATKY…………………………………………………………………………..1543
DWAXKA – Bucket2 dump solenoid open circuit……………………………………………………………………..1544
Wiring Diagram (BHA) and monitoring screen for message DWAXKA………………………………………………….1545
Wiring Diagram (FSA) and monitoring screen for message DWAXKA………………………………………………….1546
DWAXKB – Bucket2 dump solenoid short circuit…………………………………………………………………….1547
Wiring Diagram (BHA) and monitoring screen for message DWAXKB………………………………………………….1548
Wiring Diagram (FSA) and monitoring screen for message DWAXKB………………………………………………….1549
DWAXKY – Bucket2 dump solenoid hot short circuit…………………………………………………………………1550
Wiring Diagram and monitoring screen for message DWAXKY……………………………………………………….1551
D5ZWKB – Travel hour meter short circuit………………………………………………………………………..1552
Wiring Diagram and monitoring screen for message D5ZWKB……………………………………………………….1553
D1EUKB – Travel alarm relay short circuit……………………………………………………………………….1554
Wiring Diagram and monitoring screen for message D1EUKB……………………………………………………….1555
DBX9KQ – Model Selection Abnormality……………………………………………………………………………1556
Wiring Diagram and monitoring screen for message DBX9KQ……………………………………………………….1557
DBXZKQ – Lever Control Selection Abnormality…………………………………………………………………….1558
Wiring Diagram and monitoring screen for message DBXZKQ……………………………………………………….1559
DBXYKQ – Attachment selection abnormality……………………………………………………………………….1560
Wiring Diagram – Attachment selection abnormality (DBXYKQ)…………………………………………………….1561
D561MA – Lock lever sol. power cut abnorm(VALVE/S1)………………………………………………………………1562
Wiring Diagram 1 for message D561MA…………………………………………………………………………1564
Monitoring screens and Wiring Diagram 2 for message D561MA…………………………………………………….1565
D563MA – Ladder up sensor sol cut abnorm(VLV/S1)…………………………………………………………………1566
Wiring Diagram 1 for message D563MA…………………………………………………………………………1568
Monitoring screens and Wiring Diagram 2 for message D563MA…………………………………………………….1569
D565MA – Service arm (up) sensor sol cut abnorm(VLV/S1)…………………………………………………………..1570
Wiring Diagram 1 for message D565MA…………………………………………………………………………1572
Wiring Diagram 2 and monitoring screens for message D565MA…………………………………………………….1573
DBX2KK – Solenoid Power Low Error(VALVE/S1 Con)………………………………………………………………….1574
Monitoring screen and Wiring Diagram 1 for message DBX2KK……………………………………………………..1575
Wiring Diagram 2 for message DBX2KK – PPC safety circuit………………………………………………………1576
DBX0KQ – VALVE/S1 Con Selection Abnormality……………………………………………………………………..1577
Wiring Diagram and monitoring screen for message DBX0KQ……………………………………………………….1578
DBX0MA – VALVE/S1 Con Error……………………………………………………………………………………1579
DBYLKA – Operating Lamp Open Circuit(VALVE/S2 Con)……………………………………………………………….1580
Wiring Diagram – Operating Lamp Open Circuit(VALVE/S2 Con)…………………………………………………….1581
DBYLKB – Operating Lamp Short Circuit(VALVE/S2 Con)………………………………………………………………1582
Wiring Diagram – Operating Lamp Short Circuit(VALVE/S2 Con)……………………………………………………1583
DWAUKA – Bucket3 fill solenoid open circuit……………………………………………………………………..1584
Wiring Diagram and monitoring screen for message DWAUKA……………………………………………………….1585
DWAUKB – Bucket3 fill solenoid short circuit…………………………………………………………………….1586
Wiring Diagram and monitoring screen for message DWAUKB……………………………………………………….1587
DWAUKY – Bucket3 fill solenoid hot short circuit…………………………………………………………………1588
Wiring Diagram and monitoring screen for message DWAUKY……………………………………………………….1589
DWAYKA – Bucket3 dump solenoid open circuit……………………………………………………………………..1590
Wiring Diagram and monitoring screen for message DWAYKA……………………………………………………….1591
DWAYKB – Bucket3 dump solenoid short circuit…………………………………………………………………….1592
Wiring Diagram and monitoring screen for message DWAYKB……………………………………………………….1593
DWAYKY – Bucket3 dump solenoid hot short circuit…………………………………………………………………1594
Wiring Diagram and monitoring screen for message DWAYKY……………………………………………………….1595
DWBCKA – Boom3 up solenoid open circuit…………………………………………………………………………1596
Wiring Diagram and monitoring screen for message DWBCKA……………………………………………………….1597
DWBCKB – Boom3 up solenoid short circuit………………………………………………………………………..1598
Wiring Diagram and monitoring screen for message DWBCKB……………………………………………………….1599
DWBCKY – Boom3 up solenoid hot short circuit…………………………………………………………………….1600
Wiring Diagram and monitoring screen for message DWBCKY……………………………………………………….1601
DWBGKA – Boom3 down solenoid open circuit……………………………………………………………………….1602
Wiring Diagram and monitoring screen for message DWBGKA……………………………………………………….1603
DWBGKB – Boom3 down solenoid short circuit………………………………………………………………………1604
Wiring Diagram and monitoring screen for message DWBGKB……………………………………………………….1605
DWBGKY – Boom3 down solenoid hot short circuit…………………………………………………………………..1606
Wiring Diagram and monitoring screen for message DWBGKY……………………………………………………….1607
DWBLKA – Stick3 out solenoid open circuit……………………………………………………………………….1608
Wiring Diagram (BHA) and monitoring screen for message DWBLKA………………………………………………….1609
Wiring Diagram (FSA) and monitoring screen for message DWBLKA………………………………………………….1610
DWBLKB – Stick3 out solenoid short circuit………………………………………………………………………1611
Wiring Diagram (BHA) and monitoring screen for message DWBLKB………………………………………………….1612
Wiring Diagram (FSA) and monitoring screen for message DWBLKB………………………………………………….1613
DWBLKY – Stick3 out solenoid hot short circuit…………………………………………………………………..1614
Wiring Diagram and monitoring screen for message DWBLKY……………………………………………………….1615
DWBQKA – Stick3 in solenoid open circuit………………………………………………………………………..1616
Wiring Diagram (BHA) and monitoring screen for message DWBQKA………………………………………………….1617
Wiring Diagram (FSA) and monitoring screen for message DWBQKA………………………………………………….1618
DWBQKB – Stick3 in solenoid short circuit……………………………………………………………………….1619
Wiring Diagram (BHA) and monitoring screen for message DWBQKB………………………………………………….1620
Wiring Diagram (FSA) and monitoring screen for message DWBQKB………………………………………………….1621
DWBQKY – Stick3 in solenoid hot short circuit……………………………………………………………………1622
Wiring Diagram and monitoring screen for message DWBQKY……………………………………………………….1623
DWKQKA – Travel3 right backward sol. open circuit………………………………………………………………..1624
Wiring Diagram and monitoring screen for message DWKQKA……………………………………………………….1625
DWKQKB – Travel3 right backward sol. short circuit……………………………………………………………….1626
Wiring Diagram and monitoring screen for message DWKQKB……………………………………………………….1627
DWKQKY – Travel3 right backward sol. hot short…………………………………………………………………..1628
Wiring Diagram and monitoring screen for message DWKQKY……………………………………………………….1629
DWKLKA – Travel3 right forward sol. open circuit…………………………………………………………………1630
Wiring Diagram and monitoring screen for message DWKLKA……………………………………………………….1631
DWKLKB – Travel3 right forward sol. short circuit………………………………………………………………..1632
Wiring Diagram and monitoring screen for message DWKLKB……………………………………………………….1633
DWKLKY – Travel3 right forward sol. hot short……………………………………………………………………1634
Wiring Diagram and monitoring screen for message DWKLKY……………………………………………………….1635
DWARKA – Slew4 right solenoid open circuit………………………………………………………………………1636
Wiring Diagram and monitoring screen for message DWARKA……………………………………………………….1637
DWARKB – Slew4 right solenoid short circuit……………………………………………………………………..1638
Wiring Diagram and monitoring screen for message DWARKB……………………………………………………….1639
DWARKY – Slew4 right solenoid hot short circuit………………………………………………………………….1640
Wiring Diagram and monitoring screen for message DWARKY……………………………………………………….1641
DWAMKA – Slew4 left solenoid open circuit……………………………………………………………………….1642
Wiring Diagram and monitoring screen for message DWAMKA……………………………………………………….1643
DWAMKB – Slew4 left solenoid short circuit………………………………………………………………………1644
Wiring Diagram and monitoring screen for message DWAMKB……………………………………………………….1645
DWAMKY – Slew4 left solenoid hot short circuit…………………………………………………………………..1646
Wiring Diagram and monitoring screen for message DWAMKY……………………………………………………….1647
DXEDKA – Hydraulic slew brake epc sol. open circuit………………………………………………………………1648
Wiring Diagram and monitoring screen for message DXEDKA……………………………………………………….1649
DXEDKB – Hyd. slew brake epc sol. short circuit………………………………………………………………….1650
Wiring Diagram and monitoring screen for message DXEDKB……………………………………………………….1651
DXEDKY – Hyd. slew brake epc sol. hot short circuit………………………………………………………………1652
Wiring Diagram and monitoring screen for message DXEDKY……………………………………………………….1653
DBY9KQ – Model Selection Abnormality……………………………………………………………………………1654
Wiring Diagram and monitoring screen for message DBY9KQ……………………………………………………….1655
DBYZKQ – Lever Control Selection Abnormality…………………………………………………………………….1656
Wiring Diagram and monitoring screen for message DBYZKQ……………………………………………………….1657
DBYYKQ – Attachment selection abnormality……………………………………………………………………….1658
Wiring Diagram – Attachment selection abnormality (DBYYKQ)…………………………………………………….1659
D562MA – Lock lever sol power cut abnorm(VALVE/S2)……………………………………………………………….1660
Wiring Diagram 1 for message D562MA…………………………………………………………………………1662
Monitoring screens and Wiring Diagram 2 for message D562MA…………………………………………………….1663
D564MA – Ladder up sensor sol cut abnorm(VLV/S2)…………………………………………………………………1664
Wiring Diagram 1 for message D564MA…………………………………………………………………………1666
Monitoring screens and Wiring Diagram 2 for message D564MA…………………………………………………….1667
D566MA – Service arm sensor sol cut abnorm(VALV/S2)………………………………………………………………1668
Wiring Diagram 1 for message D566MA…………………………………………………………………………1670
Monitoring screens and Wiring Diagram 2 for message D566MA…………………………………………………….1671
DBY2KK – Solenoid Power Low Error(VALVE/S2 Con)………………………………………………………………….1672
Monitoring screen and Wiring Diagram 1 for message DBY2KK……………………………………………………..1673
Wiring Diagram 2 for message DBY2KK – PPC safety circuit………………………………………………………1674
DBY0KQ – VALVE/S2 Con Selection Abnormality……………………………………………………………………..1675
Wiring Diagram and monitoring screen for message DBY0KQ……………………………………………………….1676
DBY0MA – VALVE/S2 Con Error……………………………………………………………………………………1677
DJH2KX – Hydraulic oil level sensor abnormality………………………………………………………………….1678
Wiring Diagram and monitoring screen for message DJH2KX……………………………………………………….1679
DJE3KX – Remote engine oil level1 sens. abnormality………………………………………………………………1680
DJE4KX – Remote engine oil level2 sens. abnormality………………………………………………………………1680
Wiring Diagram and monitoring screen for message DJE3KX & DJE4KX……………………………………………….1681
B@NHKX – Hydraulic oil tank air filter sensor abnormality…………………………………………………………1682
Wiring Diagram and monitoring screen for message B@NHKX……………………………………………………….1683
DH2GKX – Suction tank pressure sensor abnormality………………………………………………………………..1684
Wiring Diagram and monitoring screen for message DH2GKX……………………………………………………….1685
DH2HKX – Oil cooler pressure sensor abnormality………………………………………………………………….1686
Wiring Diagram and monitoring screen for message DH2HKX……………………………………………………….1687
DH2JKX – Preload valve return oil press abnormality………………………………………………………………1688
Wiring Diagram and monitoring screen for message DH2JKX……………………………………………………….1689
DHSUKX – X2 pressure sensor abnormality…………………………………………………………………………1690
Wiring Diagram and monitoring screen for message DHSUKX……………………………………………………….1691
DJF1KX – Fuel level sensor abnormality………………………………………………………………………….1692
Wiring Diagram and monitoring screen for message DJF1KX……………………………………………………….1693
DH2KKX – Return oil chamber press. sensor abnormal……………………………………………………………….1694
Wiring Diagram and monitoring screen for message DH2KKX……………………………………………………….1695
DH2LKX – Leak oil chamber press. sensor abnormality………………………………………………………………1696
Wiring Diagram and monitoring screen for message DH2LKX……………………………………………………….1697
DJE5L4 – SLS sensor system abnormality………………………………………………………………………….1698
Wiring Diagram and monitoring screen for message DJE5L4……………………………………………………….1699
DJE6L4 – CLS sensor system abnormality………………………………………………………………………….1700
Wiring Diagram and monitoring screen for message DJE6L4……………………………………………………….1701
DBVLKA – Operating Lamp Open Circuit(KOMTRAX)……………………………………………………………………1702
Wiring Diagram for message DBVLKA…………………………………………………………………………..1703
DBVLKB – Operating Lamp Short Circuit(KOMTRAX)…………………………………………………………………..1704
Wiring Diagram for message DBVLKB…………………………………………………………………………..1705
DBV1KK – KOMTRAX Plus source voltage Error………………………………………………………………………1706
Wiring Diagram for message DBV1KK…………………………………………………………………………..1707
DBV6KB – 24V Sensor Power Abnormality…………………………………………………………………………..1708
Wiring Diagram 1 and monitoring screens for message DBV6KB…………………………………………………….1709
DAFGMC – GPS Module Error……………………………………………………………………………………..1710
Wiring Diagram for message DAFGMC…………………………………………………………………………..1711
D862KA – GPS Antenna Open Circuit………………………………………………………………………………1712
DBVVKR – Ethernet 1 Disconnection………………………………………………………………………………1713
DBVWKR – Ethernet 2 Disconnection………………………………………………………………………………1714
DA2RKR – CAN1 Discon (Pump Con)………………………………………………………………………………..1716
CAN1 overview for message DA2RKR……………………………………………………………………………1717
DBZRKR – CAN1 Discon (Pump2 Con)……………………………………………………………………………….1718
CAN1 overview for message DBZRKR……………………………………………………………………………1719
DBWRKR – CAN1 Discon (Valve/M Con)……………………………………………………………………………..1720
CAN1 overview for message DBWRKR……………………………………………………………………………1721
DBXRKR – CAN1 Discon (Valve/S1 Con)…………………………………………………………………………….1722
CAN1 overview for message DBXRKR……………………………………………………………………………1723
DBYRKR – CAN1 Discon (Valve/S2 Con)…………………………………………………………………………….1724
CAN1 overview for message DBYRKR……………………………………………………………………………1725
DB2QKR – CAN2 Discon (Engine Con)………………………………………………………………………………1726
CAN2 overview for message DB2QKR……………………………………………………………………………1727
Wiring Diagram for PWR supply at 52K014-1 (DB2QKR)……………………………………………………………1728
F72QKR – CAN2 Discon (Engine2 Con)……………………………………………………………………………..1729
CAN2 overview for message F72QKR……………………………………………………………………………1730
Wiring Diagram for PWR supply at 52K014-2 (F72QKR)……………………………………………………………1731
DA2QKR – CAN2 Discon (Pump Con)………………………………………………………………………………..1732
CAN2 overview for message DA2QKR……………………………………………………………………………1733
DBZQKR – CAN2 Discon (Pump2 Con)……………………………………………………………………………….1734
CAN2 overview for message DBZQKR……………………………………………………………………………1735
DBWQKR – CAN2 Discon (Valve/M Con)……………………………………………………………………………..1736
CAN2 overview for message DBWQKR……………………………………………………………………………1737
DBXQKR – CAN2 Discon (Valve/S1 Con)…………………………………………………………………………….1738
CAN2 overview for message DBXQKR……………………………………………………………………………1739
DBYQKR – CAN2 Discon (Valve/S2 Con)…………………………………………………………………………….1740
CAN2 overview for message DBYQKR……………………………………………………………………………1741
DBVRKR – CAN1 Discon (KOMTRAX Plus)…………………………………………………………………………….1742
CAN1 overview for message DBVRKR……………………………………………………………………………1743
DBVQKR – CAN2 Discon (KOMTRAX Plus)…………………………………………………………………………….1744
CAN2 overview for message DBVQKR……………………………………………………………………………1745
DBPRKR – CAN1 Discon (KomVision)……………………………………………………………………………….1746
Wiring Diagram for DBPRKR………………………………………………………………………………….1747
DBPQKR – CAN2 Discon (KomVision)……………………………………………………………………………….1748
Wiring Diagram for DBPQKR………………………………………………………………………………….1749
DAFLKA – Operating Lamp Open Circuit(Monitor)……………………………………………………………………1750
Wiring Diagram for message DAFLKA…………………………………………………………………………..1751
DAFLKB – Operating Lamp Short Circuit(Monitor)…………………………………………………………………..1752
Wiring Diagram for message DAFLKB…………………………………………………………………………..1753
D5XLMA – Fuel Filter Failure…………………………………………………………………………………..1754
Wiring Diagram overview – fuel filtration system……………………………………………………………..1756
D19YKB – Emergency Lighting Ladder Relay Short Circuit……………………………………………………………1758
Wiring Diagram and monitoring screen for message D19YKB……………………………………………………….1759
DV00KB – Shutdown Buzzer Short Circuit………………………………………………………………………….1760
Wiring Diagram and monitoring screen for message DV00KB……………………………………………………….1761
DAF0KM – Inconsistency of KomVision Setting……………………………………………………………………..1762
DBP5KP – Camera Power Output Voltage Low………………………………………………………………………..1764
Wiring Diagram for message DBP5KP…………………………………………………………………………..1765
DBP0NR – KomVision Controller High Temperature Error……………………………………………………………..1766
DPQ4KB – Short Circuit of KomVision Monitor ON/OFF Signal…………………………………………………………1768
Wiring Diagram for message DPQ4KB…………………………………………………………………………..1769
DBP0KT – KomVision Controller Internal Error…………………………………………………………………….1770
DBP0KM – KomVision Controller Setting Error……………………………………………………………………..1771
DR10KA – Disconnection of Camera 1 NTSC Input……………………………………………………………………1772
DR20KA – Disconnection of Camera 2 NTSC Input……………………………………………………………………1772
DR30KA – Disconnection of Camera 3 NTSC Input……………………………………………………………………1772
DR40KA – Disconnection of Camera 4 NTSC Input……………………………………………………………………1772
DR50KA – Disconnection of Camera 5 NTSC Input……………………………………………………………………1772
DR60KA – Disconnection of Camera 6 NTSC Input……………………………………………………………………1772
DR90KA – Disconnection of Camera 7 NTSC Input……………………………………………………………………1772
Wiring Diagram for message DR10KA…DR90KA…………………………………………………………………..1773
DPQ4KT – KomVision Monitor Internal Error……………………………………………………………………….1774
DBPLKA – Operating Lamp Open Circuit (KomVision)…………………………………………………………………1776
Wiring Diagram for message DBPLKA…………………………………………………………………………..1777
DBPLKB – Operating Lamp Short Circuit (KomVision)………………………………………………………………..1778
Wiring Diagram for message DBPLKB…………………………………………………………………………..1779
DBPWKR – Ethernet 1 Discon (KomVision)………………………………………………………………………….1780
DBPXKR – Ethernet 2 Discon (KomVision)………………………………………………………………………….1780
7 Troubleshooting by Symptoms……………………………………………………………………………………..1781
7.1 Symptoms of engines and related electrical systems……………………………………………………………1782
SEL001 – Engine does not start (engine does not rotate)…………………………………………………………..1782
Wiring Diagram 1 (batteries) for symptom code SEL001………………………………………………………….1784
Wiring Diagram 2 (20S030 & 20S105a/b) for symptom code SEL001………………………………………………….1785
Wiring Diagram 3 (engine enable) for symptom code SEL001………………………………………………………1786
Wiring Diagram 4 (starter motors) for symptom code SEL001 (engine 1 as example)………………………………….1787
SEL002 – Engine stops while in operation………………………………………………………………………..1788
View onto the fuel system water separator (SEL002)……………………………………………………………1789
SEL003 – Engine speed is hunting during boom-up movement………………………………………………………….1790
SEL004 – Engine does not stop………………………………………………………………………………….1792
SEL005 – Engine lacks output (no power)…………………………………………………………………………1793
Judgment Table for SEL005………………………………………………………………………………….1794
SEL006 – Engine does not start (Pre-lube does not stop)…………………………………………………………..1795
SEL007 – Oil consumption is excessive…………………………………………………………………………..1796
Judgment Table for SEL007………………………………………………………………………………….1797
SEL008 – Oil becomes contaminated quickly……………………………………………………………………….1798
Judgment Table for SEL008………………………………………………………………………………….1799
SEL009 – Fuel consumption is excessive………………………………………………………………………….1800
Judgment Table for SEL009………………………………………………………………………………….1801
SEL010 – Oil is in engine coolant………………………………………………………………………………1802
Judgment Table for SEL010………………………………………………………………………………….1803
SEL011 – Oil level rises………………………………………………………………………………………1804
Judgment Table for SEL011………………………………………………………………………………….1805
SEL012 – Coolant temperature becomes too high (overheating)……………………………………………………….1806
Judgment Table for SEL012………………………………………………………………………………….1807
7.2 Symptoms of Hydraulic System……………………………………………………………………………….1808
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function)……………….1808
SHY002 – Engine speed sharply drops or engine stalls too much……………………………………………………..1810
SHY003 – No work equipment, travel, or slew movement……………………………………………………………..1811
SHY004 – Work equipment has too much hydraulic drift……………………………………………………………..1812
SHY005 – Work equipment has big time lag………………………………………………………………………..1813
SHY006 – Excavator deviates during travel movement……………………………………………………………….1814
SHY007 – Hydraulic system has lack of power……………………………………………………………………..1815
SHY008 – Excavator does not slew……………………………………………………………………………….1816
Slew brake block (SHY008)………………………………………………………………………………….1817
SHY009 – Slew acceleration is poor……………………………………………………………………………..1818
SHY010 – Excessive overrun when stopping slew movement……………………………………………………………1820
SHY011 – Floating system without function (FSA only)……………………………………………………………..1822
SHY012 – Abnormal noise coming from SRV or MRV…………………………………………………………………..1823
SHY013 – Track tensioning system without function………………………………………………………………..1824
Track tensioning – overview (SHY013)………………………………………………………………………..1825
SHY014 – Stairway does not move, or slow movement………………………………………………………………..1826
SHY015 – Refilling arm does not move, or slow movement……………………………………………………………1828
SHY016 – Hydraulic driven grease pump does not move………………………………………………………………1830
SHY017 – Abnormal track chain movement during digging…………………………………………………………….1832
SHY018 – Slew parking brake without function…………………………………………………………………….1833
SHY019 – Travel parking brake without function…………………………………………………………………..1834
7.3 Symptoms of Mechanical System………………………………………………………………………………1836
SME001 – Abnormal noise is made………………………………………………………………………………..1836
Judgment Table for SME001………………………………………………………………………………….1837
SME002 – Abnormal noise around PTOs / hydraulic pumps…………………………………………………………….1838
SME003 – Vibration is excessive (engine mountings)……………………………………………………………….1840
Judgment Table for SME003………………………………………………………………………………….1841
SME004 – Vibration is excessive (engine torsion)…………………………………………………………………1842
SME005 – There is a big shock when stopping slew movement…………………………………………………………1843
SME006 – There is a big abnormal noise when moving/stopping slew movement…………………………………………..1844
SME007 – Fan blades make abnormal noise…………………………………………………………………………1846
SME008 – Abnormal noise coming from a travel gearbox……………………………………………………………..1848
SME009 – Abnormal noise coming from work equipment (lack of grease)………………………………………………..1850
SME010 – Abnormal idler movement……………………………………………………………………………….1852
SME011 – Leak at PTO drive shaft seal…………………………………………………………………………..1854
7.4 Symptoms of Additional Systems……………………………………………………………………………..1856
SAD001 – Air conditioner for cabin does not work…………………………………………………………………1856
View onto A/C unit (SAD001)………………………………………………………………………………..1857
SAD002 – Air conditioner compressor clutch is burnt………………………………………………………………1858
View onto A/C compressor and its mounting (SAD002)……………………………………………………………1859
SAD003 – Air conditioning system defective (pipes and hoses full of moisture)……………………………………….1860
View onto A/C filling and service station……………………………………………………………………1861
50 DISASSEMBLY & ASSEMBLY…………………………………………………………………………………………….1863
TOC…………………………………………………………………………………………………………….1865
1 Introduction…………………………………………………………………………………………………..1873
1.1 Foreword…………………………………………………………………………………………………1874
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels…………………1875
1.3 Diagrams and illustrations in this manual……………………………………………………………………1875
1.4 Procedures for disassembling and assembling in this manual…………………………………………………….1876
2 Safety………………………………………………………………………………………………………..1877
2.1 Overview…………………………………………………………………………………………………1878
2.1.1 Method of using this manual…………………………………………………………………………..1878
2.2 General precautions……………………………………………………………………………………….1880
2.2.1 General…………………………………………………………………………………………….1880
2.2.2 Personal protective clothing………………………………………………………………………….1880
2.2.3 When using a hammer………………………………………………………………………………….1881
2.2.4 Proper tools………………………………………………………………………………………..1881
2.2.5 Personnel…………………………………………………………………………………………..1881
2.2.6 Fire prevention……………………………………………………………………………………..1882
2.2.7 Unauthorized modification…………………………………………………………………………….1882
2.3 Precautions for maintenance and repair………………………………………………………………………1883
2.3.1 General precautions………………………………………………………………………………….1883
2.3.2 Keep work place clean and tidy………………………………………………………………………..1883
2.3.3 Precautions when welding……………………………………………………………………………..1884
2.3.4 Precaution with high pressure fluids…………………………………………………………………..1884
2.3.4.1 Handling high pressure hoses and pipes……………………………………………………………1884
2.3.5 Compressed air………………………………………………………………………………………1884
2.3.6 Waste materials……………………………………………………………………………………..1885
2.3.7 Isolate the excavator using the transfer pump…………………………………………………………..1886
2.3.8 Isolate the excavator………………………………………………………………………………..1886
2.3.9 De-isolate the excavator……………………………………………………………………………..1887
3 Superstructure…………………………………………………………………………………………………1889
3.1 Superstructure overview……………………………………………………………………………………1890
3.2 Machinery house…………………………………………………………………………………………..1892
3.2.1 Disconnection plates…………………………………………………………………………………1894
3.2.1.1 R.H.-side disconnection plate [56XH01] – port allocations…………………………………………..1894
3.2.1.2 L.H.-side disconnection plate [50XH01] – port allocations…………………………………………..1895
3.2.2 Machinery house roof…………………………………………………………………………………1896
3.2.2.1 Disassembling of the machinery house roof cover plates……………………………………………..1898
3.2.2.2 Assembling of the machinery house roof cover plates………………………………………………..1904
3.2.2.3 Disassembling of the SCR catalysts (T4 Equipment)………………………………………………….1910
3.2.2.4 Assembling of the SCR catalysts (T4 Equipment)…………………………………………………….1915
3.2.2.5 Disassembling of the tank assembly (T4 Equipment)………………………………………………….1920
3.2.2.6 Assembling of the DEF tank assembly (T4 Equipment)…………………………………………………1923
3.2.3 Air intake system……………………………………………………………………………………1926
3.2.3.1 Disassembling of the air intake system……………………………………………………………1926
3.2.3.2 Assembling of the air intake system………………………………………………………………1929
3.2.4 Lubrication pump station……………………………………………………………………………..1932
3.2.4.1 Disassembling of the lubrication pump station……………………………………………………..1932
3.2.4.2 Assembling of the lubricating pump station………………………………………………………..1934
3.2.5 Diesel engines………………………………………………………………………………………1936
3.2.5.1 Disassembling of the Diesel engine (engine 1 or 2)…………………………………………………1936
3.2.5.2 Assembling of the Diesel engine (engine 1 or 2)……………………………………………………1943
3.2.5.3 Disassembling of the alternator………………………………………………………………….1950
3.2.5.4 Assembling of the alternator…………………………………………………………………….1951
3.2.5.5 Disassembling of the starter motor……………………………………………………………….1952
3.2.5.6 Assembling of the starter motor………………………………………………………………….1953
3.2.6 Batteries…………………………………………………………………………………………..1954
3.2.6.1 Disassembling of the batteries…………………………………………………………………..1954
3.2.6.2 Assembling of the batteries……………………………………………………………………..1956
3.2.7 Engine cooling system………………………………………………………………………………..1958
3.2.7.1 Disassembling of the radiator assembly……………………………………………………………1959
3.2.7.2 Assembling of the radiator assembly………………………………………………………………1962
3.2.7.3 Disassembling of the radiator fan assembly………………………………………………………..1965
3.2.7.4 Assembling of the radiator fan assembly…………………………………………………………..1968
3.2.8 Flexible drive coupling………………………………………………………………………………1971
3.2.8.1 Disassembling of the Geislinger coupling………………………………………………………….1971
3.2.8.2 Assembling of the Geislinger coupling…………………………………………………………….1973
3.2.8.3 Disassembling of the CentaFlex coupling assembly…………………………………………………..1975
3.2.8.4 Assembling of the CentaFlex coupling assembly……………………………………………………..1978
3.2.8.5 Replacing the rubber rollers of the CentaFlex coupling……………………………………………..1980
3.2.9 Main pump assemblies…………………………………………………………………………………1982
3.2.9.1 Disassembling of the main pump assemblies…………………………………………………………1983
3.2.9.2 Assembling of the main pump assemblies……………………………………………………………1987
3.2.10 Universal pump distributor gear box (PTO)……………………………………………………………..1990
3.2.10.1 Disassembling of the universal pump distributor gear box (PTO)……………………………………..1991
3.2.10.2 Assembling of the universal pump distributor gear box (PTO)………………………………………..1995
3.2.10.3 Disassembling of the control and filter plate assemblies…………………………………………..2000
3.2.10.4 Assembling of the control and filter plate assemblies……………………………………………..2009
3.2.10.5 Disassembling of the PTO gear oil pump…………………………………………………………..2018
3.2.10.6 Assembling of the PTO gear oil pump……………………………………………………………..2020
3.3 Hydraulic system………………………………………………………………………………………….2022
3.3.1 Hydraulic oil cooler assembly…………………………………………………………………………2022
3.3.1.1 Disassembling of hydraulic cooler fan…………………………………………………………….2023
3.3.1.2 Assembling of hydraulic cooler fan……………………………………………………………….2024
3.3.1.3 Disassembling of hydraulic cooler fan motor……………………………………………………….2025
3.3.1.4 Assembling of hydraulic cooler fan motor………………………………………………………….2027
3.3.1.5 Disassembling of the hydraulic oil coolers………………………………………………………..2029
3.3.1.6 Assembling of the hydraulic oil coolers…………………………………………………………..2032
3.3.1.7 Disassembling of the hydraulic oil cooler assembly…………………………………………………2035
3.3.1.8 Assembling of the hydraulic oil cooler assembly……………………………………………………2040
3.3.2 Hydraulic oil tank…………………………………………………………………………………..2046
3.3.2.1 Disassembling of the main shut-off valve………………………………………………………….2048
3.3.2.2 Assembling of the main shut-off valve…………………………………………………………….2050
3.3.2.3 Disassembling of the hydraulic oil tank…………………………………………………………..2052
3.3.2.4 Assembling of the hydraulic oil tank……………………………………………………………..2062
3.3.3 Control frame assembly……………………………………………………………………………….2074
3.3.3.1 Disassembling of the main control valve blocks I, II and III………………………………………..2075
3.3.3.2 Assembling of the main control valve blocks I, II and III…………………………………………..2079
3.3.3.3 Disassembling of the main control valve block IV (Slewing)………………………………………….2083
3.3.3.4 Assembling of the main control valve block IV (Slewing)…………………………………………….2085
3.3.3.5 Disassembling of the high pressure filters at the main control valve blocks…………………………..2087
3.3.3.6 Assembling of the high pressure filters at the main control valve blocks……………………………..2090
3.3.3.7 Disassembling of the MRV at the main control valve blocks…………………………………………..2093
3.3.3.8 Assembling of the MRV at the main control valve blocks……………………………………………..2094
3.3.3.9 Disassembling of SRV on main control valve block…………………………………………………..2095
3.3.3.10 Assembling of SRV on main control valve blocks……………………………………………………2097
3.3.3.11 Disassembling of ACV-/SRV-block on main control valve blocks……………………………………….2098
3.3.3.12 Assembling of ACV-/SRV-block on main control valve blocks………………………………………….2100
3.3.4 Distributor manifold…………………………………………………………………………………2102
3.3.4.1 Disassembling of throttle check valves at the distributor manifold…………………………………..2103
3.3.4.2 Assembling of throttle check valves at the distributor manifold……………………………………..2105
3.3.4.3 Disassembling of anti cavitation valves at the distributor manifold………………………………….2107
3.3.4.4 Assembling of anti cavitation valves at the distributor manifold…………………………………….2110
3.3.4.5 Disassembling of the distributor manifold…………………………………………………………2113
3.3.4.6 Assembling of the distributor manifold……………………………………………………………2116
3.4 Slew system………………………………………………………………………………………………2118
3.4.1 Slew gears………………………………………………………………………………………….2118
3.4.1.1 Disassembling of the slew gear…………………………………………………………………..2119
3.4.1.2 Assembling of the slew gear……………………………………………………………………..2123
3.4.2 Slew brake valve block……………………………………………………………………………….2127
3.4.2.1 Disassembling of the slew brake valve block……………………………………………………….2127
3.4.2.2 Assembling of the slew brake valve block………………………………………………………….2129
3.4.3 Hydraulic slew motors………………………………………………………………………………..2132
3.4.3.1 Disassembling of the slew motor………………………………………………………………….2132
3.4.3.2 Assembling of the slew motor…………………………………………………………………….2134
3.4.4 Slew parking brake…………………………………………………………………………………..2136
3.4.4.1 Disassembly of the slew parking brake of slew gear type 2063………………………………………..2137
3.4.4.2 Assembly of the slew parking brake of slew gear type 2063…………………………………………..2140
3.4.4.3 Disassembling of the slew parking brake of slew gear type 632770…………………………………….2143
3.4.4.4 Assembling of the slew parking brake of slew gear type 632770……………………………………….2147
3.4.5 Slew circle…………………………………………………………………………………………2150
3.4.5.1 Disassembling of the slew circle…………………………………………………………………2150
3.4.5.2 Assembling of the slew circle……………………………………………………………………2154
3.4.6 Slew circle lubrication pinion (dummy wheel)……………………………………………………………2155
3.4.6.1 Disassembling of the lubrication pinion assembly…………………………………………………..2156
3.4.6.2 Assembling of the lubrication pinion assembly……………………………………………………..2158
3.5 Operator’s cab……………………………………………………………………………………………2160
3.5.1 Disassembling of the operator’s cab……………………………………………………………………2161
3.5.2 Assembling of the operator’s cab………………………………………………………………………2165
3.5.3 Disassembling of the operator’s cab together with the cab support frame……………………………………2169
3.5.4 Assembling of the operator’s cab together with the cab support frame………………………………………2173
3.5.5 Cab-mounts………………………………………………………………………………………….2177
3.5.5.1 Disassembling of the cab-mounts………………………………………………………………….2177
3.5.5.2 Assembling of the cab-mounts…………………………………………………………………….2179
3.5.6 Front window………………………………………………………………………………………..2182
3.5.6.1 Disassembling of the front window………………………………………………………………..2182
3.5.6.2 Assembling of the front window…………………………………………………………………..2183
3.5.7 Operator’s seat……………………………………………………………………………………..2184
3.5.7.1 Disassembling of the operator’s seat……………………………………………………………..2184
3.5.7.2 Assembling of the operator’s seat………………………………………………………………..2185
3.6 Cab base…………………………………………………………………………………………………2186
3.6.1 Disassembling of the cab support frame…………………………………………………………………2187
3.6.2 Assembling of the cab support frame……………………………………………………………………2189
3.6.3 Disassembling of the cab base…………………………………………………………………………2191
3.6.4 Assembling of the cab base……………………………………………………………………………2194
3.7 Stairways, ladders and platforms……………………………………………………………………………2198
3.7.1 Hydraulic access stairway…………………………………………………………………………….2198
3.7.1.1 Disassembling of the hydraulic access stairway…………………………………………………….2198
3.7.1.2 Assembling of the hydraulic access stairway……………………………………………………….2200
3.7.1.3 Disassembling of the access stairway cylinder……………………………………………………..2202
3.7.1.4 Assembling of the access stairway cylinder………………………………………………………..2204
3.7.2 Fuel tank step………………………………………………………………………………………2205
3.7.2.1 Disassembling of the fuel tank step………………………………………………………………2205
3.7.2.2 Assembling of the fuel tank step…………………………………………………………………2207
3.7.3 Access stairway platform……………………………………………………………………………..2208
3.7.3.1 Disassembling of the access stairway platform……………………………………………………..2208
3.7.3.2 Assembling of the access stairway platform………………………………………………………..2211
3.7.4 Emergency escape ladders……………………………………………………………………………..2214
3.7.4.1 Disassembling of the emergency escape ladder assembly at the cab base………………………………..2214
3.7.4.2 Assembling of the emergency escape ladder assembly at the cab base…………………………………..2216
3.7.4.3 Disassembling of the emergency escape ladder assembly at the machinery house………………………….2217
3.7.4.4 Assembling of the emergency escape ladder assembly at the machinery house…………………………….2219
3.8 Counterweight…………………………………………………………………………………………….2220
3.8.1 Disassembling of the counterweight…………………………………………………………………….2220
3.8.2 Assembling of the counterweight……………………………………………………………………….2223
3.9 Fuel tank………………………………………………………………………………………………..2228
3.9.1 General information regarding disassembling and assembling……………………………………………….2228
3.9.2 Disassembling of the fuel tank………………………………………………………………………..2230
3.9.3 Assembling of the fuel tank…………………………………………………………………………..2239
3.10 Superstructure lifting……………………………………………………………………………………2250
3.10.1 Disassembling the superstructure from the undercarriage…………………………………………………2250
3.10.2 Assembling the superstructure onto the undercarriage……………………………………………………2253
4 Undercarriage………………………………………………………………………………………………….2257
4.1 Undercarriage overview…………………………………………………………………………………….2258
4.2 Travel system…………………………………………………………………………………………….2260
4.2.1 Crawler track……………………………………………………………………………………….2260
4.2.1.1 Changing of the crawler track……………………………………………………………………2260
4.2.1.2 Disassembling of the sprocket assembly……………………………………………………………2266
4.2.1.3 Assembling of the sprocket assembly………………………………………………………………2272
4.2.2 Guide wheel assembly…………………………………………………………………………………2275
4.2.2.1 Disassembling of the guide wheel assembly…………………………………………………………2275
4.2.2.2 Assembling of the guide wheel assembly……………………………………………………………2278
4.2.3 Track tensioning accumulators…………………………………………………………………………2281
4.2.3.1 Disassembling of the low pressure accumulators…………………………………………………….2281
4.2.3.2 Assembling of the low pressure accumulators……………………………………………………….2283
4.2.3.3 Disassembling of the high pressure accumulators……………………………………………………2285
4.2.3.4 Assembling of the high pressure accumulators………………………………………………………2286
4.2.4 Track tensioning valve block………………………………………………………………………….2287
4.2.4.1 Disassembling of the track tensioning valve block………………………………………………….2287
4.2.4.2 Assembling of the track tensioning valve block…………………………………………………….2289
4.2.5 Track tensioning cylinders……………………………………………………………………………2290
4.2.5.1 Disassembling of the track tensioning cylinders……………………………………………………2290
4.2.5.2 Assembling of the track tensioning cylinders………………………………………………………2292
4.2.6 Replace the hydraulic hoses of the track tensioning system……………………………………………….2294
4.2.6.1 Precursory work………………………………………………………………………………..2294
4.2.6.2 Replace the hydraulic hoses inside the undercarriage center body…………………………………….2296
4.2.6.3 Replace the hydraulic hose between undercarriage center body and crawler frame………………………..2296
4.2.6.4 Replace the hydraulic hoses inside the crawler frame……………………………………………….2298
4.2.6.5 Subsequent work………………………………………………………………………………..2298
4.2.7 Travel brake valve block (overspeed valve)……………………………………………………………..2299
4.2.7.1 Disassembling of the travel brake valve block……………………………………………………..2299
4.2.7.2 Assembling of the travel brake valve block………………………………………………………..2300
4.2.8 Travel motor………………………………………………………………………………………..2302
4.2.8.1 Disassembling of the travel motors……………………………………………………………….2302
4.2.8.2 Assembling of the travel motors………………………………………………………………….2304
4.2.9 Travel parking brake…………………………………………………………………………………2306
4.2.9.1 Disassembling of the travel parking brake of type 631053 and 2063……………………………………2307
4.2.9.2 Assembling of the travel parking brake of type 631053 and type 2063………………………………….2311
4.2.10 Travel gearbox……………………………………………………………………………………..2316
4.2.10.1 Disassembling of the travel gearbox……………………………………………………………..2317
4.2.10.2 Assembling of the travel gearbox………………………………………………………………..2319
4.2.11 Carrier rollers…………………………………………………………………………………….2322
4.2.11.1 Disassembling of the carrier roller assembly……………………………………………………..2322
4.2.11.2 Assembling of the carrier roller assembly………………………………………………………..2324
4.2.12 Track rollers………………………………………………………………………………………2326
4.2.12.1 Disassembling of the track roller assembly……………………………………………………….2326
4.2.12.2 Assembling of the track roller assembly………………………………………………………….2328
4.2.13 Replace the hydraulic hoses of the traveling system…………………………………………………….2332
4.3 Undercarriage center body………………………………………………………………………………….2336
4.3.1 Disassembling of the undercarriage center body and the crawler carriers……………………………………2336
4.3.2 Assembling of the undercarriage center body and the crawler carriers………………………………………2341
4.3.2.1 Install crawler carrier mounting bolts……………………………………………………………2346
4.3.3 Rotary joint………………………………………………………………………………………..2347
4.3.3.1 Disassembling of the rotary joint………………………………………………………………..2347
4.3.3.2 Assembling of the rotary joint…………………………………………………………………..2350
5 Attachment…………………………………………………………………………………………………….2355
5.1 Attachment bearings at superstructure……………………………………………………………………….2356
5.1.1 Boom foot bearings with full floating pins……………………………………………………………..2356
5.1.1.1 Disassembling of the boom foot bearings…………………………………………………………..2357
5.1.1.2 Assembling of the boom foot bearings……………………………………………………………..2359
5.1.2 Boom cylinder foot bearings with full floating pins……………………………………………………..2362
5.1.2.1 Disassembling of the boom cylinder foot bearings – BHA arrangement…………………………………..2364
5.1.2.2 Assembling of the boom cylinder foot bearings – BHA arrangement……………………………………..2366
5.1.2.3 Disassembling of the boom cylinder foot bearings – FSA arrangement…………………………………..2368
5.1.2.4 Assembling of the boom cylinder foot bearings – FSA arrangement……………………………………..2370
5.2 Repair procedures…………………………………………………………………………………………2372
5.2.1 Replacement of bushings at the attachment………………………………………………………………2372
5.2.1.1 Removal of the bushings…………………………………………………………………………2372
5.2.1.2 Installation of the bushings…………………………………………………………………….2373
5.2.2 General installation instructions for attachment pins……………………………………………………2374
5.3 Backhoe (BHA)…………………………………………………………………………………………….2376
5.3.1 Overview……………………………………………………………………………………………2376
5.3.2 Pin Sealing bucket – steering rod – bucket link rod……………………………………………………..2378
5.3.3 Boom assembly……………………………………………………………………………………….2380
5.3.3.1 Disassembling of the boom……………………………………………………………………….2380
5.3.3.2 Assembling of the boom………………………………………………………………………….2382
5.3.3.3 Disassembling of the boom cylinders………………………………………………………………2384
5.3.3.4 Assembling of the boom cylinders…………………………………………………………………2388
5.3.4 Stick assembly………………………………………………………………………………………2393
5.3.4.1 Disassembling of the stick………………………………………………………………………2393
5.3.4.2 Assembling of the stick…………………………………………………………………………2398
5.3.4.3 Disassembling of the stick cylinders……………………………………………………………..2403
5.3.4.4 Assembling of the stick cylinders………………………………………………………………..2408
5.3.5 Bucket and steering………………………………………………………………………………….2413
5.3.5.1 Disassembling of the bucket……………………………………………………………………..2413
5.3.5.2 Assembling of the bucket………………………………………………………………………..2417
5.3.5.3 Disassembling of the bucket cylinders…………………………………………………………….2420
5.3.5.4 Assembling of the bucket cylinders……………………………………………………………….2427
5.3.5.5 Disassembling of the bucket link rod……………………………………………………………..2434
5.3.5.6 Assembling of the bucket link rod………………………………………………………………..2438
5.3.5.7 Disassembling of the steering rods……………………………………………………………….2441
5.3.5.8 Assembling of the steering rods………………………………………………………………….2447
5.3.6 Hydraulic hoses at the backhoe attachment………………………………………………………………2452
5.3.6.1 Replace the boom arc hoses………………………………………………………………………2452
5.3.6.2 Replace the boom cylinder hoses………………………………………………………………….2456
5.3.6.3 Replace the stick cylinder hoses…………………………………………………………………2458
5.3.6.4 Replace the bucket cylinder hoses………………………………………………………………..2460
5.4 Front shovel (FSA)………………………………………………………………………………………..2462
5.4.1 Overview……………………………………………………………………………………………2462
5.4.2 Using the cylinder mounting device for front shovel attachments (PN 967 000 40)…………………………….2464
5.4.2.1 Designated usage……………………………………………………………………………….2465
5.4.2.2 Non-designated usage……………………………………………………………………………2465
5.4.3 Boom assembly……………………………………………………………………………………….2466
5.4.3.1 Disassembling of the boom……………………………………………………………………….2466
5.4.3.2 Assembling of the boom………………………………………………………………………….2468
5.4.3.3 Disassembling of the boom cylinders………………………………………………………………2470
5.4.3.4 Assembling of the boom cylinders…………………………………………………………………2474
5.4.4 Stick assembly………………………………………………………………………………………2480
5.4.4.1 Disassembling of the stick………………………………………………………………………2480
5.4.4.2 Assembling of the stick…………………………………………………………………………2485
5.4.4.3 Disassembling of the stick cylinders……………………………………………………………..2490
5.4.4.4 Assembling of the stick cylinders………………………………………………………………..2494
5.4.5 Bull clam bucket…………………………………………………………………………………….2498
5.4.5.1 Disassembling of the bull clam bucket…………………………………………………………….2498
5.4.5.2 Assembling of the bull clam bucket……………………………………………………………….2502
5.4.5.3 Disassembling of the bucket cylinders…………………………………………………………….2506
5.4.5.4 Assembling of the bucket cylinders……………………………………………………………….2512
5.4.5.5 Disassembling of the clam cylinders………………………………………………………………2518
5.4.5.6 Assembling of the clam cylinders…………………………………………………………………2523
5.4.6 Hydraulic hoses at the front shovel attachment………………………………………………………….2528
5.4.6.1 Replace the boom arc hoses………………………………………………………………………2528
5.4.6.2 Replace the boom cylinder hoses………………………………………………………………….2532
5.4.6.3 Replace the stick arc hoses……………………………………………………………………..2534
5.4.6.4 Replace the stick cylinder hoses…………………………………………………………………2536
5.4.6.5 Replace the bucket cylinder hoses………………………………………………………………..2538
5.4.6.6 Replace the clam cylinder hoses………………………………………………………………….2541
5.4.6.7 Disassembling of the clam……………………………………………………………………….2546
5.4.6.8 Assembling of the clamp…………………………………………………………………………2547
5.5 Metering valves (grease injectors) at the attachment………………………………………………………….2548
5.5.1 Disassembling of the metering valves (grease injectors)………………………………………………….2548
5.5.2 Assembling of the metering valves (grease injectors)…………………………………………………….2550
5.6 Ground engaging tools (GET)………………………………………………………………………………..2551
5.6.1 Replacement of the GET……………………………………………………………………………….2551
5.7 Cylinder bypass test………………………………………………………………………………………2552
6 Service Information…………………………………………………………………………………………….2553
6.1 Fluids and lubricants……………………………………………………………………………………..2554
6.2 Lifting Gears…………………………………………………………………………………………….2554
6.3 Safety hints for sling accessory……………………………………………………………………………2556
6.4 Weight tables…………………………………………………………………………………………….2557
6.4.1 Superstructure………………………………………………………………………………………2557
6.4.2 Undercarriage……………………………………………………………………………………….2559
6.4.3 Backhoe attachment (BHA)……………………………………………………………………………..2560
6.4.4 Face shovel attachment (FSA)………………………………………………………………………….2561
6.5 Torque charts according to KOMATSU company standard…………………………………………………………..2562
6.5.1 Metric standard thread……………………………………………………………………………….2562
6.5.2 Metric fine thread…………………………………………………………………………………..2563
6.5.3 Cummins motor torques – metric………………………………………………………………………..2564
6.5.4 Cummins motor torques – U.S. customary…………………………………………………………………2564
6.5.5 Torque Charts for Flange Joints……………………………………………………………………….2566
6.5.6 Tightening Torque for hydraulic hose connecting nut……………………………………………………..2568
6.6 Blind plugs………………………………………………………………………………………………2569
6.6.1 Dummy plates for hydraulic–flanges…………………………………………………………………….2569
6.6.2 Classification of threads to the nominal width………………………………………………………….2571
6.6.3 Plugs and fittings according to DIN 2353……………………………………………………………….2572
6.7 Conversion table………………………………………………………………………………………….2573
6.7.1 Method of using the conversion table…………………………………………………………………..2573
6.7.2 Millimeter – inch & kilogram – pound…………………………………………………………………..2574
6.7.3 Liter – U.S. gallon & liter – U.K. gallon………………………………………………………………2575
6.7.4 Nm- ft.lb…………………………………………………………………………………………..2576
6.7.5 Bar – PSI – kPa – MPa………………………………………………………………………………..2577
6.7.6 Temperature…………………………………………………………………………………………2578
6.8 Tools……………………………………………………………………………………………………2579
6.8.1 Standard tool case…………………………………………………………………………………..2579
6.8.2 Used special tools (Overview)…………………………………………………………………………2581
6.9 Work instructions…………………………………………………………………………………………2584
6.9.1 Bleeding the track tensioning system…………………………………………………………………..2584
6.9.2 General installation procedures for hydraulic hose lines…………………………………………………2586
6.9.3 Remove / install the crawler carrier…………………………………………………………………..2589
6.9.4 Repair procedure for the radiator assembly……………………………………………………………..2590
7 Parts & Service News……………………………………………………………………………………………2591
7.1 List of the PARTS AND SERVICE NEWS………………………………………………………………………….2592

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