Komatsu HYDRAULIC MINING SHOVEL PC4000-11 T4 Shop Manual(08246-xD-GB-1) – PDF DOWNLOAD

Komatsu HYDRAULIC MINING SHOVEL PC4000-11 T4 Shop Manual(08246-xD-GB-1) – PDF DOWNLOAD

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Komatsu HYDRAULIC MINING SHOVEL PC4000-11 T4 Shop Manual(08246-xD-GB-1) – PDF DOWNLOAD

serial Number: 08246 and up

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

Komatsu HYDRAULIC MINING SHOVEL PC4000-11 T4 Shop Manual(08246-xD-GB-1) – PDF DOWNLOAD

SHOP MANUAL Cover……………………………………………………………………………………… 1
00 FOREWORD & SAFETY………………………………………………………………………………….. 3
1 Foreword………………………………………………………………………………………… 5
1.1 BEFORE READING THIS MANUAL…………………………………………………………………… 6
1.2 CONTENTS OF THIS BINDER……………………………………………………………………… 7
1.2.1 Contacting the Service…………………………………………………………………. 7
1.2.2 Guarantee…………………………………………………………………………….. 7
1.3 DIVISION OF THE BINDER………………………………………………………………………. 8
2 SAFETY………………………………………………………………………………………….. 9
2.1 SAFETY INFORMATION………………………………………………………………………….. 10
2.2 OVERVIEW…………………………………………………………………………………… 11
2.2.1 NORMAL OPERATIONS……………………………………………………………………… 11
2.2.2 REGULAR MAINTENANCE……………………………………………………………………. 11
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR………………………………………………….. 11
2.2.4 ADDITIONAL SAFETY PRECAUTIONS…………………………………………………………… 11
2.3 SOUND PRESSURE AND VIBRATION LEVELs IN THE OPERATOR’S CAB……………………………………….. 12
2.3.1 SOUND………………………………………………………………………………… 12
2.3.2 VIBRATION…………………………………………………………………………….. 12
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR………………………………………… 13
2.4.1 UNDERSTANDING THE MACHINE………………………………………………………………. 13
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR…………………………………….. 13
2.4.2.1 ENSURING SAFE OPERATION…………………………………………………………… 13
2.4.3 PREPARATIONS FOR SAFE OPERATION…………………………………………………………. 13
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT………………………………………. 13
2.4.3.2 INSPECTING THE MACHINE……………………………………………………………. 13
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT…………………………………… 14
2.4.3.4 KEEP MACHINE CLEAN……………………………………………………………….. 14
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT…………………………………………… 14
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT…………………………………………. 15
2.4.3.7 IF A PROBLEM IS FOUND…………………………………………………………….. 15
2.4.4 FIRE PREVENTION……………………………………………………………………….. 15
2.4.4.1 PRECAUTIONS TO PREVENT FIRE……………………………………………………….. 15
2.4.4.2 ACTION IF FIRE OCCURS…………………………………………………………….. 17
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB…………………………………………………. 17
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE……………………………………………. 18
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE……………………………. 18
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE…………………………………………………… 18
2.4.5.3 NO PEOPLE ON THE ATTACHMENT……………………………………………………….. 18
2.4.5.4 WORKING IN HIGH PLACES……………………………………………………………. 18
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK………………………………………………….. 19
2.4.5.6 LEAVING THE MACHINE………………………………………………………………. 19
2.4.6 BURN PREVENTION……………………………………………………………………….. 19
2.4.6.1 Hot coolant……………………………………………………………………… 19
2.4.6.2 Hot oil…………………………………………………………………………. 20
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS……………………………………………………… 20
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES……………………………………………… 20
2.4.8.1 UNAUTHORIZED MODIFICATION…………………………………………………………. 21
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS………………………………………. 21
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)……………………………………………………… 21
2.4.10 PRECAUTIONS AT JOBSITE………………………………………………………………… 22
2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT…………………………………………………… 23
2.4.10.2 CAMERA SYSTEM WITH MONITORS………………………………………………………. 23
2.4.10.3 ENSURE GOOD VISIBILITY…………………………………………………………… 23
2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS…………………………………………….. 23
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS…………………………………………. 24
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES…………………………………………….. 24
2.4.10.7 WORKING ON LOOSE GROUND………………………………………………………….. 25
2.4.10.8 GAS, DUST, STEAM AND SMOKE……………………………………………………….. 25
2.4.10.9 VENTILATION OF ENCLOSED AREAS…………………………………………………….. 26
2.4.11 STARTING motor……………………………………………………………………….. 27
2.4.11.1 WARNING TAG…………………………………………………………………….. 27
2.4.11.2 CHECKS BEFORE STARTING motor……………………………………………………… 27
2.4.11.3 PRECAUTION WHEN STARTING motor……………………………………………………. 27
2.4.11.4 PRECAUTION IN COLD AREAS…………………………………………………………. 28
2.4.12 OPERATION……………………………………………………………………………. 28
2.4.12.1 CHECKS BEFORE OPERATION………………………………………………………….. 28
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE…………………………………… 29
2.4.12.3 PRECAUTIONS WHEN traveling……………………………………………………….. 30
2.4.12.4 TRAVELLING ON SLOPES…………………………………………………………….. 31
2.4.12.5 OPERATIONS ON SLOPES…………………………………………………………….. 32
2.4.12.6 PROHIBITED OPERATIONS……………………………………………………………. 32
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES………………………………………. 33
2.4.12.8 PARKING THE MACHINE……………………………………………………………… 33
2.4.12.9 TRANSPORTATION………………………………………………………………….. 33
2.5 PRECAUTION FOR MAINTENANCE…………………………………………………………………… 34
2.5.1 GENERAL PRECAUTIONS……………………………………………………………………. 34
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES……………………… 35
2.5.1.2 STOP motor FOR MAINTENANCE………………………………………………………… 36
2.5.1.3 WARNING TAG……………………………………………………………………… 37
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY……………………………………………………… 38
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS…………………………………………….. 38
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING………………………………. 39
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS…………………………………………. 39
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT………………………………. 40
2.5.1.9 NOISE…………………………………………………………………………… 40
2.5.1.10 WHEN USING A HAMMER……………………………………………………………… 40
2.5.1.11 PROPER TOOLS……………………………………………………………………. 41
2.5.1.12 ACCUMULATOR…………………………………………………………………….. 41
2.5.1.13 PERSONNEL………………………………………………………………………. 41
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE……………………………………………….. 42
2.5.2.1 PRECAUTION WHEN WELDING…………………………………………………………… 42
2.5.2.2 BATTERY HANDLING…………………………………………………………………. 42
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID…………………………………………………….. 43
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE………………………………………………… 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 MACHINE IS RUNNING DURING ADJUSTMENTS…………………………….. 48
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR……………………………………………. 48
2.7 SPECIAL SAFETY EQUIPMENT…………………………………………………………………….. 49
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB………………………………….. 50
2.7.2 OBJECT HANDLING……………………………………………………………………….. 50
2.7.3 LIGHTING……………………………………………………………………………… 50
2.7.4 WARNING BEACON………………………………………………………………………… 50
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)……………………………….. 50
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)………………………….. 50
2.7.5.2 INSTRUCTIONS FOR USE……………………………………………………………… 52
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL…………………………………….. 54
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS….. 54
2.7.5.5 INSTRUCTIONS FOR USE……………………………………………………………… 56
01 SPECIFICATION………………………………………………………………………………………. 57
PC4000-11…………………………………………………………………………………………. 59
10 STRUCTURE & FUNCTION………………………………………………………………………………… 67
TOC………………………………………………………………………………………………. 69
1 Introduction…………………………………………………………………………………….. 81
1.1 Foreword…………………………………………………………………………………… 82
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels…… 83
1.3 Explanation of abbreviations…………………………………………………………………. 84
1.4 Diagrams and illustrations in this manual……………………………………………………… 85
2 Specifications…………………………………………………………………………………… 87
2.1 Lifting Gears………………………………………………………………………………. 88
2.2 Safety hints for sling accessory……………………………………………………………… 90
2.3 Standard Tightening Torque Chart……………………………………………………………… 91
2.4 Conversion Table……………………………………………………………………………. 92
2.5 Blind plugs………………………………………………………………………………… 98
2.6 Classification of threads to the nominal width…………………………………………………. 100
2.7 Plugs and fittings according to ISO 8434-1 / DIN 2353…………………………………………… 101
3 Main assembly groups……………………………………………………………………………… 103
3.1 General layout……………………………………………………………………………… 104
3.2 Superstructure……………………………………………………………………………… 106
3.2.1 Side view…………………………………………………………………………….. 106
3.2.2 Top view……………………………………………………………………………… 108
3.3 Machine house………………………………………………………………………………. 110
3.4 Hydraulic oil tank………………………………………………………………………….. 112
3.5 Hydraulic oil cooler………………………………………………………………………… 114
3.6 Fuel tank………………………………………………………………………………….. 116
3.7 Cab base…………………………………………………………………………………… 118
3.8 Operator’s cab……………………………………………………………………………… 120
3.9 Control blocks……………………………………………………………………………… 122
3.10 Slew gear…………………………………………………………………………………. 124
3.10.1 Slew gear L&S………………………………………………………………………… 124
3.10.2 Slew gear SIEBENHAAR………………………………………………………………….. 126
3.11 Undercarriage……………………………………………………………………………… 128
3.12 Slew ring…………………………………………………………………………………. 130
3.13 Attachment………………………………………………………………………………… 132
3.13.1 Front Shovel Attachment (FSA)………………………………………………………….. 132
3.13.2 Backhoe Attachment (BHA)………………………………………………………………. 134
3.14 Counterweight……………………………………………………………………………… 136
3.15 Safety circuit (pilot control circuit)……………………………………………………….. 138
3.15.1 Wiring Diagram of 20S105 and 20S105a……………………………………………………. 140
4 Drive…………………………………………………………………………………………… 141
4.1 Prime drive assembly………………………………………………………………………… 142
4.2 Engine and PTO mounts……………………………………………………………………….. 144
4.2.1 Engine Mounts…………………………………………………………………………. 144
4.2.2 Torque Support………………………………………………………………………… 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 Fan drive and radiator assembly………………………………………………………………. 152
4.4.1 Radiator fan drive…………………………………………………………………….. 154
4.4.2 Fan pump……………………………………………………………………………… 156
4.4.3 Radiator fan drive speed adjustment……………………………………………………… 158
4.5 Fuel cooling (T4 equipment)………………………………………………………………….. 160
4.6 Pump distributor gearbox (PTO)……………………………………………………………….. 162
4.6.1 Pump spline lubrication………………………………………………………………… 164
4.6.1.1 Oil level in the main pump drive shaft housing………………………………………. 165
4.6.2 PTO lubrication and cooling…………………………………………………………….. 166
4.6.2.1 Checks and adjustments……………………………………………………………. 168
4.7 Hydraulic pumps – location, drive speed and flow rates………………………………………….. 170
4.7.1 Pump data…………………………………………………………………………….. 172
4.8 Air filter…………………………………………………………………………………. 174
5 Hydraulic oil tank……………………………………………………………………………….. 177
5.1 General layout……………………………………………………………………………… 178
5.2 Hydraulic oil tank, location of the electric equipment………………………………………….. 180
5.3 Suction oil tank with strainers………………………………………………………………. 182
5.4 Return oil collector pipe with strainer……………………………………………………….. 184
5.5 Back pressure valve…………………………………………………………………………. 186
5.6 Transfer pump………………………………………………………………………………. 188
5.7 Return and leak oil filter…………………………………………………………………… 190
5.8 Breather filter…………………………………………………………………………….. 192
6 Hydraulic oil cooling…………………………………………………………………………….. 195
6.1 Overall view of the hydraulic oil cooling……………………………………………………… 196
6.2 Function of the hydraulic oil cooling circuit………………………………………………….. 198
6.3 Adjustment of the back pressure valve…………………………………………………………. 200
6.4 Two stage cooler fan RPM control……………………………………………………………… 202
6.4.1 Pressure reducing valve………………………………………………………………… 204
6.4.2 Solenoid valves……………………………………………………………………….. 206
6.4.3 Fan pump……………………………………………………………………………… 208
6.5 Checks and Adjustments of the cooler fan drive speeds…………………………………………… 210
6.5.1 Function Check of Fan Speed Control……………………………………………………… 214
7 Controlling……………………………………………………………………………………… 215
7.1 General layout……………………………………………………………………………… 216
7.2 Control and filter panel…………………………………………………………………….. 218
7.3 Valve cartridge block……………………………………………………………………….. 220
7.4 Pilot pressure supply and adjustments…………………………………………………………. 222
7.4.1 Pilot pressure control (PPC) circuit…………………………………………………….. 222
7.4.2 Checks and adjustment of pilot pressure………………………………………………….. 226
7.4.3 Remote control valves arrangement……………………………………………………….. 228
7.5 Function of the electro-hydraulic control system……………………………………………….. 230
7.5.1 Electronic hand lever (joystick)………………………………………………………… 234
7.5.1.1 Voltage supply of hand lever 20S020………………………………………………… 235
7.5.1.2 Direction signal course from hand lever to controllers……………………………….. 236
7.5.1.3 Double ratiometric* output diagram…………………………………………………. 237
7.6 Foot pedal control………………………………………………………………………….. 238
7.6.1 Voltage supply of Foot lever (20S021a)…………………………………………………… 240
7.6.2 Direction signal course from foot pedal to controllers…………………………………….. 241
7.6.3 Double ratiometric* output diagram for 2 direction pedal…………………………………… 242
7.6.4 Single ratiometric* output diagram for 1 direction pedal…………………………………… 242
7.7 Hand lever & foot pedal monitoring……………………………………………………………. 243
7.7.1 Lever monitoring screens (example)………………………………………………………. 244
7.7.2 Valve monitoring screen (example)……………………………………………………….. 246
7.8 Valve solenoid adjustment……………………………………………………………………. 248
7.8.1 Overview sol min/max current & adjustment range…………………………………………… 249
7.9 ACCEL & DECEL time adjustment………………………………………………………………… 250
7.9.1 Accel & Decel times……………………………………………………………………. 250
8 Components………………………………………………………………………………………. 253
8.1 Main control blocks and high pressure screens (FSA)…………………………………………….. 254
8.2 Main control blocks and high pressure screens (BHA)…………………………………………….. 256
8.3 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA)………………. 258
8.4 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA)………………. 260
8.5 Single control blocks (floating) for stick and boom (FSA)……………………………………….. 262
8.6 Restrictor block with secondary relief valve…………………………………………………… 264
8.7 Anti-cavitation valve (ACV) block…………………………………………………………….. 266
8.8 Remote control valves……………………………………………………………………….. 268
8.9 4/3 Directional solenoid valves………………………………………………………………. 270
8.10 Proportional solenoid valves………………………………………………………………… 272
8.11 High pressure screen……………………………………………………………………….. 274
8.12 Control blocks and valves…………………………………………………………………… 276
8.12.1 Spool types………………………………………………………………………….. 282
8.12.2 MRV, SRV and ACV……………………………………………………………………… 284
8.12.3 Load holding valve……………………………………………………………………. 286
8.13 Travel brake valve…………………………………………………………………………. 290
8.14 Pressure reducing valve…………………………………………………………………….. 292
8.15 4/2 Directional valves……………………………………………………………………… 294
8.16 Pressure double stage valve…………………………………………………………………. 296
8.17 Hydraulic cylinder with NOK-3 sealing………………………………………………………… 298
8.17.1 Cylinder data markings………………………………………………………………… 301
9 Main hydraulic pumps and pump regulation……………………………………………………………. 303
9.1 General……………………………………………………………………………………. 304
9.1.1 Pump locations and pump data……………………………………………………………. 306
9.2 Main pumps…………………………………………………………………………………. 308
9.2.1 Hydraulic pump type HPV375+375………………………………………………………….. 308
9.2.1.1 Main pump sectional drawings………………………………………………………. 310
9.2.2 Servo valve…………………………………………………………………………… 312
9.2.2.1 VC valve  servo piston…………………………………………………………… 313
9.2.2.2 EPC valve……………………………………………………………………….. 318
9.3 Electronic pump regulation system…………………………………………………………….. 320
9.3.1 Cut-off function………………………………………………………………………. 322
9.3.2 Slew control………………………………………………………………………….. 323
9.3.2.1 Function of slew speed switch 20S154……………………………………………….. 323
9.3.3 Temperature control……………………………………………………………………. 324
9.3.3.1 Hydraulic oil temperature charts…………………………………………………… 324
9.3.4 Energy efficiency (economy mode)………………………………………………………… 325
9.4 Pump controller (14K305)…………………………………………………………………….. 326
9.5 Monitoring, error indication, adjustment………………………………………………………. 328
9.5.1 Monitoring items of the pump controller………………………………………………….. 328
9.5.2 Error indication of the pump controller………………………………………………….. 331
9.5.3 Adjustable parameters of the pump controller……………………………………………… 332
9.5.3.1 Description of the Primary P-Factor………………………………………………… 334
9.5.4 Pump sol ’min’ current values according to pump type plate…………………………………. 335
9.5.5 Pump sol ’max’ current values according to pump type plate…………………………………. 336
9.6 Checks and adjustments………………………………………………………………………. 338
9.6.1 Engine power check…………………………………………………………………….. 338
9.6.2 Cut-off function check…………………………………………………………………. 340
9.6.2.1 Cut-off for clam close (FSA only)………………………………………………….. 341
9.7 Engine speed sensor (pick-up)………………………………………………………………… 342
9.7.1 General………………………………………………………………………………. 343
9.7.2 Engine speed sensor (pick-up) adjustment…………………………………………………. 343
9.7.3 In case of problems – when correct speed sensor adjustment is guaranteed…………………….. 344
10 Operating hydraulics…………………………………………………………………………….. 345
10.1 General…………………………………………………………………………………… 346
10.1.1 Floating system (FSA only)…………………………………………………………….. 348
10.2 Hydraulics for the attachment cylinders………………………………………………………. 352
10.2.1 Electric / hydraulic flowchart “Boom UP” (FSA)…………………………………………… 352
10.2.2 Electric / hydraulic flowchart “boom up” (BHA)…………………………………………… 354
10.2.3 Electric / hydraulic flowchart “boom down” (FSA)…………………………………………. 356
10.2.4 Electric / hydraulic flowchart “Boom down” (BHA)…………………………………………. 358
10.2.5 Electric / hydraulic flowchart “Stick out” (FSA)…………………………………………. 360
10.2.6 Electric / hydraulic flowchart “Stick out” (BHA)…………………………………………. 362
10.2.7 Electric / hydraulic flowchart “Stick in” (FSA)………………………………………….. 364
10.2.8 Electric / hydraulic flowchart “Stick in” (BHA)………………………………………….. 366
10.2.9 Electric / hydraulic flowchart “Bucket fill” (FSA)……………………………………….. 368
10.2.10 Electric / hydraulic flowchart “Bucket fill” (BHA)………………………………………. 370
10.2.11 Electric / hydraulic flowchart “Bucket dump” (FSA)………………………………………. 372
10.2.12 Electric / hydraulic flowchart “Bucket dump” (BHA)………………………………………. 374
10.2.13 Electric / hydraulic flowchart “Clam open” (FSA)………………………………………… 376
10.2.14 Electric / hydraulic flowchart “Clam close” (FSA)……………………………………….. 378
10.2.15 Checks & adjustments of the main relief valve (MRV)……………………………………… 380
10.2.16 Checks and adjustments of the secondary relief valves (SRV)………………………………. 382
10.2.16.1 Boom cylinders, piston side (BHA & FSA), boom up…………………………………… 382
10.2.16.2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down………………………………. 386
10.2.16.3 Stick cylinders, piston side (FSA), stick out……………………………………… 390
10.2.16.4 Stick cylinders, piston side (BHA), stick in………………………………………. 394
10.2.16.5 Stick cylinders, piston rod side (FSA), stick in…………………………………… 398
10.2.16.6 Stick cylinders, piston rod side (BHA), stick out………………………………….. 402
10.2.16.7 Bucket cylinders, piston side (FSA), bucket fill…………………………………… 406
10.2.16.8 Bucket cylinders, piston side (BHA), bucket fill…………………………………… 410
10.2.16.9 Bucket cylinders, piston rod side (FSA), bucket dump……………………………….. 414
10.2.16.10 Bucket cylinders, piston rod side (BHA), bucket dump………………………………. 418
10.2.16.11 Clam cylinders, piston rod side (FSA), clam open………………………………….. 422
10.2.16.12 Clam cylinders, piston side (FSA), clam close…………………………………….. 426
10.2.17 Checks and adjustments of the lowering speed……………………………………………. 430
10.2.17.1 Checks and adjustments of the lowering speed – boom (FSA)…………………………… 430
10.2.17.2 Checks and adjustments of the lowering speed – boom (BHA)…………………………… 436
10.2.17.3 Checks and adjustments of the lowering speed – stick (FSA)………………………….. 438
10.2.17.4 Checks and adjustments of the lowering speed – stick (BHA)………………………….. 444
10.2.17.5 Checks and adjustments of the lowering speed – bucket (FSA)…………………………. 446
10.2.17.6 Checks and adjustments of the lowering speed – bucket (BHA)…………………………. 448
10.2.17.7 Checks and adjustments of the lowering speed – clam (FSA)…………………………… 450
10.3 Hydraulics for the slew circuit……………………………………………………………… 452
10.3.1 Slew circuit…………………………………………………………………………. 452
10.3.2 Slew motor…………………………………………………………………………… 456
10.3.3 Slew gearbox (L&S)……………………………………………………………………. 458
10.3.4 Slew gearbox (SIEBENHAAR)……………………………………………………………… 460
10.3.5 Slew parking brake (L&S)………………………………………………………………. 462
10.3.6 Slew parking brake (SIEBENHAAR)………………………………………………………… 464
10.3.7 Slew brake valve……………………………………………………………………… 466
10.3.8 Electric / hydraulic flowchart “Slew left”………………………………………………. 470
10.3.9 Electric / hydraulic flowchart “Slew right”……………………………………………… 472
10.3.10 Checks and adjustments for the slew circuit…………………………………………….. 474
10.3.10.1 Checks & adjustments, slew speed…………………………………………………. 474
10.3.10.2 Checks & adjustments, double stage valve………………………………………….. 476
10.3.10.3 Checks of the brake pilot pressure……………………………………………….. 479
10.3.11 Function check for hydraulic slew parking brake…………………………………………. 480
10.3.12 Slew parking brake release function check………………………………………………. 482
10.4 Hydraulics for the travel system…………………………………………………………….. 484
10.4.1 Travel circuit……………………………………………………………………….. 484
10.4.2 Travel motor…………………………………………………………………………. 486
10.4.3 Rotary joint…………………………………………………………………………. 488
10.4.4 Travel gearbox……………………………………………………………………….. 490
10.4.4.1 Travel gearbox (L & S)…………………………………………………………… 490
10.4.4.2 Travel gearbox (Zollern)…………………………………………………………. 492
10.4.5 Travel parking brake………………………………………………………………….. 494
10.4.5.1 Travel parking brake (Zollern)……………………………………………………. 494
10.4.5.2 Travel parking brake (L&S)……………………………………………………….. 495
10.5 Travel brake valve…………………………………………………………………………. 496
10.5.1 Electric / hydraulic flowchart “travel forward”………………………………………….. 498
10.5.2 Electric / hydraulic flowchart “travel backwards”………………………………………… 500
10.5.3 Checks and adjustments………………………………………………………………… 502
10.5.3.1 Checks and adjustments for the travel circuit………………………………………. 502
10.5.3.2 Function check for the travel parking brake………………………………………… 506
11 Hydraulic track tensioning system…………………………………………………………………. 509
11.1 General…………………………………………………………………………………… 510
11.2 Functional description……………………………………………………………………… 512
11.3 Double stage valve…………………………………………………………………………. 514
11.4 Tensioning cylinder………………………………………………………………………… 516
11.5 Adjustments / checks……………………………………………………………………….. 518
12 Access ladder, hydraulically operated……………………………………………………………… 521
12.1 General…………………………………………………………………………………… 522
12.2 Function of the hydraulically operated access ladder…………………………………………… 524
12.3 Adjustments / checks……………………………………………………………………….. 530
13 Central refilling system (Service arm)…………………………………………………………….. 533
13.1 General…………………………………………………………………………………… 534
13.2 Function………………………………………………………………………………….. 536
14 Hints for reading the Hydraulic Diagram……………………………………………………………. 539
14.1 General…………………………………………………………………………………… 540
14.2 Hydraulic symbols………………………………………………………………………….. 542
14.2.1 Lines, unions………………………………………………………………………… 543
14.2.2 Components, valves……………………………………………………………………. 545
14.2.3 Sensors……………………………………………………………………………… 545
14.2.4 Valves, valve components………………………………………………………………. 546
14.2.5 Pump, motor, cylinder…………………………………………………………………. 550
15 Hints for reading the electric Wiring Diagram………………………………………………………. 555
15.1 General…………………………………………………………………………………… 556
15.2 Reference code of the electrical components…………………………………………………… 557
15.2.1 Area code……………………………………………………………………………. 557
15.2.2 Component identifying letter…………………………………………………………… 558
15.3 Graphical symbols………………………………………………………………………….. 559
15.4 Concept of the Wiring Diagram……………………………………………………………….. 564
15.4.1 Cover page of the Komatsu W/D………………………………………………………….. 564
15.4.2 Example 1 from the schematics in the W/D………………………………………………… 566
15.4.3 Example 2 from the schematics in the W/D………………………………………………… 568
15.4.4 Table of contents in the W/D (page 1 of 2)………………………………………………. 570
15.4.5 Location list………………………………………………………………………… 572
15.4.6 Cross reference list for electr. components in the W/D……………………………………. 574
15.4.7 Cross reference list for terminals in the W/D……………………………………………. 576
15.4.8 Cross reference list for connectors in the W/D…………………………………………… 578
15.4.9 Cross reference list for terminal boards in the W/D………………………………………. 580
15.4.10 Connection table…………………………………………………………………….. 582
15.5 Cable and connector marking…………………………………………………………………. 584
15.6 Cable color identification………………………………………………………………….. 586
16 Monitoring & Control System………………………………………………………………………. 587
16.1 General…………………………………………………………………………………… 588
16.1.1 Monitoring & control system – overview………………………………………………….. 588
16.1.2 Global layout PC4000-11 T4…………………………………………………………….. 589
16.1.3 Controller system overview PC4000-11 T4…………………………………………………. 590
16.1.4 Interface connection………………………………………………………………….. 592
16.1.5 General description…………………………………………………………………… 593
16.2 Machine monitor – Operator level…………………………………………………………….. 594
16.2.1 Main gauge screens……………………………………………………………………. 596
16.2.2 Operator menu / tabs / functions of keys F1…F6…………………………………………. 600
16.2.2.1 Operator menu: ECO Guidance – Operation Records…………………………………….. 602
16.2.2.2 Operator menu: ECO Guidance-Average Fuel Consumption Logs……………………………. 604
16.2.2.3 Operator menu: Machine Setting……………………………………………………. 606
16.2.2.4 Operator menu: Aftertreatment cleaning…………………………………………….. 608
16.2.2.5 Operator menu: SCR Information……………………………………………………. 614
16.2.2.6 Operator menu: Maintenance……………………………………………………….. 618
16.2.2.7 Reset of ’remaining time’ till next maintenance interval…………………………….. 620
16.2.2.8 Usage limitation………………………………………………………………… 621
16.2.2.9 Operator menu: Monitor Setting – Screen Adjustment………………………………….. 623
16.2.2.10 Operator menu: Monitor Setting – Clock Adjustment – Calender………………………… 624
16.2.2.11 Operator menu: Monitor Setting – Clock Adjustment – Time……………………………. 625
16.2.2.12 Operator menu: Monitor Setting – Clock Adjustment – 12h/24h Mode…………………….. 626
16.2.2.13 Operator menu: Monitor Setting – Clock Adjustment – Daylight Saving Time……………… 627
16.2.2.14 Operator menu: Monitor Setting – Language…………………………………………. 628
16.2.2.15 Operator menu: Message screen……………………………………………………. 629
16.3 Error and status indication on the operator level……………………………………………… 630
16.3.1 Prompts (status indications)…………………………………………………………… 630
16.3.2 Cautions…………………………………………………………………………….. 631
16.3.3 Warning icons for Tier 4 equipment……………………………………………………… 632
16.3.4 Emergency shutdown screen……………………………………………………………… 634
16.3.5 Fault levels for error messages………………………………………………………… 636
16.3.6 Action code level L01…………………………………………………………………. 637
16.3.7 Action code level L02…………………………………………………………………. 638
16.3.8 Action code level L03…………………………………………………………………. 639
16.3.9 Action code level L04…………………………………………………………………. 640
16.3.10 Error list………………………………………………………………………….. 641
16.4 Table of failure codes……………………………………………………………………… 642
16.4.1 Failure codes without monitor indication………………………………………………… 655
16.4.2 Additional text information for action codes…………………………………………….. 655
16.5 Table of C-codes – Diesel engine Tier4……………………………………………………….. 656
16.6 Flow charts of machine monitor screens……………………………………………………….. 674
16.6.1 Flow chart Operator Level……………………………………………………………… 674
16.6.2 Flow chart Service Level………………………………………………………………. 675
16.7 Machine monitor……………………………………………………………………………. 676
16.7.1 Entering the Service Level…………………………………………………………….. 676
16.7.2 Key symbols (F1…F6) on the Service Level………………………………………………. 678
16.7.3 Service Menu selection screens…………………………………………………………. 679
16.8 Service Menu – item 01 Monitoring / Custom……………………………………………………. 681
16.8.1 Monitoring list for: ENG controller…………………………………………………….. 681
16.8.2 Monitoring list for: PUMP controller……………………………………………………. 683
16.8.3 Monitoring list for: VALVE0 controller………………………………………………….. 686
16.8.4 Monitoring list for: VALVE1 controller………………………………………………….. 689
16.8.5 Monitoring list for: VALVE2 controller………………………………………………….. 692
16.8.6 Monitoring list for: MON (monitor)……………………………………………………… 694
16.8.7 Monitoring list for: KOM PLS (K+ controller)…………………………………………….. 696
16.8.8 How to perform the monitoring function………………………………………………….. 698
16.9 Service Menu – item 02 PM Clinic…………………………………………………………….. 700
16.9.1 PM Clinic (General)…………………………………………………………………… 700
16.9.2 PM Clinic (Power Check)……………………………………………………………….. 701
16.9.3 Functions of PM CLINIC (POWER CHECK)……………………………………………………. 702
16.10 Service Menu – item 03 Memory Clear…………………………………………………………. 703
16.11 Service Menu – item 04 Abnormality record……………………………………………………. 704
16.11.1 Reset error messages…………………………………………………………………. 705
16.12 Service Menu – item 05 Maintenance record……………………………………………………. 706
16.13 Service Menu – item 06 Maintenance Mode Setting………………………………………………. 707
16.14 Service Menu – item 07 Snap Shot……………………………………………………………. 708
16.15 Service Menu – item 08 Phone Number Entry……………………………………………………. 709
16.16 Service Menu – item 09 Default……………………………………………………………… 710
16.17 Service Menu – item 10 Unit………………………………………………………………… 712
16.18 Service Menu – item 11 Adjustment…………………………………………………………… 713
16.18.1 Adjustments for: PUMP controller………………………………………………………. 713
16.18.2 Pump sol ’min’ current values according to pump type plate……………………………….. 716
16.18.3 Pump sol ’max’ current values according to pump type plate……………………………….. 717
16.18.4 Adjustments for: VALVE0 controller…………………………………………………….. 718
16.18.5 Accel & Decel times………………………………………………………………….. 725
16.18.6 Adjustments for: VALVE2 controller…………………………………………………….. 726
16.18.7 Adjustments for: MON (Monitor)………………………………………………………… 727
16.18.7.1 Using the Idling Stop Timer……………………………………………………… 728
16.19 Service Menu – item 12 Machine Configuration…………………………………………………. 730
16.19.1 Details of Machine Configuration for PC4000-11 T4……………………………………….. 731
16.19.2 Changing lever control from EURO to KMG………………………………………………… 732
16.19.2.1 Changing lever control from KMG to EURO…………………………………………… 732
16.19.3 Changing attachment type from FSA to BHA……………………………………………….. 734
16.19.3.1 Changing attachment type from BHA to FSA………………………………………….. 734
16.19.4 In case of problems during changing procedure for lever control or attachment type………….. 735
16.19.5 Hydraulic Oil & PTO Gear Oil Definition Tables………………………………………….. 736
16.19.5.1 Hydraulic oil temperature charts…………………………………………………. 736
16.19.5.2 PTO gear oil temperature charts………………………………………………….. 736
16.20 Service Menu – item 13 KOMTRAX Settings……………………………………………………… 737
16.21 Service Menu – item 14 Service Message………………………………………………………. 738
16.22 Automatic engine speed control……………………………………………………………… 739
16.22.1 Auto Deceleration mode……………………………………………………………….. 739
16.22.2 Auto Low Idle mode…………………………………………………………………… 739
16.22.3 Idling Stop Timer……………………………………………………………………. 739
16.23 KOMTRAX Plus controller (UM600)…………………………………………………………….. 740
16.24 CR720 controller………………………………………………………………………….. 744
16.24.1 Location of CR720 controllers…………………………………………………………. 744
16.25 Controller replacement procedure……………………………………………………………. 746
16.25.1 Sequence of the controller replacement procedure………………………………………… 746
16.25.2 After controller replacement………………………………………………………….. 747
16.25.3 Controller location………………………………………………………………….. 748
17 Lubrication system………………………………………………………………………………. 749
17.1 General overview (SLS & CLS )……………………………………………………………….. 750
17.1.1 General description…………………………………………………………………… 751
17.2 Basic function of the lubrication systems…………………………………………………….. 752
17.3 Lubrication systems (CLS 1 & SLS)……………………………………………………………. 754
17.3.1 Lubrication pump station………………………………………………………………. 754
17.3.2 General Information on CLS 1…………………………………………………………… 756
17.3.3 General information on the SLS…………………………………………………………. 756
17.3.4 Manual lube activation………………………………………………………………… 756
17.4 Lubrication cycle………………………………………………………………………….. 757
17.4.1 Operation and control…………………………………………………………………. 757
17.4.2 Lubrication cycle – processing…………………………………………………………. 758
17.4.3 Time segments & switch points of a lubrication cycle……………………………………… 759
17.4.4 Lubrication modes…………………………………………………………………….. 760
17.4.4.1 Automatic lubrication mode……………………………………………………….. 760
17.4.4.2 Manual lubrication mode………………………………………………………….. 760
17.4.4.3 REDUCED PAUSE TIME FOR SERVICE……………………………………………………. 760
17.5 Hydraulically driven lube pump………………………………………………………………. 762
17.5.1 Adjustment of lube pump speed………………………………………………………….. 764
17.5.1.1 Stroke speed adjustment………………………………………………………….. 765
17.5.1.2 Working pressure………………………………………………………………… 765
17.6 Lubricant injectors………………………………………………………………………… 766
17.6.1 Tightening torques for fittings at grease injectors………………………………………. 767
17.6.2 Description………………………………………………………………………….. 767
17.6.3 Adjustment of the lubricant output……………………………………………………… 768
17.6.4 Operation principle of lubricant injectors………………………………………………. 770
17.6.4.1 Function description…………………………………………………………….. 771
17.6.5 Connection of one or more injectors…………………………………………………….. 772
17.7 Vent Valve and grease outlet filter………………………………………………………….. 774
17.7.1 Vent valve description………………………………………………………………… 775
17.8 End-line switch……………………………………………………………………………. 776
17.8.1 Description………………………………………………………………………….. 777
17.8.2 CLS 1 end-line switch adjustment……………………………………………………….. 778
17.8.3 SLS end-line switch adjustment…………………………………………………………. 780
17.9 Lubricant level sensors…………………………………………………………………….. 782
17.9.1 Description………………………………………………………………………….. 783
17.9.1.1 Checks…………………………………………………………………………. 783
17.10 Commissioning…………………………………………………………………………….. 784
17.10.1 Commissioning of the CLS 1 lubrication system…………………………………………… 784
17.10.2 Fine adjustment……………………………………………………………………… 785
17.10.3 Commissioning of the SLS lubrication system…………………………………………….. 786
18 Deep temperature equipment (option)……………………………………………………………….. 789
18.1 General information………………………………………………………………………… 790
18.1.1 Introduction…………………………………………………………………………. 790
18.1.2 Deep temperature components overview……………………………………………………. 790
18.1.3 Power supply preconditions for preheating……………………………………………….. 791
18.1.4 Power requirements for preheating systems……………………………………………….. 792
18.2 Preheating procedure……………………………………………………………………….. 793
18.2.1 Global flow chart of the preheating procedure……………………………………………. 793
18.2.2 Starting the preheating procedure………………………………………………………. 794
18.2.3 Preheating of operator’s cab and Diesel engine [coolant system]……………………………. 795
18.2.4 Preheating of lubricants and superstructure (Diesel) [electric system]……………………… 796
18.3 Constant heating of travel motors (TTT equipment below-40°C only)……………………………….. 797
18.4 Component location…………………………………………………………………………. 798
18.4.1 Electric heating elements for hydraulic & batteries [electric machine]……………………… 798
18.4.2 Electric heating elements for hydraulics [Diesel machine]…………………………………. 800
18.4.3 Electric heating elements for engines & batteries [Diesel machine]…………………………. 802
18.5 Components of TT equipment………………………………………………………………….. 804
18.5.1 Preheating components on a Diesel machine……………………………………………….. 804
18.5.2 Preheating components on an electric machine…………………………………………….. 805
18.5.3 Wiring Diagrams for preheating systems (examples)………………………………………… 806
18.5.3.1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3…………………………… 806
18.5.3.2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3…………………………… 807
18.5.3.3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3…………………………… 808
18.5.3.4 Wiring diagram “Suction Oil Manifold Preheating”……………………………………. 809
18.5.3.5 Wiring diagram “PTO Preheating”…………………………………………………… 810
18.5.3.6 Wiring diagram “Battery heater pads”………………………………………………. 811
40 TROUBLESHOOTING…………………………………………………………………………………….. 813
TOC………………………………………………………………………………………………. 815
1 Introduction…………………………………………………………………………………….. 841
1.1 Overview…………………………………………………………………………………… 842
1.1.1 General advice when using troubleshooting charts………………………………………….. 842
1.2 General Precautions…………………………………………………………………………. 843
2 General Information for Troubleshooting…………………………………………………………….. 845
2.1 Preparations For Work……………………………………………………………………….. 846
2.2 Precautions During Work……………………………………………………………………… 846
2.3 Precautions When Carrying Out Any Operation……………………………………………………. 847
2.3.1 Precautions when carrying out removal work……………………………………………….. 847
2.3.2 Precautions when carrying out installation work…………………………………………… 847
2.3.3 Precautions when completing the operation………………………………………………… 848
2.4 Fundamental Requirements for Trouble shooting………………………………………………….. 849
2.4.1 Technical documentation………………………………………………………………… 849
2.4.2 Tools………………………………………………………………………………… 849
2.4.2.1 Reference Guide for Deutsch Removal Tools…………………………………………… 852
2.4.3 Personnel…………………………………………………………………………….. 853
2.5 Points To Remember When Trouble- shooting……………………………………………………… 853
2.6 Sequence Of Events In Troubleshooting…………………………………………………………. 855
2.7 Checks Before Troubleshooting………………………………………………………………… 856
2.8 Handling Of Electric Equipment And Hydraulic Components…………………………………………. 857
2.8.1 Points to remember when handling electric equipment……………………………………….. 857
2.8.2 Points To Remember When Handling Hydraulic Equipment………………………………………. 859
2.9 General working procedures…………………………………………………………………… 862
2.9.1 Air Bleeding of Various Hydraulic Parts………………………………………………….. 862
2.9.2 Air bleeding from the hydraulic pumps……………………………………………………. 862
2.9.3 Air bleeding from hydraulic cylinders……………………………………………………. 862
2.10 Cylinder bypass test……………………………………………………………………….. 863
2.11 Basics about “How to crimp” (with strain relief)………………………………………………. 864
2.11.1 Crimp tool & repair kit……………………………………………………………….. 864
2.11.2 General……………………………………………………………………………… 865
2.11.3 Select the required connector components………………………………………………… 865
2.11.4 Stripping a wire……………………………………………………………………… 866
2.11.5 Crimping…………………………………………………………………………….. 867
2.11.6 Connector assembly after crimping………………………………………………………. 868
2.12 Cable Shielding……………………………………………………………………………. 869
3 Mounting Locations and Connector Types……………………………………………………………… 871
3.1 Side view onto the superstructure…………………………………………………………….. 872
3.2 Top view onto the superstructure……………………………………………………………… 874
3.3 Location of engine electrical parts…………………………………………………………… 876
3.3.1 Engine side view………………………………………………………………………. 876
3.3.2 Engine top view……………………………………………………………………….. 877
3.3.3 Location of engine remote oil tank sensors……………………………………………….. 879
3.4 Location of hydraulic components (1)………………………………………………………….. 880
3.4.1 Location of hydraulic components (2)…………………………………………………….. 882
3.4.2 Location of hydraulic components (3)…………………………………………………….. 884
3.5 View onto the SLS or CLS grease barrel and the lubrication cycle components……………………….. 886
3.6 Batteries, battery main switches & safety switch for maintenance…………………………………. 888
3.7 Hydraulic oil tank & suction oil tank – Location of electrical components…………………………. 890
3.8 Hydraulically operated access ladder………………………………………………………….. 892
3.9 Service arm………………………………………………………………………………… 894
3.10 Connector Types Overview……………………………………………………………………. 896
4 Standard Value Table for Electrical Components………………………………………………………. 901
5 Tables for Testing and Troubleshooting……………………………………………………………… 915
5.1 Test Value Tables for Transducers…………………………………………………………….. 916
5.1.1 Pump press. transducers………………………………………………………………… 916
5.1.2 Hydraulic oil pressure transducers………………………………………………………. 917
5.1.3 Miscellaneous Pressure Transducers………………………………………………………. 918
5.1.4 Temperature Transducers………………………………………………………………… 919
5.2 Hydraulic oil temperature charts……………………………………………………………… 920
5.3 PTO gear oil temperature charts………………………………………………………………. 920
5.4 Table of failure codes………………………………………………………………………. 921
5.5 Table of C-codes – Diesel engine Tier4………………………………………………………… 934
5.6 Tables of Symptom Codes……………………………………………………………………… 951
5.6.1 Symptoms of the engine and Related electrical systems……………………………………… 951
5.6.2 Symptoms of the Hydraulic System………………………………………………………… 951
5.6.3 Symptoms of the Mechanical System……………………………………………………….. 952
5.6.4 Symptoms of Additional Systems………………………………………………………….. 952
5.7 Cable colour identification………………………………………………………………….. 953
6 Troubleshooting by Trouble Code……………………………………………………………………. 955
B@HANS – Hyd Oil Overheat……………………………………………………………………….. 956
Hydraulic diagram and location of 57K506a/b-1 for message B@HANS…………………………………. 958
6A1BMA – Trouble Shut-Off (gate) valve not open error………………………………………………. 959
View onto the gap of proximity switch 40B031…………………………………………………… 960
Wiring Diagram (40B031) for message 6A1BMA…………………………………………………….. 961
AA10NX – Air Cleaner1 Clogging…………………………………………………………………… 962
View onto the engine air cleaner (AA10NX)……………………………………………………… 963
AB00KE – Charge Voltage Low……………………………………………………………………… 966
Wiring Diagram (alternator) for message AB00KE…………………………………………………. 967
K@3A00 – Fire In System…………………………………………………………………………. 968
Configuration information for Fire Suppression System Machinery House…………………………….. 969
Monitoring information for Fire Suppression System Machinery House……………………………….. 969
Wiring Diagram (20K351) for message K@3A00…………………………………………………….. 970
Wiring Diagram (controller input of fire suppression system MH) for K@3A00………………………… 971
B@F0MA – CLS1 Lubrication System Error……………………………………………………………. 972
B@CPMA – SLS Lubrication System Error…………………………………………………………….. 973
B@F0N9 – CLS1 pressure increase time too long……………………………………………………… 974
B@CPN9 – SLS pressure increase time too long………………………………………………………. 974
Allocation of vent valves and end-of-line switches……………………………………………… 975
Vent valve (62Q507a & 62Q509a)……………………………………………………………….. 976
Wiring Diagram – lube pump solenoid & vent valve (CLS1 & SLS)……………………………………. 977
B@F0N0 – CLS1 pressure decrease time too long……………………………………………………… 978
B@CPN0 – SLS pressure decrease time too long………………………………………………………. 978
Vent valve (62Q507a & 62Q509a)……………………………………………………………….. 979
B@F0ZK – CLS1 grease level too low……………………………………………………………….. 980
B@CPZK – SLS grease level too low………………………………………………………………… 980
Wiring Diagram – grease level sensors (CLS1 & SLS)……………………………………………… 982
B@HAZK – Hydraulic oil level too low……………………………………………………………… 983
Hydraulic oil level in defined machine position………………………………………………… 984
Wiring Diagram – hydraulic oil level sensor 40B004……………………………………………… 985
B@CBNS – PTO1 Gear Oil Temp High…………………………………………………………………. 986
View onto the universal pump distributor gearbox (PTO)………………………………………….. 988
B@CBZG – PTO1 Gear Lubrication Error……………………………………………………………… 990
Monitoring PTO lube oil pressure……………………………………………………………… 991
Shutdown adjustment for PTO lube oil pressure………………………………………………….. 991
B@H2NX – Breather Filter Clogging………………………………………………………………… 992
Location of 40B024 and hydraulic oil level definitions………………………………………….. 993
B@M9NX – PTO1 Gear Oil Filter Clogging……………………………………………………………. 994
View onto the PTO1 gear oil filter with pressure sensor 57B027-1…………………………………. 995
B@HBNX – Return Oil Filter Clogging………………………………………………………………. 996
B@L4NX – Leak Oil Filter Clogging………………………………………………………………… 997
B@L5N9 – Pilot Press X2 Too Low………………………………………………………………….. 998
Valve cartridge block, location of components………………………………………………….. 999
B@L5N0 – Pilot Press X2 Too High………………………………………………………………….1000
Valve cartridge block, location of components…………………………………………………..1001
B@BKPQ – Eng Remote Oil Tank1 Empty……………………………………………………………….1002
B@HANX – Screen At Hyd Cooler Entry Clogging……………………………………………………….1003
Hydraulic oil tank & return oil collector pipe with strainer, location of components………………..1004
AB30MA – Starter Circuit Abnormality………………………………………………………………1006
Wiring Diagram for AB30MA…………………………………………………………………….1007
989HMA – Emergency stop line abnormality…………………………………………………………..1008
Wiring Diagram – emergency line for 989HMA……………………………………………………..1009
Monitoring screens for message 989HMA………………………………………………………….1010
DGT3MA – PTO1 oil temperature sensor abnormality……………………………………………………1012
Wiring Diagram and location of 57B049-1………………………………………………………..1013
DGH2MA – Hydraulic oil temp sensor abnormality……………………………………………………..1014
Wiring Diagram and monitoring selection for 59B015………………………………………………1015
DHQ7MA – PTO1 lube pressure sensor abnormality……………………………………………………..1016
Wiring Diagram and monitoring selection for 57B017-1…………………………………………….1017
D1E7KB – Starter cut relay short circuit…………………………………………………………..1018
Wiring Diagram – Starter cut relay for message D1E7KB……………………………………………1019
D1E7KY – Starter cut relay hot short circuit……………………………………………………….1020
Wiring Diagram – Starter cut relay for message D1E7KY……………………………………………1021
DHPEMA – Pump-1/2 pressure sensor abnormality………………………………………………………1022
DHPGMA – Pump-3/4 pressure sensor abnormality………………………………………………………1022
DHPJMA – Pump-5/6 pressure sensor abnormality………………………………………………………1022
DHPLMA – Pump-7/8 pressure sensor abnormality………………………………………………………1022
Wiring Diagram – PWR and GND supply for pump pressure transducers…………………………………1024
DLE2MA – Engine speed sensor abnormality…………………………………………………………..1026
Wiring Diagram – 52B064 for message DLE2MA……………………………………………………..1027
DA27KP – 24V sensor power abnormality……………………………………………………………..1028
Wiring Diagram – 24V sensor power supply for DA27KP……………………………………………..1029
DA26KP – 5V sensor2 power abnormality……………………………………………………………..1030
Wiring Diagram – 5V sensor power supply for DA26KP………………………………………………1031
DA22KK – Solenoid Power Low Error(Pump Con)………………………………………………………..1032
DA22MA – Solenoid Power Circuit Abnormality………………………………………………………..1033
Wiring Diagram 1 – emergency stop line for DA22MA……………………………………………….1034
Wiring Diagram 2 for DA22MA…………………………………………………………………..1035
DXAAKA – Pump1 Solenoid open circuit………………………………………………………………1036
DXABKA – Pump2 Solenoid open circuit………………………………………………………………1036
DXACKA – Pump3 Solenoid open circuit………………………………………………………………1036
DXADKA – Pump4 Solenoid open circuit………………………………………………………………1036
DXAEKA – Pump5 Solenoid open circuit………………………………………………………………1036
DXAFKA – Pump6 Solenoid open circuit………………………………………………………………1036
DXAGKA – Pump7 Solenoid open circuit………………………………………………………………1036
DXAHKA – Pump8 Solenoid open circuit………………………………………………………………1036
Wiring Diagram – EPC valve control…………………………………………………………….1038
DXAAKB – Pump1 Solenoid short circuit……………………………………………………………..1039
DXABKB – Pump2 Solenoid short circuit……………………………………………………………..1039
DXACKB – Pump3 Solenoid short circuit……………………………………………………………..1039
DXADKB – Pump4 Solenoid short circuit……………………………………………………………..1039
DXAEKB – Pump5 Solenoid short circuit……………………………………………………………..1039
DXAFKB – Pump6 Solenoid short circuit……………………………………………………………..1039
DXAGKB – Pump7 Solenoid short circuit……………………………………………………………..1039
DXAHKB – Pump8 Solenoid short circuit……………………………………………………………..1039
Wiring Diagram – EPC valve control…………………………………………………………….1041
DWA5KA – CLS pump solenoid open circuit……………………………………………………………1042
DWA8KA – SLS pump solenoid open circuit……………………………………………………………1042
Wiring Diagram – CLS/SLS pump solenoid control………………………………………………….1043
DWA5KB – CLS pump solenoid short circuit…………………………………………………………..1044
DWA8KB – SLS pump solenoid short circuit…………………………………………………………..1044
Wiring Diagram – CLS/SLS pump solenoid control………………………………………………….1045
DWA5KY – CLS pump solenoid hot short circuit……………………………………………………….1046
DWA8KY – SLS pump solenoid hot short circuit……………………………………………………….1046
Wiring Diagram – CLS/SLS pump solenoid / hot short circuit……………………………………….1047
DWA7KA – CLS line release solenoid open circuit…………………………………………………….1048
DWA9KA – SLS lube line release sol. open circuit……………………………………………………1048
Wiring Diagram – CLS/SLS lube line release solenoid control………………………………………1049
DWA7KB – CLS line release solenoid short circuit……………………………………………………1050
DWA9KB – SLS lube line release solenoid short circuit……………………………………………….1050
Wiring Diagram – CLS/SLS lube line release solenoid control………………………………………1051
DWA7KY – CLS line release sol. hot short circuit……………………………………………………1052
DWA9KY – SLS lube line release sol hot short circuit………………………………………………..1052
Wiring Diagram – CLS/SLS lube line release solenoid / hot short circuit……………………………1053
DWAAKA – PTO lube preload solenoid open circuit…………………………………………………….1054
Wiring Diagram and monitoring screen for message DWAAKA………………………………………….1055
DWAAKB – PTO lube preload solenoid short circuit……………………………………………………1056
Wiring Diagram and monitoring screen for message DWAAKB………………………………………….1057
DWAAKY – PTO lube preload sol. hot short circuit……………………………………………………1058
Wiring Diagram for message DWAAKY……………………………………………………………..1059
D166KB – Oil cooler fan sol(Min)relay short circuit…………………………………………………1060
Wiring Diagram – relay 11K068 for 57K506a (D166KB)………………………………………………1061
D167KB – Oil cooler fan sol(Mid)relay short circuit…………………………………………………1062
Wiring Diagram – relay 11K069 for 57K506b (D167KB)………………………………………………1063
D168KB – Oil cooler preload sol relay short circuit…………………………………………………1064
Wiring Diagram – Relay 11K070 (D168KB)…………………………………………………………1065
D1E9KB – Wiper fast relay short circuit……………………………………………………………1066
D1ETKB – Wiper slow relay short circuit……………………………………………………………1066
D1EBKB – Wiper stop relay short circuit……………………………………………………………1066
Wiring Diagram – wiper motor control…………………………………………………………..1067
D162KB – Horn relay short circuit…………………………………………………………………1068
Wiring Diagram – signal horn control…………………………………………………………..1069
D1F0KB – Engine1/motor1 shutdown relay short circuit………………………………………………..1070
Wiring Diagram 1 – engine1 shutdown relay 11K064-1………………………………………………1071
D1F0KY – Engine1/motor1 shutdown relay hot short……………………………………………………1072
Wiring Diagram for D1F0KY…………………………………………………………………….1073
D110KA – Battery relay open circuit……………………………………………………………….1074
Wiring Diagram – battery relay 11Q044d…………………………………………………………1075
D110KB – Battery relay short circuit………………………………………………………………1076
Wiring Diagram – Battery relay 11Q044d…………………………………………………………1077
DA29KQ – Model Selection Abnormality………………………………………………………………1078
Monitoring screen for machine selection………………………………………………………..1078
Wiring Diagram – machine selection abnormality (DA29KQ)………………………………………….1079
DA2YKQ – Motor/Engine Selection Abnormality………………………………………………………..1080
Monitoring screen for motor/engine selection……………………………………………………1080
Wiring Diagram – motor/engine selection abnormality (DA2YKQ)……………………………………..1081
DA20KQ – Pump Con Selection Abnormality……………………………………………………………1082
Monitoring screen for PUMP controller selection…………………………………………………1082
DDABMC – Lock lever switch abnormality…………………………………………………………….1084
Wiring Diagram – lock lever switch 20S105 (DDABMC)………………………………………………1085
DKURMA – R lever right-left potentio abnormality……………………………………………………1086
Wiring Diagram – right lever right-left potentiometer input (DKURMA)………………………………1087
DKUSMA – R lever right-left redu pot abnorm(VALVE/M)………………………………………………..1088
Wiring Diagram – right lever redundant right-left potentiometer input (DKUSMA)……………………..1089
DKUQL8 – R lever right-left potentio error…………………………………………………………1090
Wiring Diagram – right lever main + redundant right-left signal voltage (DKUQL8)……………………1091
DKUQL4 – R lever right-left sig. mismatch(VALVE/M)………………………………………………….1092
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1……………………………..1094
DKUNMA – R lever front-back potentio abnormality……………………………………………………1096
Wiring Diagram – right lever front-back potentiometer input (DKUNMA)………………………………1097
DKUPMA – R lever front-back redu pot abnorm(VALVE/M)………………………………………………..1098
Wiring Diagram – right lever redundant front-back potentiometer input (DKUPMA)……………………..1099
DKUML8 – R lever front-back potentio error…………………………………………………………1100
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8)……………………….1101
DKUML4 – R lever front-back sig. mismatch(VALVE/M)………………………………………………….1102
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1……………………………..1104
DKUXMA – Left lever right-left potentio abnormality…………………………………………………1106
Wiring Diagram – left lever right-left potentiometer input (DKUXMA)……………………………….1107
DKUYMA – L lever right-left redu pot abnorm(VALVE/M)………………………………………………..1108
Wiring Diagram – left lever redundant right-left potentiometer input (DKUYMA)………………………1109
DKUWL8 – L lever right-left potentio error…………………………………………………………1110
Wiring Diagram – left lever main + redundant right-left signal voltage (DKUWL8)…………………….1111
DKUWL4 – L lever right-left sig. mismatch(VALVE/M)………………………………………………….1112
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1……………………………..1114
DKUUMA – L lever front-back potentio abnormality……………………………………………………1116
Wiring Diagram – left lever front-back potentiometer input (DKUUMA)……………………………….1117
DKUVMA – L lever front-back redu pot abnorm(VALVE/M)………………………………………………..1118
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/M) for DKUVMA……………………………1119
DKUTL8 – L lever front-back potentio error…………………………………………………………1120
Wiring Diagram – L lever front-back potentio error (DKUTL8)………………………………………1121
DKUTL4 – L lever front-back sig. mismatch(VALVE/M)………………………………………………….1122
Wiring Diagram – L lever front-back sig. mismatch(VALVE/M) for DKUTL4……………………………..1124
DKW1MA – R pedal potentio abnormality……………………………………………………………..1126
Wiring Diagram – R pedal potentio abnormality (DKW1MA)…………………………………………..1127
DKW2MA – R pedal redundant pot abnormality(VALVE/M)…………………………………………………1128
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA…………………………….1129
DKW0L8 – R pedal potentio error…………………………………………………………………..1130
Wiring Diagram – R pedal potentio error (DKW0L8)………………………………………………..1131
DKW0L4 – R pedal signal mismatch(VALVE/M Con)………………………………………………………1132
Wiring Diagram – R pedal signal mismatch(VALVE/M Con) for DKW0L4………………………………….1134
DKW4MA – L pedal potentio abnormality……………………………………………………………..1136
Wiring Diagram – L pedal potentio abnormality (DKW4MA)…………………………………………..1137
DKW5MA – L pedal redundant pot abnormality(VALVE/M)…………………………………………………1138
Wiring Diagram – L pedal redundant pot abnormality(VALVE/M) for DKW5MA…………………………….1139
DKW3L8 – L pedal potentio error…………………………………………………………………..1140
Wiring Diagram – L pedal potentio error (DKW3L8)………………………………………………..1141
DKW3L4 – L pedal signal mismatch(VALVE/M Con)………………………………………………………1142
Wiring Diagram – L pedal signal mismatch(VALVE/M Con) for DKW3L4………………………………….1144
DKW7MA – Clam open potentio abnormality……………………………………………………………1146
Wiring Diagram – Clam open potentio abnormality (DKW7MA)…………………………………………1147
DKW8MA – Clam open redu pot abnormality(VALVE/M)……………………………………………………1148
Wiring Diagram – Clam open redu pot abnormality(VALVE/M) for DKW8MA……………………………….1149
DKW6L8 – Clam open potentio error…………………………………………………………………1150
Wiring Diagram – Clam open potentio error (DKW6L8)………………………………………………1151
DKW6L4 – Clam open signal mismatch(VALVE/M Con)…………………………………………………….1152
Wiring Diagram – Clam open signal mismatch(VALVE/M Con) for DKW6L4………………………………..1154
DKWAMA – Clam close potentio abnormality…………………………………………………………..1156
Wiring Diagram – Clam close potentio abnormality (DKWAMA)………………………………………..1157
DKWBMA – Clam close redundant pot abnorm(VALVE/M)…………………………………………………..1158
Wiring Diagram – Clam close redundant pot abnorm(VALVE/M) for DKWBMA………………………………1159
DKW9L8 – Clam close potentio error………………………………………………………………..1160
Wiring Diagram – Clam close potentio error (DKW9L8)……………………………………………..1161
DKW9L4 – Clam close signal mismatch(VALVE/M Con)……………………………………………………1162
Wiring Diagram – Clam close signal mismatch(VALVE/M Con) for DKW9L4……………………………….1164
DKWDMA – Hydraulic slew brake potentio abnormality………………………………………………….1166
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA)……………………………….1167
DKWEMA – Hyd. slew brake redu pot abnorm(VALVE/M)…………………………………………………..1168
Wiring Diagram – Hyd. slew brake redu pot abnorm(VALVE/M) for DKWEMA………………………………1169
DKWCL8 – Hydraulic slew brake potentio error……………………………………………………….1170
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8)…………………………………….1171
DKWCL4 – Hyd. slew brake sig. mismatch(VALVE/M)…………………………………………………….1172
Wiring Diagram – Hyd. slew brake sig. mismatch(VALVE/M) for DKWCL4………………………………..1174
DWNPKA – Service arm up solenoid open circuit………………………………………………………1176
Wiring Diagram and monitoring screen for message DWNPKA………………………………………….1177
DWNPKB – Service arm up solenoid short circuit……………………………………………………..1178
Wiring Diagram and monitoring screen for message DWNPKB………………………………………….1179
DWNPKY – Service arm up solenoid hot short circuit………………………………………………….1180
Wiring Diagram and monitoring screen for message DWNPKY………………………………………….1181
DWNQKA – Service arm down solenoid open circuit…………………………………………………….1182
Wiring Diagram and monitoring screen for message DWNQKA………………………………………….1183
DWNQKB – Service arm down solenoid short circuit……………………………………………………1184
Wiring Diagram and monitoring screen for message DWNQKB………………………………………….1185
DWNQKY – Service arm down solenoid hot short circuit………………………………………………..1186
Wiring Diagram and monitoring screen for message DWNQKY………………………………………….1187
DW4BKA – Travel parking brake solenoid open circuit…………………………………………………1188
Wiring Diagram and monitoring screen for message DW4BKA………………………………………….1189
DW4BKB – Travel parking brake sol. short circuit……………………………………………………1190
Wiring Diagram and monitoring screen for message DW4BKB………………………………………….1191
DW4BKY – Travel parking brake sol. hot short circuit………………………………………………..1192
Wiring Diagram and monitoring screen for message DW4BKY………………………………………….1193
DW45KA – Slew parking brake solenoid open circuit…………………………………………………..1194
Wiring Diagram and monitoring screen for message DW45KA………………………………………….1195
DW45KB – Slew parking brake solenoid short circuit………………………………………………….1196
Wiring Diagram and monitoring screen for message DW45KB………………………………………….1197
DW45KY – Slew parking brake sol. hot short circuit………………………………………………….1198
Wiring Diagram and monitoring screen for message DW45KY………………………………………….1199
DXN0KA – Slew1 epc solenoid open circuit…………………………………………………………..1200
DXN1KA – Bucket/Boom1 epc solenoid open circuit (FSA)……………………………………………….1200
DXN2KA – Boom1 epc solenoid open circuit (BHA)……………………………………………………..1200
DXN3KA – Stick1 epc solenoid open circuit………………………………………………………….1200
DXN4KA – Boom2 epc solenoid open circuit…………………………………………………………..1200
DXN5KA – Clam2 epc solenoid open circuit (FSA)……………………………………………………..1200
DXN6KA – Stick2 epc solenoid open circuit (BHA)…………………………………………………….1200
DXN7KA – Stick/Bucket2 epc solenoid open circuit (FSA)………………………………………………1200
DXN8KA – Bucket2 epc solenoid open circuit (BHA)……………………………………………………1200
DXN9KA – Travel2 left epc solenoid open circuit…………………………………………………….1200
DXNAKA – Slew3 epc solenoid open circuit…………………………………………………………..1200
DXNBKA – Bucket3 epc solenoid open circuit…………………………………………………………1200
DXNCKA – Boom3 epc solenoid open circuit…………………………………………………………..1200
DXNDKA – Boom4 epc solenoid open circuit…………………………………………………………..1200
DXNEKA – Bucket4 epc solenoid open circuit…………………………………………………………1200
DXNFKA – Stick4 epc solenoid open circuit………………………………………………………….1200
DXNGKA – Travel4 right epc solenoid open circuit……………………………………………………1200
Details of the above 6-digit failure codes (FSA & BHA)…………………………………………..1201
Wiring Diagram for EPC 61K620 – 61K621 – 61K622…………………………………………………1202
Wiring Diagram for EPC 61K624 – 61K625…………………………………………………………1203
Wiring Diagram for EPC 61K626 – 61K627…………………………………………………………1204
Wiring Diagram for EPC 61K628 – 61K629 – 61K630…………………………………………………1205
Wiring Diagram for EPC 61K632 – 61K633…………………………………………………………1206
Wiring Diagram for EPC 61K634 – 61K635…………………………………………………………1207
Monitoring screens as an example………………………………………………………………1208
DXN0KB – Slew1 epc solenoid short circuit………………………………………………………….1210
DXN1KB – Bucket/Boom1 epc solenoid short circuit (FSA)………………………………………………1210
DXN2KB – Boom1 epc solenoid short circuit (BHA)…………………………………………………….1210
DXN3KB – Stick1 epc solenoid short circuit…………………………………………………………1210
DXN4KB – Boom2 epc solenoid short circuit………………………………………………………….1210
DXN5KB – Clam2 epc solenoid short circuit FSA)……………………………………………………..1210
DXN6KB – Stick2 epc solenoid short circuit (BHA)……………………………………………………1210
DXN7KB – Stick/Bucket2 epc solenoid short circuit (FSA)……………………………………………..1210
DXN8KB – Bucket2 epc solenoid short circuit (BHA)…………………………………………………..1210
DXN9KB – Travel2 left epc solenoid short circuit……………………………………………………1210
DXNAKB – Slew3 epc solenoid short circuit………………………………………………………….1210
DXNBKB – Bucket3 epc solenoid short circuit………………………………………………………..1210
DXNCKB – Boom3 epc solenoid short circuit………………………………………………………….1210
DXNDKB – Boom4 epc solenoid short circuit………………………………………………………….1210
DXNEKB – Bucket4 epc solenoid short circuit………………………………………………………..1210
DXNFKB – Stick4 epc solenoid short circuit…………………………………………………………1210
DXNGKB – Travel4 right epc solenoid short circuit…………………………………………………..1210
Details of the above 6-digit failure codes (FSA & BHA)…………………………………………..1211
DXN0KY – Slew1 epc solenoid hot short circuit………………………………………………………1212
DXN1KY – Bucket/Boom1 epc sol. hot short circuit (FSA)………………………………………………1212
DXN2KY – Boom1 epc solenoid hot short circuit (BHA)…………………………………………………1212
DXN3KY – Stick1 epc solenoid hot short circuit……………………………………………………..1212
DXN4KY – Boom2 epc solenoid hot short circuit………………………………………………………1212
DXN5KY – Clam2 epc solenoid hot short circuit (FSA)…………………………………………………1212
DXN6KY – Stick2 epc solenoid hot short circuit (BHA)………………………………………………..1212
DXN7KY – Stick/Bucket2 epc sol. hot short circuit (FSA)……………………………………………..1212
DXN8KY – Bucket2 epc solenoid hot short circuit (BHA)……………………………………………….1212
DXN9KY – Travel2 left epc sol. hot short circuit……………………………………………………1212
DXNAKY – Slew3 epc solenoid hot short circuit………………………………………………………1212
DXNBKY – Bucket3 epc solenoid hot short circuit…………………………………………………….1212
DXNCKY – Boom3 epc solenoid hot short circuit………………………………………………………1212
DXNDKY – Boom4 epc solenoid hot short circuit………………………………………………………1212
DXNEKY – Bucket4 epc solenoid hot short circuit…………………………………………………….1212
DXNFKY – Stick4 epc solenoid hot short circuit……………………………………………………..1212
DXNGKY – Travel4 right epc sol. hot short circuit…………………………………………………..1212
Details of the above 6-digit failure codes (FSA & BHA)…………………………………………..1213
Wiring Diagram for EPC 61K620 – 61K621 – 61K622…………………………………………………1214
Wiring Diagram for EPC 61K624 – 61K625…………………………………………………………1215
Wiring Diagram for EPC 61K626 – 61K627…………………………………………………………1216
Wiring Diagram for EPC 61K628 – 61K629 – 61K630…………………………………………………1217
Wiring Diagram for EPC 61K632 – 61K633…………………………………………………………1218
Wiring Diagram for EPC 61K634 – 61K635…………………………………………………………1219
DWACKA – Service arm check valve sol. open circuit………………………………………………….1220
Wiring Diagram and monitoring screen for message DWACKA………………………………………….1221
DWACKB – Service arm check valve sol. short circuit…………………………………………………1222
Wiring Diagram and monitoring screen for message DWACKB………………………………………….1223
DWACKY – Service arm check valveSol hotShortCircuit…………………………………………………1224
Wiring Diagram and monitoring screen for message DWACKY………………………………………….1225
DWADKA – Ladder speed control solenoid open circuit…………………………………………………1226
Wiring Diagram and monitoring screen for message DWADKA………………………………………….1227
DWADKB – Ladder speed control sol. short circuit……………………………………………………1228
Wiring Diagram and monitoring screen for message DWADKB………………………………………….1229
DWADKY – Ladder speed control sol. hot short circuit………………………………………………..1230
Wiring Diagram – Ladder speed control sol. hot short circuit (DWADKY)……………………………..1231
DBW5MA – 5V sensor1 power abnormality……………………………………………………………..1232
DBW6MA – 5V sensor2 power abnormality……………………………………………………………..1232
Wiring Diagram – 5V power supply and GND output at VALVE0………………………………………..1236
DBW9KQ – Model Selection Abnormality………………………………………………………………1238
Monitoring screen for machine selection………………………………………………………..1238
Wiring Diagram – model selection abnormality (DBW9KQ)……………………………………………1239
DBWZKQ – Lever control selection abnormality……………………………………………………….1240
Monitoring screen & Wiring Diagram – Lever control selection abnormality (DBWZKQ)…………………..1241
DBWYKQ – Attachment selection abnormality………………………………………………………….1242
Monitoring screen & Wiring Diagram – Attachment selection abnormality (DBWYKQ)……………………..1243
DBW2KK – Solenoid Power Low Error(VALVE/M Con)……………………………………………………..1244
Wiring Diagram 1 for message DBW2KK……………………………………………………………1246
Wiring Diagram 2 for message DBW2KK……………………………………………………………1247
DBW0KQ – VALVE/M Con Selection Abnormality…………………………………………………………1248
Monitoring screen and Wiring Diagram for message DBW0KQ………………………………………….1249
DDDWMC – Ladder operation switch abnormality……………………………………………………….1250
Wiring Diagram and monitoring screen for message DDDWMC………………………………………….1251
DKWHMA – R lever right-left redu pot abnorm(VLV/S1)…………………………………………………1252
Wiring Diagram – right lever redundant right-left potentiometer input (DKWHMA)……………………..1253
DKWFL4 – R lever right-left sig. mismatch(VALVE/S1)…………………………………………………1254
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1……………………………..1256
DKWLMA – R lever front-back redu pot abnorm(VLV/S1)…………………………………………………1258
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA)……………………..1259
DKWJL4 – R lever front-back sig. mismatch(VALVE/S1)…………………………………………………1260
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1……………………………..1262
DKWPMA – L lever right-left redu pot abnorm(VLV/S1)…………………………………………………1264
Wiring Diagram – left lever redundant right-left potentiometer input (DKWPMA)………………………1265
DKWML4 – L lever right-left sig. mismatch(VALVE/S1)…………………………………………………1266
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1……………………………..1268
DKWSMA – L lever front-back redu pot abnorm(VLV/S1)…………………………………………………1270
Wiring Diagram – L lever front-back redu pot abnorm(VLV/S1) for DKWSMA…………………………….1271
DKWQL4 – L lever front-back sig. mismatch(VALVE/S1)…………………………………………………1272
Wiring Diagram – L lever front-back sig. mismatch(VALVE/S1) for DKWQL4…………………………….1274
DKWVMA – R pedal red pot abnormality(VALVE/S1)……………………………………………………..1276
Wiring Diagram – R pedal red pot abnormality(VALVE/S1) for DKWVMA…………………………………1277
DKWTL4 – R pedal signal mismatch(VALVE/S1 Con)……………………………………………………..1278
Wiring Diagram – R pedal signal mismatch(VALVE/S1 Con) for DKWTL4…………………………………1280
DKWYMA – L pedal red pot abnormality(VALVE/S1)……………………………………………………..1282
Wiring Diagram – L pedal red pot abnormality(VALVE/S1) for DKWYMA…………………………………1283
DKWWL4 – L pedal signal mismatch(VALVE/S1 Con)……………………………………………………..1284
Wiring Diagram – L pedal signal mismatch(VALVE/S1 Con) for DKWWL4…………………………………1286
DKX2MA – Clam open redu pot abnormality(VALVE/S1)…………………………………………………..1288
Wiring Diagram – Clam open redu pot abnormality(VALVE/S1) for DKX2MA………………………………1289
DKX0L4 – Clam open signal mismatch(VALVE/S1 Con)……………………………………………………1290
Wiring Diagram – Clam open signal mismatch(VALVE/S1 Con) for DKX0L4……………………………….1292
DKX5MA – Clam close redu pot abnormality(VALVE/S1)………………………………………………….1294
Wiring Diagram – Clam close redu pot abnormality(VALVE/S1) for DKX5MA……………………………..1295
DKX3L4 – Clam close signal mismatch(VALVE/S1 Con)…………………………………………………..1296
Wiring Diagram – Clam close signal mismatch(VALVE/S1 Con) for DKX3L4………………………………1298
DKX8MA – Hyd. slew brake redu pot abnorm(VALVE/S1)………………………………………………….1300
Wiring Diagram – Hyd. slew brake redu pot abnorm(VALVE/S1) for DKX8MA……………………………..1301
DKX6L4 – Hyd. slew brake signal mismatch(VALVE/S1)………………………………………………….1302
Wiring Diagram – Hyd. slew brake signal mismatch(VALVE/S1) for DKX6L4……………………………..1304
DWNRKA – Ladder up solenoid open circuit…………………………………………………………..1306
Wiring Diagram and monitoring screen for message DWNRKA………………………………………….1307
DWNRKB – Ladder up solenoid short circuit………………………………………………………….1308
Wiring Diagram and monitoring screen for message DWNRKB………………………………………….1309
DWNRKY – Ladder up solenoid hot short circuit………………………………………………………1310
Wiring Diagram – Ladder up solenoid hot short circuit (DWNRKY)……………………………………1311
DW7RKA – Hydraulic slew brake solenoid open circuit…………………………………………………1312
Wiring Diagram and monitoring screen for message DW7RKA………………………………………….1313
DW7RKB – Hydraulic slew brake sol. short circuit……………………………………………………1314
Wiring Diagram and monitoring screen for message DW7RKB………………………………………….1315
DW7RKY – Hyd. slew brake sol. hot short circuit…………………………………………………….1316
Wiring Diagram – Hyd. slew brake sol. hot short circuit (DW7RKY)………………………………….1317
DWANKA – Slew1 right solenoid open circuit…………………………………………………………1318
Wiring Diagram and monitoring screen for message DWANKA………………………………………….1319
DWANKB – Slew1 right solenoid short circuit………………………………………………………..1320
Wiring Diagram and monitoring screen for message DWANKB………………………………………….1321
DWANKY – Slew1 right solenoid hot short circuit…………………………………………………….1322
Wiring Diagram and monitoring screen for message DWANKY………………………………………….1323
DWAJKA – Slew1 left solenoid open circuit………………………………………………………….1324
Wiring Diagram and monitoring screen for message DWAJKA………………………………………….1325
DWAJKB – Slew1 left solenoid short circuit…………………………………………………………1326
Wiring Diagram and monitoring screen for message DWAJKB………………………………………….1327
DWAJKY – Slew1 left solenoid hot short circuit……………………………………………………..1328
Wiring Diagram and monitoring screen for message DWAJKY………………………………………….1329
DWASKA – Bucket1 fill solenoid open circuit………………………………………………………..1330
Wiring Diagram and monitoring screen for message DWASKA………………………………………….1331
DWASKB – Bucket1 fill solenoid short circuit……………………………………………………….1332
Wiring Diagram and monitoring screen for message DWASKB………………………………………….1333
DWASKY – Bucket1 fill solenoid hot short circuit……………………………………………………1334
Wiring Diagram and monitoring screen for message DWASKY………………………………………….1335
DWBEKA – Boom1 down solenoid open circuit………………………………………………………….1336
Wiring Diagram and monitoring screen for message DWBEKA………………………………………….1337
DWBEKB – Boom1 down solenoid short circuit…………………………………………………………1338
Wiring Diagram and monitoring screen for message DWBEKB………………………………………….1339
DWBEKY – Boom1 down solenoid hot short circuit……………………………………………………..1340
Wiring Diagram and monitoring screen for message DWBEKY………………………………………….1341
DWBAKA – Boom1 up solenoid open circuit……………………………………………………………1342
Wiring Diagram and monitoring screen for message DWBAKA………………………………………….1343
DWBAKB – Boom1 up solenoid short circuit…………………………………………………………..1344
Wiring Diagram and monitoring screen for message DWBAKB………………………………………….1345
DWBAKY – Boom1 up solenoid hot short circuit……………………………………………………….1346
Wiring Diagram and monitoring screen for message DWBAKY………………………………………….1347
DWBJKA – Stick1 out solenoid open circuit………………………………………………………….1348
Wiring Diagram and monitoring screen for message DWBJKA………………………………………….1349
DWBJKB – Stick1 out solenoid short circuit…………………………………………………………1350
Wiring Diagram and monitoring screen for message DWBJKB………………………………………….1351
DWBJKY – Stick1 out solenoid hot short circuit……………………………………………………..1352
Wiring Diagram and monitoring screen for message DWBJKY………………………………………….1353
DWBNKA – Stick1 in solenoid open circuit…………………………………………………………..1354
Wiring Diagram and monitoring screen for message DWBNKA………………………………………….1355
DWBNKB – Stick1 in solenoid short circuit………………………………………………………….1356
Wiring Diagram and monitoring screen for message DWBNKB………………………………………….1357
DWBNKY – Stick1 in solenoid hot short circuit………………………………………………………1358
Wiring Diagram and monitoring screen for message DWBNKY………………………………………….1359
DWBBKA – Boom2 up solenoid open circuit……………………………………………………………1360
Wiring Diagram and monitoring screen for message DWBBKA………………………………………….1361
DWBBKB – Boom2 up solenoid short circuit…………………………………………………………..1362
Wiring Diagram and monitoring screen for message DWBBKB………………………………………….1363
DWBBKY – Boom2 up solenoid hot short circuit……………………………………………………….1364
Wiring Diagram and monitoring screen for message DWBBKY………………………………………….1365
DWBFKA – Boom2 down solenoid open circuit………………………………………………………….1366
Wiring Diagram and monitoring screen for message DWBFKA………………………………………….1367
DWBFKB – Boom2 down solenoid short circuit…………………………………………………………1368
Wiring Diagram and monitoring screen for message DWBFKB………………………………………….1369
DWBFKY – Boom2 down solenoid hot short circuit……………………………………………………..1370
Wiring Diagram and monitoring screen for message DWBFKY………………………………………….1371
DWBXKA – Clam2 close solenoid open circuit…………………………………………………………1372
Wiring Diagram and monitoring screen for message DWBXKA………………………………………….1373
DWBXKB – Clam2 close solenoid short circuit………………………………………………………..1374
Wiring Diagram and monitoring screen for message DWBXKB………………………………………….1375
DWBXKY – Clam2 close solenoid hot short circuit…………………………………………………….1376
Wiring Diagram and monitoring screen for message DWBXKY………………………………………….1377
DWBKKA – Stick2 out solenoid open circuit………………………………………………………….1378
Wiring Diagram and monitoring screen for message DWBKKA (FSA only)………………………………..1379
DWBKKB – Stick2 out solenoid short circuit…………………………………………………………1380
Wiring Diagram and monitoring screen for message DWBKKB………………………………………….1381
DWBKKY – Stick2 out solenoid hot short circuit……………………………………………………..1382
Wiring Diagram and monitoring screen for message DWBKKY………………………………………….1383
DWBTKA – Clam2 open solenoid open circuit………………………………………………………….1384
Wiring Diagram and monitoring screen for message DWBTKA………………………………………….1385
DWBTKB – Clam2 open solenoid short circuit…………………………………………………………1386
Wiring Diagram and monitoring screen for message DWBTKB………………………………………….1387
DWBTKY – Clam2 open solenoid hot short circuit……………………………………………………..1388
Wiring Diagram and monitoring screen for message DWBTKY………………………………………….1389
DWBPKA – Stick2 in solenoid open circuit…………………………………………………………..1390
Wiring Diagram and monitoring screen for message DWBPKA………………………………………….1391
DWBPKB – Stick2 in solenoid short circuit………………………………………………………….1392
Wiring Diagram and monitoring screen for message DWBPKB………………………………………….1393
DWBPKY – Stick2 in solenoid hot short circuit………………………………………………………1394
Wiring Diagram and monitoring screen for message DWBPKY………………………………………….1395
DWATKA – Bucket2 fill solenoid open circuit………………………………………………………..1396
Wiring Diagram and monitoring screen for message DWATKA………………………………………….1397
DWATKB – Bucket2 fill solenoid short circuit……………………………………………………….1398
Wiring Diagram and monitoring screen for message DWATKB………………………………………….1399
DWATKY – Bucket2 fill solenoid hot short circuit……………………………………………………1400
Wiring Diagram and monitoring screen for message DWATKY………………………………………….1401
DWAXKA – Bucket2 dump solenoid open circuit………………………………………………………..1402
Wiring Diagram and monitoring screen for message DWAXKA………………………………………….1403
DWAXKB – Bucket2 dump solenoid short circuit……………………………………………………….1404
Wiring Diagram and monitoring screen for message DWAXKB………………………………………….1405
DWAXKY – Bucket2 dump solenoid hot short circuit……………………………………………………1406
Wiring Diagram and monitoring screen for message DWAXKY………………………………………….1407
DWKFKA – Travel2 left backward sol. open circuit……………………………………………………1408
Wiring Diagram and monitoring screen for message DWKFKA………………………………………….1409
DWKFKB – Travel2 left backward sol. short circuit…………………………………………………..1410
Wiring Diagram and monitoring screen for message DWKFKB………………………………………….1411
DWKFKY – Travel2 left backward sol. hot short circuit……………………………………………….1412
Wiring Diagram and monitoring screen for message DWKFKY………………………………………….1413
DWKBKA – Travel2 left forward sol. open circuit…………………………………………………….1414
Wiring Diagram and monitoring screen for message DWKBKA………………………………………….1415
DWKBKB – Travel2 left forward sol. short circuit……………………………………………………1416
Wiring Diagram and monitoring screen for message DWKBKB………………………………………….1417
DWKBKY – Travel2 left forward sol. hot short……………………………………………………….1418
Wiring Diagram and monitoring screen for message DWKBKY………………………………………….1419
D5ZWKB – Travel hour meter short circuit…………………………………………………………..1420
Wiring Diagram and monitoring screen for message D5ZWKB………………………………………….1421
D1EUKB – Travel alarm relay short circuit………………………………………………………….1422
Wiring Diagram and monitoring screen for message D1EUKB………………………………………….1423
DBX9KQ – Model Selection Abnormality………………………………………………………………1424
Wiring Diagram and monitoring screen for message DBX9KQ………………………………………….1425
DBXZKQ – Lever Control Selection Abnormality……………………………………………………….1426
Wiring Diagram and monitoring screen for message DBXZKQ………………………………………….1427
DBXYKQ – Attachment selection abnormality………………………………………………………….1428
Wiring Diagram – Attachment selection abnormality (DBXYKQ)……………………………………….1429
D561MA – Lock lever sol. power cut abnorm(VALVE/S1)…………………………………………………1430
Monitoring screens and Wiring Diagram 1 for message D561MA……………………………………….1431
Wiring Diagram 2 for message D561MA……………………………………………………………1432
D563MA – Ladder up sensor sol cut abnorm(VLV/S1)……………………………………………………1433
Monitoring screens and Wiring Diagram 1 for message D563MA……………………………………….1434
Wiring Diagram 2 for message D563MA……………………………………………………………1435
D565MA – Service arm (up) sensor sol cut abnorm(VLV/S1)……………………………………………..1436
Wiring Diagram 1 and monitoring screens for message D565MA……………………………………….1437
Wiring Diagram 2 for message D565MA……………………………………………………………1438
DBX2KK – Solenoid Power Low Error(VALVE/S1 Con)…………………………………………………….1439
Monitoring screen and Wiring Diagram 1 for message DBX2KK………………………………………..1440
Wiring Diagram 2 for message DBX2KK – Safety circuit…………………………………………….1441
DBX0KQ – VALVE/S1 Con Selection Abnormality………………………………………………………..1442
Wiring Diagram and monitoring screen for message DBX0KQ………………………………………….1443
DWAQKA – Slew3 right solenoid open circuit…………………………………………………………1444
Wiring Diagram and monitoring screen for message DWAQKA………………………………………….1445
DWAQKB – Slew3 right solenoid short circuit………………………………………………………..1446
Wiring Diagram and monitoring screen for message DWAQKB………………………………………….1447
DWAQKY – Slew3 right solenoid hot short circuit…………………………………………………….1448
Wiring Diagram and monitoring screen for message DWAQKY………………………………………….1449
DWALKA – Slew3 left solenoid open circuit………………………………………………………….1450
Wiring Diagram and monitoring screen for message DWALKA………………………………………….1451
DWALKB – Slew3 left solenoid short circuit…………………………………………………………1452
Wiring Diagram and monitoring screen for message DWALKB………………………………………….1453
DWALKY – Slew3 left solenoid hot short circuit……………………………………………………..1454
Wiring Diagram and monitoring screen for message DWALKY………………………………………….1455
DWAUKA – Bucket3 fill solenoid open circuit………………………………………………………..1456
Wiring Diagram and monitoring screen for message DWAUKA………………………………………….1457
DWAUKB – Bucket3 fill solenoid short circuit……………………………………………………….1458
Wiring Diagram and monitoring screen for message DWAUKB………………………………………….1459
DWAUKY – Bucket3 fill solenoid hot short circuit……………………………………………………1460
Wiring Diagram and monitoring screen for message DWAUKY………………………………………….1461
DWAYKA – Bucket3 dump solenoid open circuit………………………………………………………..1462
Wiring Diagram and monitoring screen for message DWAYKA………………………………………….1463
DWAYKB – Bucket3 dump solenoid short circuit……………………………………………………….1464
Wiring Diagram and monitoring screen for message DWAYKB………………………………………….1465
DWAYKY – Bucket3 dump solenoid hot short circuit……………………………………………………1466
Wiring Diagram and monitoring screen for message DWAYKY………………………………………….1467
DWBGKA – Boom3 down solenoid open circuit………………………………………………………….1468
Wiring Diagram and monitoring screen for message DWBGKA………………………………………….1469
DWBGKB – Boom3 down solenoid short circuit…………………………………………………………1470
Wiring Diagram and monitoring screen for message DWBGKB………………………………………….1471
DWBGKY – Boom3 down solenoid hot short circuit……………………………………………………..1472
Wiring Diagram and monitoring screen for message DWBGKY………………………………………….1473
DWBDKA – Boom4 up solenoid open circuit……………………………………………………………1474
Wiring Diagram and monitoring screen for message DWBDKA………………………………………….1475
DWBDKB – Boom4 up solenoid short circuit…………………………………………………………..1476
Wiring Diagram and monitoring screen for message DWBDKB………………………………………….1477
DWBDKY – Boom4 up solenoid hot short circuit……………………………………………………….1478
Wiring Diagram and monitoring screen for message DWBDKY………………………………………….1479
DWBHKA – Boom4 down solenoid open circuit………………………………………………………….1480
Wiring Diagram and monitoring screen for message DWBHKA………………………………………….1481
DWBHKB – Boom4 down solenoid short circuit…………………………………………………………1482
Wiring Diagram and monitoring screen for message DWBHKB………………………………………….1483
DWBHKY – Boom4 down solenoid hot short circuit……………………………………………………..1484
Wiring Diagram and monitoring screen for message DWBHKY………………………………………….1485
DWAVKA – Bucket4 fill solenoid open circuit………………………………………………………..1486
Wiring Diagram and monitoring screen for message DWAVKA………………………………………….1487
DWAVKB – Bucket4 fill solenoid short circuit……………………………………………………….1488
Wiring Diagram and monitoring screen for message DWAVKB………………………………………….1489
DWAVKY – Bucket4 fill solenoid hot short circuit……………………………………………………1490
Wiring Diagram and monitoring screen for message DWAVKY………………………………………….1491
DWAZKA – Bucket4 dump solenoid open circuit………………………………………………………..1492
Wiring Diagram and monitoring screen for message DWAZKA………………………………………….1493
DWAZKB – Bucket4 dump solenoid short circuit……………………………………………………….1494
Wiring Diagram and monitoring screen for message DWAZKB………………………………………….1495
DWAZKY – Bucket4 dump solenoid hot short circuit……………………………………………………1496
Wiring Diagram and monitoring screen for message DWAZKY………………………………………….1497
DWBMKA – Stick4 out solenoid open circuit………………………………………………………….1498
Wiring Diagram and monitoring screen for message DWBMKA………………………………………….1499
DWBMKB – Stick4 out solenoid short circuit…………………………………………………………1500
Wiring Diagram and monitoring screen for message DWBMKB………………………………………….1501
DWBMKY – Stick4 out solenoid hot short circuit……………………………………………………..1502
Wiring Diagram and monitoring screen for message DWBMKY………………………………………….1503
DWBRKA – Stick4 in solenoid open circuit…………………………………………………………..1504
Wiring Diagram and monitoring screen for message DWBRKA………………………………………….1505
DWBRKB – Stick4 in solenoid short circuit………………………………………………………….1506
Wiring Diagram and monitoring screen for message DWBRKB………………………………………….1507
DWBRKY – Stick4 in solenoid hot short circuit………………………………………………………1508
Wiring Diagram and monitoring screen for message DWBRKY………………………………………….1509
DWKRKA – Travel4 right backward sol. open circuit…………………………………………………..1510
Wiring Diagram and monitoring screen for message DWKRKA………………………………………….1511
DWKRKB – Travel4 right backward sol. short circuit………………………………………………….1512
Wiring Diagram and monitoring screen for message DWKRKB………………………………………….1513
DWKRKY – Travel4 right backward sol. hot short……………………………………………………..1514
Wiring Diagram and monitoring screen for message DWKRKY………………………………………….1515
DWKMKA – Travel4 right forward sol. open circuit……………………………………………………1516
Wiring Diagram and monitoring screen for message DWKMKA………………………………………….1517
DWKMKB – Travel4 right forward sol. short circuit…………………………………………………..1518
Wiring Diagram and monitoring screen for message DWKMKB………………………………………….1519
DWKMKY – Travel4 right forward sol. hot short………………………………………………………1520
Wiring Diagram and monitoring screen for message DWKMKY………………………………………….1521
DXEDKA – Hydraulic slew brake epc sol. open circuit…………………………………………………1522
Wiring Diagram and monitoring screen for message DXEDKA………………………………………….1523
DXEDKB – Hyd. slew brake epc sol. short circuit…………………………………………………….1524
Wiring Diagram and monitoring screen for message DXEDKB………………………………………….1525
DXEDKY – Hyd. slew brake epc sol. hot short circuit…………………………………………………1526
Wiring Diagram and monitoring screen for message DXEDKY………………………………………….1527
DWKVKA – Boom4 float solenoid open circuit…………………………………………………………1528
Wiring Diagram and monitoring screen for message DWKVKA………………………………………….1529
DWKVKB – Boom4 float solenoid short circuit………………………………………………………..1530
Wiring Diagram and monitoring screen for message DWKVKB………………………………………….1531
DWKVKY – Boom4 float solenoid hot short circuit…………………………………………………….1532
Wiring Diagram and monitoring screen for message DWKVKY………………………………………….1533
DWKWKA – Stick1 float solenoid open circuit………………………………………………………..1534
Wiring Diagram and monitoring screen for message DWKWKA………………………………………….1535
DWKWKB – Stick1 float solenoid short circuit……………………………………………………….1536
Wiring Diagram and monitoring screen for message DWKWKB………………………………………….1537
DWKWKY – Stick1 float solenoid hot short circuit……………………………………………………1538
Wiring Diagram and monitoring screen for message DWKWKY………………………………………….1539
DWKZKA – Stick4 float solenoid open circuit………………………………………………………..1540
Wiring Diagram and monitoring screen for message DWKZKA………………………………………….1541
DWKZKB – Stick4 float solenoid short circuit……………………………………………………….1542
Wiring Diagram and monitoring screen for message DWKZKB………………………………………….1543
DWKZKY – Stick4 float solenoid hot short circuit……………………………………………………1544
Wiring Diagram and monitoring screen for message DWKZKY………………………………………….1545
DBY9KQ – Model Selection Abnormality………………………………………………………………1546
Wiring Diagram and monitoring screen for message DBY9KQ………………………………………….1547
DBYZKQ – Lever Control Selection Abnormality……………………………………………………….1548
Wiring Diagram and monitoring screen for message DBYZKQ………………………………………….1549
DBYYKQ – Attachment selection abnormality………………………………………………………….1550
Wiring Diagram – Attachment selection abnormality (DBYYKQ)……………………………………….1551
D562MA – Lock lever sol power cut abnorm(VALVE/S2)………………………………………………….1552
Wiring Diagram 1 and monitoring screen for message D562MA………………………………………..1553
Wiring Diagram 2 for message D562MA……………………………………………………………1554
D564MA – Ladder up sensor sol cut abnorm(VLV/S2)……………………………………………………1555
Monitoring screens and Wiring Diagram 1 for message D564MA……………………………………….1556
Wiring Diagram 2 for message D564MA……………………………………………………………1557
D566MA – Service arm sensor sol cut abnorm(VALV/S2)…………………………………………………1558
Wiring Diagram 1 and monitoring screens for message D566MA……………………………………….1559
Wiring Diagram 2 for message D566MA……………………………………………………………1560
DBY2KK – Solenoid Power Low Error(VALVE/S2 Con)…………………………………………………….1561
Monitoring screen and Wiring Diagram 1 for message DBY2KK………………………………………..1562
Wiring Diagram 2 for message DBY2KK – Safety circuit…………………………………………….1563
DBY0KQ – VALVE/S2 Con Selection Abnormality………………………………………………………..1564
Wiring Diagram and monitoring screen for message DBY0KQ………………………………………….1565
DJH2KX – Hydraulic oil level sensor abnormality…………………………………………………….1566
Wiring Diagram and monitoring screen for message DJH2KX………………………………………….1567
DJE3KX – Remote engine oil level1 sens. abnormality…………………………………………………1568
Wiring Diagram and monitoring screen for message DJE3KX………………………………………….1569
DH2GKX – Suction tank pressure sensor abnormality…………………………………………………..1570
Wiring Diagram and monitoring screen for message DH2GKX………………………………………….1571
DH2HKX – Oil cooler pressure sensor abnormality…………………………………………………….1572
Wiring Diagram and monitoring screen for message DH2HKX………………………………………….1573
DH2JKX – Preload valve return oil press abnormality…………………………………………………1574
Wiring Diagram and monitoring screen for message DH2JKX………………………………………….1575
DHSUKX – X2 pressure sensor abnormality……………………………………………………………1576
Wiring Diagram and monitoring screen for message DHSUKX………………………………………….1577
DJF1KX – Fuel level sensor abnormality…………………………………………………………….1578
Wiring Diagram and monitoring screen for message DJF1KX………………………………………….1579
DGE5MA – Ambient air temp sensor abnormality……………………………………………………….1580
Wiring Diagram and monitoring screen for message DGE5MA………………………………………….1581
DH2KKX – Return oil chamber press. sensor abnormal………………………………………………….1582
Wiring Diagram and monitoring screen for message DH2KKX………………………………………….1583
DH2LKX – Leak oil chamber press. sensor abnormality…………………………………………………1584
Wiring Diagram and monitoring screen for message DH2LKX………………………………………….1585
DJE5L4 – SLS sensor system abnormality…………………………………………………………….1586
Wiring Diagram and monitoring screen for message DJE5L4………………………………………….1587
DJE6L4 – CLS sensor system abnormality…………………………………………………………….1588
Wiring Diagram and monitoring screen for message DJE6L4………………………………………….1589
DBVLKA – Operating Lamp Open Circuit(KOMTRAX)………………………………………………………1590
Wiring Diagram for message DBVLKA……………………………………………………………..1591
DBVLKB – Operating Lamp Short Circuit(KOMTRAX)……………………………………………………..1592
Wiring Diagram for message DBVLKB……………………………………………………………..1593
DBV1KK – KOMTRAX Plus source voltage Error…………………………………………………………1594
Wiring Diagram for message DBV1KK……………………………………………………………..1595
DBV5KB – 5V sensor1 power abnormality……………………………………………………………..1596
Wiring Diagram 1 and monitoring screens for message DBV5KB……………………………………….1597
Wiring Diagram 2 for message DBV5KB……………………………………………………………1598
DBV6KB – 24V Sensor Power Abnormality……………………………………………………………..1600
Wiring Diagram 1 and monitoring screens for message DBV6KB……………………………………….1601
Wiring Diagram 2 for message DBV6KB……………………………………………………………1602
DAFGMC – GPS Module Error………………………………………………………………………..1604
Wiring Diagram for message DAFGMC……………………………………………………………..1605
D862KA – GPS Antenna Open Circuit…………………………………………………………………1606
DBVVKR – Ethernet 1 Disconnection…………………………………………………………………1607
DBVWKR – Ethernet 2 Disconnection…………………………………………………………………1608
DA2RKR – CAN1 Discon (Pump Con)…………………………………………………………………..1610
CAN1 overview for message DA2RKR………………………………………………………………1611
DBWRKR – CAN1 Discon (Valve/M Con)………………………………………………………………..1612
CAN1 overview for message DBWRKR………………………………………………………………1613
DBXRKR – CAN1 Discon (Valve/S1 Con)……………………………………………………………….1614
CAN1 overview for message DBXRKR………………………………………………………………1615
DBYRKR – CAN1 Discon (Valve/S2 Con)……………………………………………………………….1616
CAN1 overview for message DBYRKR………………………………………………………………1617
DB2QKR – CAN2 Discon (Engine Con)…………………………………………………………………1618
CAN2 overview for message DB2QKR………………………………………………………………1619
Wiring Diagram for PWR supply at 52K014-1 (DB2QKR)………………………………………………1620
DA2QKR – CAN2 Discon (Pump Con)…………………………………………………………………..1622
CAN2 overview for message DA2QKR………………………………………………………………1623
DBWQKR – CAN2 Discon (Valve/M Con)………………………………………………………………..1624
CAN2 overview for message DBWQKR………………………………………………………………1625
DBXQKR – CAN2 Discon (Valve/S1 Con)……………………………………………………………….1626
CAN2 overview for message DBXQKR………………………………………………………………1627
DBYQKR – CAN2 Discon (Valve/S2 Con)……………………………………………………………….1628
CAN2 overview for message DBYQKR………………………………………………………………1629
DBVQKR – CAN2 Discon (KOMTRAX Plus)……………………………………………………………….1630
CAN2 overview for message DBVQKR………………………………………………………………1631
DBPRKR – CAN1 Discon (KomVision)………………………………………………………………….1632
Wiring Diagram for DBPRKR…………………………………………………………………….1633
DBPQKR – CAN2 Discon (KomVision)………………………………………………………………….1634
Wiring Diagram for DBPQKR…………………………………………………………………….1635
D19YKB – Emergency Lighting Ladder Relay Short Circuit………………………………………………1636
Wiring Diagram and monitoring screen for message D19YKB………………………………………….1637
DV00KB – Shutdown Buzzer Short Circuit…………………………………………………………….1638
Wiring Diagram and monitoring screen for message DV00KB………………………………………….1639
DAF0KM – Inconsistency of KomVision Setting………………………………………………………..1640
DBP5KP – Camera Power Output Voltage Low…………………………………………………………..1642
Wiring Diagram for message DBP5KP……………………………………………………………..1643
DBP0NR – KomVision Controller High Temperature Error………………………………………………..1644
DBPVKR – CAN5 Discon (KomVision)………………………………………………………………….1645
DBPUKR – CAN4 Discon (KomVision)………………………………………………………………….1645
DPQ4KB – Short Circuit of KomVision Monitor ON/OFF Signal……………………………………………1646
Wiring Diagram for message DPQ4KB……………………………………………………………..1647
DBP0KT – KomVision Controller Internal Error……………………………………………………….1648
DBP0KM – KomVision Controller Setting Error………………………………………………………..1649
DR10KA – Disconnection of Camera 1 NTSC Input………………………………………………………1650
DR20KA – Disconnection of Camera 2 NTSC Input………………………………………………………1650
DR30KA – Disconnection of Camera 3 NTSC Input………………………………………………………1650
DR40KA – Disconnection of Camera 4 NTSC Input………………………………………………………1650
DR50KA – Disconnection of Camera 5 NTSC Input………………………………………………………1650
DR60KA – Disconnection of Camera 6 NTSC Input………………………………………………………1650
DR90KA – Disconnection of Camera 7 NTSC Input………………………………………………………1650
Wiring Diagram for message DR10KA…DR90KA……………………………………………………..1651
DPQ4KT – KomVision Monitor Internal Error………………………………………………………….1652
DBPLKA – Operating Lamp Open Circuit (KomVision)……………………………………………………1654
Wiring Diagram for message DBPLKA……………………………………………………………..1655
DBPLKB – Operating Lamp Short Circuit (KomVision)…………………………………………………..1656
Wiring Diagram for message DBPLKB……………………………………………………………..1657
DBPWKR – Ethernet 1 Discon (KomVision)…………………………………………………………….1658
DBPXKR – Ethernet 2 Discon (KomVision)…………………………………………………………….1658
7 Troubleshooting by Symptoms………………………………………………………………………..1659
7.1 Symptoms of the engine and related electrical system…………………………………………….1660
SEL001 – Engine does not start (engine does not rotate)……………………………………………..1660
Wiring Diagram 1 (batteries) for symptom code SEL001…………………………………………….1662
Wiring Diagram 2 (20S030 & 20S105) for symptom code SEL001……………………………………….1663
Wiring Diagram 3 (engine enable) for symptom code SEL001…………………………………………1664
Wiring Diagram 4 (starter motors) for symptom code SEL001………………………………………..1665
SEL002 – Engine stops while in operation…………………………………………………………..1666
View onto the fuel system water separator (SEL002)………………………………………………1667
SEL003 – Engine speed is hunting during boom-up movement…………………………………………….1668
SEL004 – Engine does not stop…………………………………………………………………….1670
SEL005 – Engine lacks output (no power)……………………………………………………………1671
Judgment Table for SEL005…………………………………………………………………….1672
SEL006 – Engine does not start (Pre-lube does not stop)……………………………………………..1673
SEL007 – Oil consumption is excessive……………………………………………………………..1674
Judgment Table for SEL007…………………………………………………………………….1675
SEL008 – Oil becomes contaminated quickly………………………………………………………….1676
Judgment Table for SEL008…………………………………………………………………….1677
SEL009 – Fuel consumption is excessive…………………………………………………………….1678
Judgment Table for SEL009…………………………………………………………………….1679
SEL010 – Oil is in engine coolant…………………………………………………………………1680
Judgment Table for SEL010…………………………………………………………………….1681
SEL011 – Oil level rises…………………………………………………………………………1682
Judgment Table for SEL011…………………………………………………………………….1683
SEL012 – Coolant temperature becomes too high (overheating)………………………………………….1684
Judgment Table for SEL012…………………………………………………………………….1685
7.2 Symptoms of the Hydraulic System………………………………………………………………1686
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function)….1686
SHY002 – Engine speed sharply drops or engine stalls too much………………………………………..1688
SHY003 – No work equipment, travel or slew movement…………………………………………………1689
SHY004 – Work equipment has too much hydraulic drift………………………………………………..1690
SHY005 – Work equipment has big time lag…………………………………………………………..1691
SHY006 – Machine deviates during travel movement……………………………………………………1692
SHY007 – Hydraulic system has lack of power………………………………………………………..1693
SHY008 – Machine does not slew……………………………………………………………………1694
Slew brake block (SHY008)…………………………………………………………………….1695
SHY009 – Slew acceleration is poor………………………………………………………………..1696
SHY010 – Excessive overrun when stopping slew movement………………………………………………1698
SHY011 – Floating system without function (FSA only)………………………………………………..1700
SHY012 – Abnormal noise coming from SRV or MRV……………………………………………………..1701
SHY013 – Track tensioning system without function…………………………………………………..1702
Track tensioning – overview (SHY013)…………………………………………………………..1703
SHY014 – Ladder does not move, or slow movement…………………………………………………….1704
SHY015 – Refilling arm does not move, or slow movement………………………………………………1706
SHY016 – The hydr. driven grease pump does not move…………………………………………………1708
SHY017 – Abnormal track chain movement during digging……………………………………………….1710
SHY018 – Slew parking brake without function……………………………………………………….1711
SHY019 – Travel parking brake without function……………………………………………………..1712
7.3 Symptoms of the Mechanical System……………………………………………………………..1714
SME001 – Abnormal noise is made…………………………………………………………………..1714
Judgment Table for SME001…………………………………………………………………….1715
SME002 – Abnormal noise around PTO / hydraulic pumps………………………………………………..1716
SME003 – Vibration is excessive (engine mountings)………………………………………………….1718
Judgment Table for SME003…………………………………………………………………….1719
SME004 – Vibration is excessive (engine torsion)……………………………………………………1720
SME005 – There is a big shock when stopping slew movement……………………………………………1721
SME006 – There is a big abnormal noise when moving/stopping slew movement……………………………..1722
SME007 – Fan blades make abnormal noise……………………………………………………………1724
SME008 – Abnormal noise coming from a travel gearbox………………………………………………..1725
SME009 – Abnormal noise coming from the work equipment (lack of grease)……………………………….1727
SME010 – Abnormal idler movement………………………………………………………………….1729
SME011 – Leak at the PTO shaft seal……………………………………………………………….1730
7.4 Symptoms of Additional Systems………………………………………………………………..1732
SAD001 – Air conditioner for the cabin does not work………………………………………………..1732
View onto the A/C unit (SAD001)……………………………………………………………….1733
SAD002 – Air conditioner compressor clutch is burnt…………………………………………………1734
View onto the A/C compressor and its mounting (SAD002)…………………………………………..1735
SAD003 – Air conditioning system defective (pipes and hoses full of moisture)………………………….1736
View onto the A/C filling and service station…………………………………………………..1737
50 DISASSEMBLY & ASSEMBLY……………………………………………………………………………….1739
Table of content……………………………………………………………………………………1741
1 Introduction……………………………………………………………………………………..1749
1.1 Foreword……………………………………………………………………………………1750
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels……1751
1.3 Diagrams and illustrations in this manual………………………………………………………1751
1.4 Procedures for disassembling and assembling in this manual……………………………………….1752
2 Safety…………………………………………………………………………………………..1753
2.1 Overview……………………………………………………………………………………1755
2.1.1 Method of using this manual……………………………………………………………..1755
2.2 General precautions………………………………………………………………………….1757
2.2.1 General……………………………………………………………………………….1757
2.2.2 Personal protective clothing…………………………………………………………….1757
2.2.3 When using a hammer…………………………………………………………………….1758
2.2.4 Proper tools…………………………………………………………………………..1758
2.2.5 Personnel……………………………………………………………………………..1758
2.2.6 Fire prevention………………………………………………………………………..1759
2.2.7 Unauthorized modification……………………………………………………………….1759
2.3 Precautions for maintenance and repair…………………………………………………………1760
2.3.1 General precautions…………………………………………………………………….1760
2.3.2 Keep work place clean and tidy…………………………………………………………..1760
2.3.3 Precautions when welding………………………………………………………………..1761
2.3.4 Precaution with high pressure fluids……………………………………………………..1761
2.3.4.1 Handling high pressure hoses and pipes………………………………………………1761
2.3.5 Compressed air…………………………………………………………………………1761
2.3.6 Waste materials………………………………………………………………………..1762
3 Superstructure……………………………………………………………………………………1763
3.1 Superstructure overview………………………………………………………………………1764
3.2 Machine House (T4)…………………………………………………………………………..1766
3.2.1 Disconnection plate at the machine house………………………………………………….1768
3.2.1.1 Machine house hose ports – port allocations………………………………………….1768
3.2.2 Machine house roof……………………………………………………………………..1770
3.2.2.1 Disassembling of the machine house roof cover plates………………………………….1773
3.2.2.2 Assembling of the machine house roof cover plates…………………………………….1780
3.2.3 Traverse assembly on machine house (T4 equipment)………………………………………….1786
3.2.3.1 Disassembling of the complete traverse assembly (T4 equipment)…………………………1786
3.2.3.2 Assembling of the complete traverse assembly (T4 equipment)……………………………1790
3.2.3.3 Disassembling of the SCR catalysts (T4 equipment)…………………………………….1794
3.2.3.4 Assembling of the SCR catalysts (T4 equipment)……………………………………….1798
3.2.3.5 Disassembling of the DEF tank assembly (T4 equipment)…………………………………1803
3.2.3.6 Assembling of the DEF tank assembly (T4 equipment)……………………………………1807
3.2.4 Air intake system………………………………………………………………………1810
3.2.4.1 Disassembling of the air intake system………………………………………………1810
3.2.4.2 Assembling of the air intake system…………………………………………………1813
3.2.5 Diesel engine………………………………………………………………………….1816
3.2.5.1 Disassembling and assembling of the Alternator……………………………………….1816
3.2.5.2 Disassembling and assembling of the starter motors……………………………………1816
3.2.5.3 Disassembling of the Diesel engine………………………………………………….1817
3.2.5.4 Assembling of the Diesel engine…………………………………………………….1823
3.2.6 Batteries……………………………………………………………………………..1830
3.2.6.1 Disassembling of the batteries……………………………………………………..1830
3.2.6.2 Assembling of the batteries………………………………………………………..1832
3.2.7 Flexible coupling………………………………………………………………………1833
3.2.7.1 Disassembling of the CentaFlex coupling assembly……………………………………..1833
3.2.7.2 Assembling of the CentaFlex coupling assembly………………………………………..1836
3.2.7.3 Replacing the rubber rollers of the CentaFlex coupling………………………………..1838
3.2.8 Radiator fan and fan drive assembly………………………………………………………1840
3.2.8.1 Disassembling of the radiator fan…………………………………………………..1842
3.2.8.2 Assembling of the radiator fan……………………………………………………..1844
3.2.8.3 Disassembling of the radiator fan motor……………………………………………..1846
3.2.8.4 Assembling of the radiator fan motor………………………………………………..1848
3.2.8.5 Disassembling of the Radiator assembly………………………………………………1850
3.2.8.6 Assembling of the radiator assembly…………………………………………………1855
3.2.9 Main pump assemblies……………………………………………………………………1860
3.2.9.1 Disassembling and assembling of the auxiliary pumps…………………………………..1861
3.2.9.2 Disassembling of the main pump assemblies……………………………………………1862
3.2.9.3 Assembling of the main pump assemblies………………………………………………1866
3.2.10 Universal PTO…………………………………………………………………………1870
3.2.10.1 Disassembling of the universal PTO…………………………………………………1870
3.2.10.2 Assembling of the universal PTO……………………………………………………1873
3.3 Hydraulic System…………………………………………………………………………….1876
3.3.1 Hydraulic oil cooler assembly……………………………………………………………1876
3.3.1.1 Disassembling of hydraulic cooler fan and motor………………………………………1877
3.3.1.2 Assembling of hydraulic cooler fan and motor…………………………………………1880
3.3.1.3 Disassembling of the hydraulic oil radiators…………………………………………1883
3.3.1.4 Assembling of the hydraulic oil coolers……………………………………………..1887
3.3.1.5 Disassembling of the hydraulic oil cooler assembly……………………………………1890
3.3.1.6 Assembling of the hydraulic oil cooler assembly………………………………………1895
3.3.2 Hydraulic oil tank……………………………………………………………………..1900
3.3.2.1 Disassembling of the main shut-off valve…………………………………………….1902
3.3.2.2 Assembling of the main shut-off valve……………………………………………….1904
3.3.2.3 Disassembling of the hydraulic oil tank……………………………………………..1906
3.3.2.4 Assembling of the hydraulic oil tank………………………………………………..1911
3.3.3 Main control valve blocks……………………………………………………………….1918
3.3.3.1 Disassembling of the main control valve blocks……………………………………….1918
3.3.3.2 Assembling of the main control valve blocks………………………………………….1921
3.3.3.3 Disassembling of the MRV at the main control valve blocks……………………………..1924
3.3.3.4 Assembling of the MRV at the main control valve blocks………………………………..1925
3.3.3.5 Disassembling of SRV on main control valve block……………………………………..1926
3.3.3.6 Assembling of SRV on main control valve blocks……………………………………….1927
3.3.3.7 Disassembling of ACV-/SRV-block on main control valve blocks…………………………..1928
3.3.3.8 Assembling of ACV-/SRV-block on main control valve blocks……………………………..1930
3.3.4 Distributor Manifold……………………………………………………………………1932
3.3.4.1 Disassembling of SRV-valve blocks / restrictor blocks at the distributor manifold………..1933
3.3.4.2 Assembling of SRV-valve blocks / restrictor blocks at the distributor manifold…………..1935
3.3.4.3 Disassembling of anti cavitation valves at the distributor manifold…………………….1937
3.3.4.4 Assembling of anti cavitation valves at the distributor manifold……………………….1939
3.3.4.5 Disassembling of the Diffuser block at the manifold (FSA)……………………………..1941
3.3.4.6 Assembling of the Diffuser block at the manifold……………………………………..1943
3.3.4.7 Disassembling of the distributor manifold……………………………………………1944
3.3.4.8 Assembling of the distributor manifold………………………………………………1947
3.4 Slew system…………………………………………………………………………………1950
3.4.1 Slew gears…………………………………………………………………………….1950
3.4.1.1 Disassembling of the slew gear……………………………………………………..1951
3.4.1.2 Assembling of the slew gear………………………………………………………..1954
3.4.2 Slew motor…………………………………………………………………………….1958
3.4.2.1 Disassembling of the slew motor…………………………………………………….1959
3.4.2.2 Assembling of the slew motor……………………………………………………….1962
3.4.3 Slew parking brake……………………………………………………………………..1964
3.4.3.1 Disassembling of the slew parking brake (L&S)………………………………………..1965
3.4.3.2 Assembling of the slew parking brake (L&S)…………………………………………..1968
3.4.3.3 Disassembling of the slew parking brake (siebenhaar)………………………………….1971
3.4.3.4 Assembling of the slew parking brake (Siebenhaar)…………………………………….1974
3.4.4 slew service brake valve………………………………………………………………..1977
3.4.4.1 Disassembling of the slew service brake valve………………………………………..1977
3.4.4.2 Assembling of the of the slew service brake valve…………………………………….1979
3.4.5 Slew circle……………………………………………………………………………1981
3.4.5.1 Disassembling of the slew circle……………………………………………………1981
3.4.5.2 Assembling of the slew circle………………………………………………………1985
3.4.6 Slew circle lubrication pinion (dummy wheel)………………………………………………1990
3.4.6.1 Disassembling of the lubrication pinion assembly……………………………………..1990
3.4.6.2 Assembling of the lubrication pinion assembly………………………………………..1991
3.5 Lubrication pumps……………………………………………………………………………1992
3.5.1 Disassembling of the lubrication pump…………………………………………………….1992
3.5.2 Assembling of the lubricating pump……………………………………………………….1993
3.6 Operator’s cab………………………………………………………………………………1994
3.6.1 Disassembling of the operator’s cab………………………………………………………1995
3.6.2 Assembling of the operator’s cab…………………………………………………………1999
3.6.3 Disassembling of the operator’s cab together with the cab support frame………………………2002
3.6.4 Assembling of the operator’s cab together with the cab support frame…………………………2006
3.6.5 Cab-mounts…………………………………………………………………………….2010
3.6.5.1 Disassembling of the cab-mounts…………………………………………………….2010
3.6.5.2 Assembling of the cab-mounts……………………………………………………….2012
3.6.6 Front window…………………………………………………………………………..2014
3.6.6.1 Disassembling of the front window…………………………………………………..2014
3.6.6.2 Assembling of the front window……………………………………………………..2015
3.6.7 Operator’s seat………………………………………………………………………..2016
3.6.7.1 Disassembling of the operator’s seat………………………………………………..2016
3.6.7.2 Assembling of the operator’s seat…………………………………………………..2017
3.7 Cab base……………………………………………………………………………………2018
3.7.1 Disassembling of the cab support frame……………………………………………………2019
3.7.2 Assembling of the cab support frame………………………………………………………2021
3.7.3 Disassembling of the cab base……………………………………………………………2023
3.7.4 Assembling of the cab base………………………………………………………………2025
3.8 Ladders and platforms………………………………………………………………………..2027
3.8.1 Hydraulic access Ladder…………………………………………………………………2027
3.8.1.1 Disassembling of the hydraulic access ladder…………………………………………2027
3.8.1.2 Assembling of the hydraulic access ladder……………………………………………2029
3.8.2 Disassembling of the access ladder cylinder……………………………………………….2031
3.8.3 Assembling of the access ladder cylinder………………………………………………….2033
3.8.4 Fuel tank step…………………………………………………………………………2034
3.8.4.1 Disassembling of the fuel tank step…………………………………………………2034
3.8.4.2 Assembling of the fuel tank step……………………………………………………2036
3.8.5 step platforms…………………………………………………………………………2037
3.8.5.1 Disassembling of the upper step platform at fuel tank…………………………………2037
3.8.5.2 Assembling of the upper step platform at fuel tank……………………………………2039
3.8.5.3 Disassembling of the lower step platform at machine house……………………………..2040
3.8.5.4 Assembling of the lower step platform at machine house………………………………..2041
3.8.6 Emergency escape ladders………………………………………………………………..2042
3.8.6.1 Disassembling of the emergency escape ladder assembly at the cab base…………………..2042
3.8.6.2 Assembling of the emergency escape ladder assembly at the cab base……………………..2044
3.8.6.3 Disassembling of the emergency escape ladder assembly at the machine house………………2045
3.8.6.4 Assembling of the emergency escape ladder assembly at the machine house…………………2047
3.9 Counterweight……………………………………………………………………………….2048
3.9.1 Disassembling of the counterweight……………………………………………………….2049
3.9.2 Assembling of the counterweight………………………………………………………….2051
3.10 Fuel tank………………………………………………………………………………….2054
3.10.1 Disassembling of the fuel tank………………………………………………………….2054
3.10.2 Assembling of the fuel tank…………………………………………………………….2058
3.10.3 Fuel cooler box (T4 equipment)………………………………………………………….2062
3.10.3.1 Disassembling of the fuel cooler box (T4 equipment)………………………………….2062
3.10.3.2 Assembling of the fuel cooler box (T4 equipment)…………………………………….2064
3.11 Superstructure Lifting………………………………………………………………………2066
3.11.1 Disassemble the superstructure from the undercarriage……………………………………..2066
3.11.2 Install the superstructure onto the undercarriage…………………………………………2069
4 Undercarriage…………………………………………………………………………………….2073
4.1 Undercarriage overview……………………………………………………………………….2074
4.2 Travel system……………………………………………………………………………….2076
4.2.1 Crawler track………………………………………………………………………….2076
4.2.1.1 Changing of the crawler track………………………………………………………2076
4.2.2 Sprocket………………………………………………………………………………2083
4.2.2.1 Disassembling of the sprocket assembly………………………………………………2083
4.2.2.2 Assembling of the sprocket assembly…………………………………………………2088
4.2.3 Guide wheel assembly……………………………………………………………………2091
4.2.3.1 Disassembling of the guide wheel assembly……………………………………………2091
4.2.3.2 Assembling of the guide wheel assembly………………………………………………2093
4.2.4 Track tensioning accumulators……………………………………………………………2096
4.2.4.1 Disassembling of the low pressure accumulators……………………………………….2096
4.2.4.2 Assembling of the low pressure accumulators………………………………………….2098
4.2.4.3 Disassembling of the high pressure accumulators………………………………………2100
4.2.4.4 Assembling of the high pressure accumulators…………………………………………2101
4.2.5 Track tension valve block……………………………………………………………….2102
4.2.5.1 Disassembling of the track tensioning valve block…………………………………….2102
4.2.5.2 Assembling of the track tensioning valve block……………………………………….2103
4.2.6 Track tensioning cylinders………………………………………………………………2104
4.2.6.1 Disassembling of the track tensioning cylinders………………………………………2104
4.2.6.2 Assembling of the track tensioning cylinders…………………………………………2106
4.2.7 Hydraulic hoses of the track tensioning system…………………………………………….2109
4.2.7.1 Precursory work…………………………………………………………………..2109
4.2.7.2 Replace the hydraulic hoses inside the center body……………………………………2111
4.2.7.3 Replace the hydraulic hoses between center body and crawler frame………………………2111
4.2.7.4 Replace the hydraulic hoses inside the crawler frame………………………………….2113
4.2.7.5 Subsequent work…………………………………………………………………..2113
4.2.8 Travel brake valve block (overspeed valve)………………………………………………..2114
4.2.8.1 Disassembling of the travel brake valve block………………………………………..2114
4.2.8.2 Assembling of the travel brake valve block…………………………………………..2116
4.2.9 Travel motors………………………………………………………………………….2118
4.2.9.1 Disassembling of the travel motors………………………………………………….2118
4.2.9.2 Assembling of the travel motors…………………………………………………….2120
4.2.10 Travel parking brake…………………………………………………………………..2122
4.2.10.1 Travel parking brake overview……………………………………………………..2122
4.2.10.2 Disassembling of the travel parking brake (L&S)……………………………………..2127
4.2.10.3 Assembling of the travel parking brake (L&S)………………………………………..2130
4.2.10.4 Disassembling of the travel parking brake (Zollern)………………………………….2133
4.2.10.5 Assembling of the travel parking brake (Zollern)…………………………………….2136
4.2.11 Travel gear box……………………………………………………………………….2140
4.2.11.1 Disassembling of the travel gear box……………………………………………….2141
4.2.11.2 Assembling of the travel gear box………………………………………………….2143
4.2.12 Carrier roller………………………………………………………………………..2146
4.2.12.1 Disassembling of the carrier roller assembly………………………………………..2146
4.2.12.2 Assembling of the carrier roller assembly…………………………………………..2148
4.2.13 Track roller………………………………………………………………………….2150
4.2.13.1 Disassembling of the track roller assembly………………………………………….2150
4.2.13.2 Assembling of the track roller assembly…………………………………………….2152
4.3 Undercarriage center body…………………………………………………………………….2154
4.3.1 Disassembling of the undercarriage center body and the crawler carriers………………………2154
4.3.2 Assembling of the undercarriage center body and the crawler carriers…………………………2159
4.3.2.1 Install crawler carrier mounting bolts………………………………………………2165
4.3.3 Rotary joint…………………………………………………………………………..2166
4.3.3.1 Disassembling of the rotary joint…………………………………………………..2166
4.3.3.2 Assembling of the rotary joint……………………………………………………..2170
5 Attachment……………………………………………………………………………………….2175
5.1 Repair procedures……………………………………………………………………………2176
5.1.1 Replacement of bushings at the attachment…………………………………………………2176
5.1.1.1 Disassembling of the bushings………………………………………………………2176
5.1.1.2 Installation of the bushings……………………………………………………….2177
5.1.2 General installation instructions for attachment pins………………………………………2178
5.2 Backhoe Attachment (BHA)……………………………………………………………………..2180
5.2.1 Overview………………………………………………………………………………2180
5.2.2 Pin Sealing bucket – Steering Rod – bucket link rod………………………………………..2182
5.2.3 Boom assembly………………………………………………………………………….2184
5.2.3.1 Disassembling of the Boom………………………………………………………….2184
5.2.3.2 Assembling of the boom…………………………………………………………….2186
5.2.3.3 Disassembling of the boom cylinders…………………………………………………2189
5.2.3.4 Assembling of the boom cylinders……………………………………………………2194
5.2.4 Stick assembly…………………………………………………………………………2199
5.2.4.1 Disassembling of the Stick…………………………………………………………2199
5.2.4.2 Assembling of the Stick……………………………………………………………2204
5.2.4.3 Disassembling of the Stick Cylinders………………………………………………..2208
5.2.4.4 Assembling of the Stick cylinders…………………………………………………..2212
5.2.5 Bucket and steering…………………………………………………………………….2217
5.2.5.1 Disassembling of the bucket………………………………………………………..2217
5.2.5.2 Assembling of the bucket…………………………………………………………..2221
5.2.5.3 Disassembling of the Bucket Cylinders……………………………………………….2224
5.2.5.4 Assembling of the Bucket Cylinders………………………………………………….2231
5.2.5.5 Disassembling of the bucket link rod………………………………………………..2238
5.2.5.6 Assembling of the bucket link rod…………………………………………………..2241
5.2.5.7 Disassembling of the steering rods………………………………………………….2244
5.2.5.8 Assembling of the steering rods…………………………………………………….2250
5.2.6 Hydraulic hoses at the backhoe attachment…………………………………………………2255
5.2.6.1 Replacing of the boom arc hoses…………………………………………………….2255
5.2.6.2 Replacing of the lubrication hoses………………………………………………….2258
5.2.6.3 Replacing of the boom cylinder hoses………………………………………………..2259
5.2.6.4 Replacing of the stick cylinder hoses……………………………………………….2262
5.2.6.5 Replacing of the bucket cylinder hoses………………………………………………2265
5.3 Front Shovel Attachment (FSA)…………………………………………………………………2268
5.3.1 Overview………………………………………………………………………………2268
5.3.2 Using the Cylinder Mounting Device for Front shovel attachments (PN 967 000 40)……………….2270
5.3.2.1 Designated usage………………………………………………………………….2271
5.3.2.2 Non-designated usage………………………………………………………………2271
5.3.3 Boom assembly………………………………………………………………………….2272
5.3.3.1 Disassembling of the boom………………………………………………………….2272
5.3.3.2 Assembling of the boom…………………………………………………………….2275
5.3.3.3 Disassembling of the boom cylinders…………………………………………………2278
5.3.3.4 Assembling of the boom cylinders……………………………………………………2283
5.3.4 Stick assembly…………………………………………………………………………2288
5.3.4.1 Disassembling of the stick…………………………………………………………2288
5.3.4.2 Assembling of the stick……………………………………………………………2293
5.3.4.3 Disassembling of the stick cylinders………………………………………………..2298
5.3.4.4 Assembling of the stick cylinders…………………………………………………..2302
5.3.5 Bull Clam bucket……………………………………………………………………….2306
5.3.5.1 Disassembling of the bull clam bucket……………………………………………….2306
5.3.5.2 Assembling of the bull clam bucket………………………………………………….2310
5.3.5.3 Disassembling of the bucket cylinders……………………………………………….2314
5.3.5.4 Assembling of the bucket cylinders………………………………………………….2320
5.3.5.5 Disassembling of the clam cylinders…………………………………………………2326
5.3.5.6 Assembling of the clam cylinders……………………………………………………2331
5.3.6 Hydraulic hoses at the Faceshovel attachment………………………………………………2337
5.3.6.1 Replacing of the boom arc hoses…………………………………………………….2337
5.3.6.2 Replacing of the lubrication hoses………………………………………………….2340
5.3.6.3 Replacing of the boom cylinder hoses………………………………………………..2341
5.3.6.4 Replacing of the stick arc hoses……………………………………………………2344
5.3.6.5 Replacing of the stick cylinder hoses……………………………………………….2347
5.3.6.6 Replacing of the bucket cylinder hoses………………………………………………2350
5.3.6.7 Replacing of the clam cylinder hoses………………………………………………..2352
5.4 Metering valves (grease injectors) at the attachment…………………………………………….2358
5.4.1 Disassembling of the metering valves (grease injectors)…………………………………….2358
5.4.2 Assembling of the metering valves (grease injectors)……………………………………….2360
5.5 Ground engaging tools (GET)…………………………………………………………………..2361
5.5.1 Disassembling and assembling of the GET…………………………………………………..2361
5.6 Cylinder bypass test…………………………………………………………………………2363
6 Service Information……………………………………………………………………………….2365
6.1 Fluids and lubricants………………………………………………………………………..2366
6.2 Lifting Gears……………………………………………………………………………….2366
6.3 Safety hints for sling accessory………………………………………………………………2368
6.4 Weight tables……………………………………………………………………………….2369
6.4.1 Superstructure…………………………………………………………………………2369
6.4.2 Undercarriage………………………………………………………………………….2371
6.4.3 Backhoe attachment (BHA)………………………………………………………………..2372
6.4.4 Face shovel attachment (FSA)…………………………………………………………….2373
6.5 Torque charts according to KOMATSU company standard……………………………………………..2374
6.5.1 Metric standard thread………………………………………………………………….2374
6.5.2 Metric fine thread……………………………………………………………………..2375
6.5.3 Cummins motor torques – metric…………………………………………………………..2376
6.5.4 Cummins motor torques – U.S. customary……………………………………………………2376
6.5.5 SAE-flange connections………………………………………………………………….2377
6.6 Blind plugs…………………………………………………………………………………2378
6.6.1 Dummy plates for SAE–flanges…………………………………………………………….2378
6.6.2 Classification of threads to the nominal width…………………………………………….2380
6.6.3 Plugs and fittings according to DIN 2353………………………………………………….2381
6.7 Conversion table…………………………………………………………………………….2382
6.7.1 Method of using the conversation table……………………………………………………2382
6.7.2 Millimeter – inch & kilogram – pound……………………………………………………..2383
6.7.3 Liter – U.S. gallon & liter – U.K. gallon…………………………………………………2384
6.7.4 Nm- ft.lb……………………………………………………………………………..2385
6.7.5 Bar – PSI – kPa – MPa…………………………………………………………………..2386
6.7.6 Temperature……………………………………………………………………………2387
6.8 Tools………………………………………………………………………………………2388
6.8.1 Standard tool case……………………………………………………………………..2388
6.8.2 Used special tools (Overview)……………………………………………………………2390
6.9 Work instructions……………………………………………………………………………2393
6.9.1 Bleeding the track tensioning system……………………………………………………..2393
6.9.2 Hints for hydraulic hose installation…………………………………………………….2395
6.9.3 Remove / install the crawler carrier……………………………………………………..2398
6.9.4 Repair procedure for the radiator assembly………………………………………………..2399
7 Parts & Service News………………………………………………………………………………2401
7.1 List of relevant PARTS AND SERVICE NEWS………………………………………………………..2402