Komatsu Hydraulic Mining Shovel PC7000-6 T2 Shop Manual – PDF DOWNLOAD

Komatsu Hydraulic Mining Shovel PC7000-6 T2 Shop Manual – PDF DOWNLOAD

DESCRIPTION:

Komatsu Hydraulic Mining Shovel PC7000-6 T2 Shop Manual – PDF DOWNLOAD

SERIAL NUMBER 35001 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 PC7000-6 T2 Shop Manual – PDF DOWNLOAD

SHOP MANUAL Cover…………………………………………………………………………………………………… 1
00 FOREWORD………………………………………………………………………………………………………… 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
TOC………………………………………………………………………………………………………… 10
2.1 SAFETY INFORMATION……………………………………………………………………………………….. 11
2.2 OVERVIEW………………………………………………………………………………………………… 12
2.2.1 NORMAL OPERATIONS…………………………………………………………………………………… 12
2.2.2 REGULAR MAINTENANCE…………………………………………………………………………………. 12
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR……………………………………………………………….. 12
2.2.4 ADDITIONAL SAFETY PRECAUTIONS………………………………………………………………………… 12
2.3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB…………………………………………………….. 13
2.3.1 SOUND……………………………………………………………………………………………… 13
2.3.2 VIBRATION………………………………………………………………………………………….. 13
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR……………………………………………………… 14
2.4.1 UNDERSTANDING THE MACHINE……………………………………………………………………………. 14
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR………………………………………………….. 14
2.4.2.1 ENSURING SAFE OPERATION………………………………………………………………………… 14
2.4.3 PREPARATIONS FOR SAFE OPERATION………………………………………………………………………. 14
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT……………………………………………………. 14
2.4.3.2 INSPECTING THE MACHINE…………………………………………………………………………. 14
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT………………………………………………… 15
2.4.3.4 KEEP MACHINE CLEAN…………………………………………………………………………….. 15
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT………………………………………………………… 15
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT………………………………………………………. 16
2.4.3.7 IF A PROBLEM IS FOUND………………………………………………………………………….. 16
2.4.4 FIRE PREVENTION…………………………………………………………………………………….. 16
2.4.4.1 PRECAUTIONS TO PREVENT FIRE…………………………………………………………………….. 16
2.4.4.2 ACTION IF FIRE OCCURS………………………………………………………………………….. 18
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB………………………………………………………………. 18
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…………………………………………………………. 19
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE…………………………………………. 19
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE………………………………………………………………… 19
2.4.5.3 NO PEOPLE ON THE ATTACHMENT…………………………………………………………………….. 19
2.4.5.4 WORKING IN HIGH PLACES…………………………………………………………………………. 19
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK……………………………………………………………….. 20
2.4.5.6 LEAVING THE MACHINE……………………………………………………………………………. 20
2.4.6 BURN PREVENTION…………………………………………………………………………………….. 20
2.4.6.1 Hot coolant…………………………………………………………………………………… 20
2.4.6.2 Hot oil………………………………………………………………………………………. 21
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…………………………………………………………………… 21
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………………………………………………………… 21
2.4.9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS…………………………………………………….. 22
2.4.9.1 UNAUTHORIZED MODIFICATION………………………………………………………………………. 22
2.4.9.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS……………………………………………………. 22
2.4.10 ELECTROMAGNETIC COMPATIBILITY (EMC)………………………………………………………………….. 22
2.4.11 PRECAUTIONS AT JOBSITE……………………………………………………………………………… 23
2.4.11.1 VISIBILITY FROM OPERATOR’S SEAT………………………………………………………………… 24
2.4.11.2 CAMERA SYSTEM WITH MONITORS……………………………………………………………………. 24
2.4.11.3 ENSURE GOOD VISIBILITY………………………………………………………………………… 24
2.4.11.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS………………………………………………………….. 24
2.4.11.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS………………………………………………………. 25
2.4.11.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES………………………………………………………….. 25
2.4.11.7 Lightning Strikes…………………………………………………………………………….. 26
2.4.11.8 WORKING ON LOOSE GROUND……………………………………………………………………….. 26
2.4.11.9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES……………………………………………………….. 27
2.4.11.10 VENTILATION OF ENCLOSED AREAS…………………………………………………………………. 28
2.4.12 STARTING motor…………………………………………………………………………………….. 29
2.4.12.1 WARNING TAG………………………………………………………………………………….. 29
2.4.12.2 CHECKS BEFORE STARTING motor…………………………………………………………………… 29
2.4.12.3 PRECAUTION WHEN STARTING motor…………………………………………………………………. 29
2.4.12.4 PRECAUTION IN COLD AREAS………………………………………………………………………. 30
2.4.13 OPERATION…………………………………………………………………………………………. 30
2.4.13.1 CHECKS BEFORE OPERATION……………………………………………………………………….. 30
2.4.13.2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE…………………………………………………. 31
2.4.13.3 PRECAUTIONS WHEN traveling…………………………………………………………………….. 32
2.4.13.4 TRAVELING ON SLOPES…………………………………………………………………………… 33
2.4.13.5 OPERATIONS ON SLOPES………………………………………………………………………….. 34
2.4.13.6 PROHIBITED OPERATIONS…………………………………………………………………………. 34
2.4.13.7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES…………………………………………………….. 35
2.4.13.8 PARKING THE MACHINE…………………………………………………………………………… 35
2.4.13.9 TRANSPORTATION……………………………………………………………………………….. 35
2.5 PRECAUTION FOR MAINTENANCE………………………………………………………………………………… 36
2.5.1 GENERAL PRECAUTIONS…………………………………………………………………………………. 36
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…………………………………… 37
2.5.1.2 STOP motor FOR MAINTENANCE……………………………………………………………………… 38
2.5.1.3 WARNING TAG…………………………………………………………………………………… 39
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY…………………………………………………………………… 40
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS………………………………………………………….. 40
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING……………………………………………. 41
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS………………………………………………………. 41
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT……………………………………………. 42
2.5.1.9 NOISE………………………………………………………………………………………… 42
2.5.1.10 WHEN USING A HAMMER…………………………………………………………………………… 42
2.5.1.11 PROPER TOOLS…………………………………………………………………………………. 43
2.5.1.12 ACCUMULATOR………………………………………………………………………………….. 43
2.5.1.13 PERSONNEL……………………………………………………………………………………. 43
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………………………………………………………….. 44
2.5.2.1 PRECAUTION WHEN WELDING………………………………………………………………………… 44
2.5.2.2 BATTERY HANDLING………………………………………………………………………………. 44
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID………………………………………………………………….. 45
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE……………………………………………………………… 46
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…………………………………………………………… 47
2.5.3.3 REPLACEMENT OF HOSE LINES………………………………………………………………………. 47
2.5.3.4 INSPECTION OF HOSE LINES……………………………………………………………………….. 47
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………………………………………………….. 48
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE……………………………………………………………………. 48
2.5.3.7 AIR CONDITIONING MAINTENANCE……………………………………………………………………. 48
2.5.3.8 COMPRESSED AIR………………………………………………………………………………… 49
2.5.3.9 WASTE MATERIALS……………………………………………………………………………….. 49
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS……………………………………………… 50
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM……………………………………………………………………. 50
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS………………………………………….. 50
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…………………………………………………………. 50
2.7 SPECIAL SAFETY EQUIPMENT………………………………………………………………………………….. 51
2.7.1 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB………………………………………………. 52
2.7.2 OBJECT HANDLING…………………………………………………………………………………….. 52
2.7.3 LIGHTING…………………………………………………………………………………………… 52
2.7.4 WARNING BEACON……………………………………………………………………………………… 52
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…………………………………………….. 52
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)……………………………………….. 52
2.7.5.2 INSTRUCTIONS FOR USE…………………………………………………………………………… 54
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL………………………………………………….. 56
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS……………….. 56
2.7.5.5 INSTRUCTIONS FOR USE…………………………………………………………………………… 58
01 SPECIFICATION……………………………………………………………………………………………………. 59
PC7000-6……………………………………………………………………………………………………….. 60
10 STRUCTURE & FUNCTION……………………………………………………………………………………………… 69
TOC……………………………………………………………………………………………………………. 71
1 Introduction………………………………………………………………………………………………….. 83
1.1 Foreword………………………………………………………………………………………………… 84
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels………………… 85
1.3 Explanation of abbreviations………………………………………………………………………………. 86
1.4 Diagrams and illustrations in this manual…………………………………………………………………… 87
2 Specifications………………………………………………………………………………………………… 89
2.1 Lifting Gears……………………………………………………………………………………………. 90
2.2 Safety hints for sling accessory…………………………………………………………………………… 92
2.3 Standard tightening torque chart…………………………………………………………………………… 93
2.4 Conversion table…………………………………………………………………………………………. 94
2.5 Blind plugs……………………………………………………………………………………………… 100
2.6 Classification of threads to the nominal width………………………………………………………………. 102
2.7 Plugs and fittings according to ISO 8434-1 / DIN 2353………………………………………………………… 103
3 Main assembly groups…………………………………………………………………………………………… 105
3.1 General layout…………………………………………………………………………………………… 106
3.2 Superstructure…………………………………………………………………………………………… 108
3.2.1 Superstructure side view…………………………………………………………………………….. 108
3.2.2 Superstructure top view……………………………………………………………………………… 110
3.3 Machine house……………………………………………………………………………………………. 112
3.4 Hydraulic oil tank……………………………………………………………………………………….. 114
3.5 Hydraulic oil cooler……………………………………………………………………………………… 116
3.6 Fuel tank……………………………………………………………………………………………….. 118
3.7 Cab support……………………………………………………………………………………………… 120
3.8 Operator’s cab…………………………………………………………………………………………… 122
3.9 Main control blocks (FSA)…………………………………………………………………………………. 124
3.10 Slew machinery………………………………………………………………………………………….. 126
3.10.1 Slew gear type 2063 / slew motor type A6VLM…………………………………………………………… 126
3.10.2 Slew gear type 632770 / Slew motor type A6VLM…………………………………………………………. 128
3.11 Undercarriage…………………………………………………………………………………………… 130
3.12 Slew ring………………………………………………………………………………………………. 132
3.13 Attachment……………………………………………………………………………………………… 134
3.13.1 Front Shovel Attachment (FSA)……………………………………………………………………….. 134
3.13.2 Back hoe Attachment (BHA)…………………………………………………………………………… 136
3.14 Counterweight…………………………………………………………………………………………… 138
3.15 PPC safety circuit………………………………………………………………………………………. 140
4 Drive………………………………………………………………………………………………………… 143
4.1 Prime drive assembly……………………………………………………………………………………… 144
4.2 Engine and PTO mounts…………………………………………………………………………………….. 146
4.2.1 Engine mounts………………………………………………………………………………………. 146
4.2.2 Checks and adjustments………………………………………………………………………………. 147
4.2.3 Torque support……………………………………………………………………………………… 147
4.3 Flexible coupling (type A)………………………………………………………………………………… 148
4.4 Flexible coupling (type B)………………………………………………………………………………… 150
4.4.1 Information for maintenance………………………………………………………………………….. 152
4.4.2 Coupling elements…………………………………………………………………………………… 153
4.4.3 Separation and assembly of the coupling inner and outer part…………………………………………….. 154
4.4.4 Operation troubles, causes, and rectification………………………………………………………….. 155
4.5 Fan drive and radiator assembly……………………………………………………………………………. 156
4.5.1 Radiator assembly…………………………………………………………………………………… 156
4.5.2 Fan motor………………………………………………………………………………………….. 158
4.5.3 Expansion tanks…………………………………………………………………………………….. 159
4.5.4 Radiator fan drive………………………………………………………………………………….. 160
4.5.4.1 Flow chart of radiator fan control………………………………………………………………. 162
4.5.4.2 Hydraulic schematic of radiator fan drive………………………………………………………… 163
4.5.5 Fan pump type HPV190………………………………………………………………………………… 164
4.5.6 Radiator fan speed testing & adjustment……………………………………………………………….. 166
4.5.6.1 Testing & readjustment procedure………………………………………………………………… 168
4.5.6.2 Basic adjustment procedure……………………………………………………………………… 169
4.6 Pump distributor gearbox (PTO)…………………………………………………………………………….. 170
4.6.1 PTO oil filling, oil level, and ventilation……………………………………………………………. 172
4.6.2 Pump spline lubrication……………………………………………………………………………… 174
4.6.2.1 Oil level in the main pump & gear oil pump drive shaft housing……………………………………… 175
4.6.3 PTO lubrication and cooling………………………………………………………………………….. 176
4.6.3.1 Hydraulic components and schematic of cooling circuit-1……………………………………………. 176
4.6.3.2 Schematic overview – PTO gear oil cooling circuit-1……………………………………………….. 178
4.6.3.3 Checks and adjustments…………………………………………………………………………. 180
4.7 Hydraulic pumps – location, drive speed and flow rates……………………………………………………….. 182
4.8 Air cleaner……………………………………………………………………………………………… 186
5 Hydraulic oil tank…………………………………………………………………………………………….. 189
5.1 General layout…………………………………………………………………………………………… 190
5.2 Hydraulic oil tank, location of the electric equipment……………………………………………………….. 192
5.3 Suction oil tank with strainers……………………………………………………………………………. 194
5.4 Return oil collector pipe with strainer…………………………………………………………………….. 196
5.5 Back pressure valve………………………………………………………………………………………. 198
5.6 Transfer pump……………………………………………………………………………………………. 200
5.7 Return and leak oil filter………………………………………………………………………………… 202
5.8 Breather filter………………………………………………………………………………………….. 204
6 Hydraulic oil cooling………………………………………………………………………………………….. 207
6.1 Overall view on the hydraulic oil cooling…………………………………………………………………… 208
6.2 Function of the hydraulic oil cooling circuit……………………………………………………………….. 210
6.3 Adjustment of the back pressure valve………………………………………………………………………. 212
6.4 Stepless cooler fan RPM control……………………………………………………………………………. 214
6.4.1 Pressure limiting valves…………………………………………………………………………….. 216
6.4.2 Components of the fan drive circuits………………………………………………………………….. 218
6.4.3 Fan pump type HPV190………………………………………………………………………………… 220
6.5 Oil cooler fan speed testing/adjustment…………………………………………………………………….. 222
6.5.1 Testing & readjustment procedure……………………………………………………………………… 224
6.5.2 Basic adjustment procedure…………………………………………………………………………… 225
6.6 OC fan resonance speed adjustment………………………………………………………………………….. 226
6.6.1 Hydraulic oil temperature charts……………………………………………………………………… 228
7 Controlling…………………………………………………………………………………………………… 229
7.1 General layout…………………………………………………………………………………………… 230
7.2 Control and filter panels – location of components…………………………………………………………… 232
7.2.1 Control and filter panel engine 1 (rear)………………………………………………………………. 232
7.2.2 Valve cartridge block engine 1 (rear)…………………………………………………………………. 234
7.2.3 Control and filter panel engine 2 (front)……………………………………………………………… 236
7.3 Pilot pressure supply and adjustments………………………………………………………………………. 238
7.3.1 Pilot pressure control (PPC) circuit………………………………………………………………….. 238
7.3.2 Pilot pressure operating the main block spools…………………………………………………………. 240
7.3.3 Checks and adjustment of pilot pressure……………………………………………………………….. 242
7.3.4 Remote control valves arrangement…………………………………………………………………….. 244
7.4 Function of the electro hydraulic control system…………………………………………………………….. 246
7.4.1 Illustration of the joystick signal flow (example)……………………………………………………… 248
7.5 Hand lever (joystick) control……………………………………………………………………………… 250
7.5.1 Voltage supply of hand lever 20S020…………………………………………………………………… 251
7.5.2 Direction signal course from hand lever to controllers………………………………………………….. 252
7.5.3 Double ratiometric* output diagram……………………………………………………………………. 253
7.6 Foot pedal control……………………………………………………………………………………….. 254
7.6.1 Voltage supply of foot lever 20S021a………………………………………………………………….. 256
7.6.2 Direction signal course from foot pedal to controllers………………………………………………….. 257
7.6.3 Double ratiometric* output diagram for 2 direction pedal………………………………………………… 258
7.6.4 Single ratiometric* output diagram for 1 direction pedal………………………………………………… 259
7.7 Hand lever & foot pedal monitoring…………………………………………………………………………. 260
7.7.1 Lever monitoring screens (example)……………………………………………………………………. 262
7.7.2 Valve monitoring screen (example)…………………………………………………………………….. 264
7.8 Valve solenoid adjustment…………………………………………………………………………………. 266
7.8.1 Overview sol min/max current & adjustment range………………………………………………………… 267
7.9 ACCEL & DECEL time adjustment……………………………………………………………………………… 268
7.9.1 Accel & Decel times…………………………………………………………………………………. 268
8 Components……………………………………………………………………………………………………. 271
8.1 Main control blocks and high pressure screens (FSA)………………………………………………………….. 272
8.2 Main control blocks with valves and hp screens (FSA)…………………………………………………………. 274
8.3 Main control blocks with valves and hp screens (BHA)…………………………………………………………. 276
8.4 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA)……………………………. 278
8.5 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA)……………………………. 280
8.6 Restrictor block with secondary relief valve………………………………………………………………… 282
8.7 Anti-cavitation valve (ACV) block………………………………………………………………………….. 284
8.7.1 Single ACV block on the manifold……………………………………………………………………… 284
8.7.2 Double ACV block on the manifold……………………………………………………………………… 286
8.8 Remote control valves…………………………………………………………………………………….. 288
8.9 4/3 Directional solenoid valves……………………………………………………………………………. 290
8.10 Proportional solenoid valves……………………………………………………………………………… 292
8.11 High-pressure screen…………………………………………………………………………………….. 294
8.12 Control blocks and valves………………………………………………………………………………… 296
8.12.1 Main control blocks I, II, III (4 spool blocks)……………………………………………………….. 296
8.12.1.1 Spin lock for valve blocks (ND52)………………………………………………………………. 297
8.12.2 Hydraulic diagram of a 4-spool valve block……………………………………………………………. 298
8.12.3 Spool types……………………………………………………………………………………….. 299
8.12.4 Spool positions (control block)……………………………………………………………………… 302
8.12.5 MRV, SRV, and ACV………………………………………………………………………………….. 304
8.12.6 Load holding valve…………………………………………………………………………………. 306
8.12.7 Main control block IV (slew)………………………………………………………………………… 308
8.13 Travel brake valve………………………………………………………………………………………. 310
8.14 Pressure reducing valve………………………………………………………………………………….. 312
8.15 4/2 Directional valves…………………………………………………………………………………… 314
8.16 Pressure double stage valve………………………………………………………………………………. 316
8.17 Hydraulic cylinder………………………………………………………………………………………. 318
8.17.1 Hydraulic cylinder – Chevron® sealing………………………………………………………………… 318
8.17.2 Hydraulic cylinder – Chesterton® 11KE sealing…………………………………………………………. 320
8.17.3 Cylinder data markings……………………………………………………………………………… 322
9 Main hydraulic pumps, pump regulation, valve control & monitoring system…………………………………………….. 323
9.1 General…………………………………………………………………………………………………. 324
9.1.1 Pump data………………………………………………………………………………………….. 326
9.2 Main pumps………………………………………………………………………………………………. 330
9.2.1 Hydraulic pump type HPV375+375……………………………………………………………………….. 330
9.2.1.1 Main pump sectional drawings……………………………………………………………………. 332
9.2.2 Servo valve………………………………………………………………………………………… 334
9.2.2.1 VC valve  servo piston………………………………………………………………………… 335
9.2.3 EPC valve………………………………………………………………………………………….. 340
9.3 Electronic pump regulation system………………………………………………………………………….. 342
9.3.1 Cut-off function……………………………………………………………………………………. 344
9.3.2 Slew control……………………………………………………………………………………….. 345
9.3.3 Temperature control…………………………………………………………………………………. 345
9.3.4 Diagnostics and monitoring…………………………………………………………………………… 345
9.3.5 Hydraulic oil temperature charts……………………………………………………………………… 346
9.3.6 PTO gear oil temperature charts………………………………………………………………………. 346
9.4 Pump & valve controllers………………………………………………………………………………….. 348
9.5 Multimonitor…………………………………………………………………………………………….. 350
9.5.1 Service menu screen…………………………………………………………………………………. 353
9.6 Service menu – 01 Monitoring………………………………………………………………………………. 353
9.6.1 Monitoring PUMP 1 controller…………………………………………………………………………. 354
9.6.2 Monitoring PUMP 2 controller…………………………………………………………………………. 355
9.6.3 Monitoring VALVE 0 controller………………………………………………………………………… 356
9.6.4 Monitoring VALVE 1 controller………………………………………………………………………… 358
9.6.5 Monitoring VALVE 2 controller………………………………………………………………………… 359
9.6.6 Monitoring all controllers…………………………………………………………………………… 359
9.7 Using multimonitor functions for monitoring…………………………………………………………………. 360
9.7.1 Hold function………………………………………………………………………………………. 360
9.8 Service menu – 02 Abnormality Record……………………………………………………………………….. 361
9.8.1 To delete any failure record from the display………………………………………………………….. 362
9.8.2 Troubleshooting procedures…………………………………………………………………………… 362
9.8.3 Failure codes for pumps & valve controllers & system connections…………………………………………. 363
9.9 Service menu – 03 Default…………………………………………………………………………………. 371
9.10 Service menu – 04 Adjustment……………………………………………………………………………… 372
9.10.1 Adjustments for PUMP 1 controller……………………………………………………………………. 372
9.10.2 Adjustments for PUMP 2 controller……………………………………………………………………. 374
9.10.3 Adjustments for VALVE 0 controller…………………………………………………………………… 376
9.10.4 Adjustments for VALVE 2 controller…………………………………………………………………… 377
9.10.5 Details on the adjustable parameters…………………………………………………………………. 378
9.10.5.1 PUMP 1 controller…………………………………………………………………………….. 378
9.10.5.2 PUMP 2 controller…………………………………………………………………………….. 380
9.10.5.3 VALVE 0 controller……………………………………………………………………………. 382
9.10.5.4 VALVE 1 & 2 controller………………………………………………………………………… 384
9.10.6 Description of the primary p-factor………………………………………………………………….. 385
9.10.7 Pump1…6F/R solenoid min. current adjustment…………………………………………………………. 386
9.10.8 Pump1…6F/R solenoid max. current adjustment…………………………………………………………. 387
9.11 Accel & Decel time adjustment…………………………………………………………………………….. 388
9.11.1 ACCEL & DECEL times………………………………………………………………………………… 388
9.12 Service menu – 05 Controller Setting………………………………………………………………………. 390
9.13 Controller replacement procedure………………………………………………………………………….. 390
9.13.1 Controller setting → wiring input check………………………………………………………………. 390
9.13.2 Controller setting → memory…………………………………………………………………………. 394
9.13.3 Confirmation………………………………………………………………………………………. 396
9.14 Service menu – 06 Display Setup…………………………………………………………………………… 397
9.15 Checks and adjustments…………………………………………………………………………………… 398
9.15.1 Engine power check…………………………………………………………………………………. 398
9.15.2 Cut-off function check……………………………………………………………………………… 400
9.15.2.1 Cut-off for clam close (FSA only)………………………………………………………………. 401
9.16 Engine speed sensors (pick-up)……………………………………………………………………………. 402
9.16.1 General…………………………………………………………………………………………… 403
9.16.2 Engine speed sensor (pick-up) adjustment……………………………………………………………… 403
10 Operating hydraulics………………………………………………………………………………………….. 405
10.1 General………………………………………………………………………………………………… 406
10.1.1 Allocation of pumps and main valve blocks…………………………………………………………….. 408
10.2 Spool functions (FSA)……………………………………………………………………………………. 410
10.2.1 Floating function for boom and stick cylinders………………………………………………………… 410
10.2.2 Spool functions (BHA)………………………………………………………………………………. 412
10.3 Hydraulics for the attachment cylinders……………………………………………………………………. 414
10.3.1 Electric / hydraulic flowchart “Boom UP” (FSA)………………………………………………………… 414
10.3.2 Electric / hydraulic flowchart “boom up” (BHA)………………………………………………………… 416
10.3.3 Electric / hydraulic flowchart “boom down” (FSA), single movement and Auto-float ON……………………….. 418
10.3.4 Electric / hydraulic flowchart “boom down” (FSA), Auto-float OFF – button 20S095 pressed and single movement…. 420
10.3.5 Electric / hydraulic flowchart “Boom down” (BHA)………………………………………………………. 422
10.3.6 Electric / hydraulic flowchart “Stick out” (FSA)………………………………………………………. 424
10.3.7 Electric / hydraulic flowchart “Stick out” (BHA)………………………………………………………. 426
10.3.8 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float ON and single movement………………………… 428
10.3.9 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float OFF – 20S098 pressed & single movement………….. 430
10.3.10 Electric / hydraulic flowchart “Stick in” (BHA)………………………………………………………. 432
10.3.11 Electric / hydraulic flowchart “Bucket fill” (FSA)……………………………………………………. 434
10.3.12 Electric / hydraulic flowchart “Bucket fill” (BHA)……………………………………………………. 436
10.3.13 Electric / hydraulic flowchart “Bucket dump” (FSA)……………………………………………………. 438
10.3.14 Electric / hydraulic flowchart “Bucket dump” (BHA)……………………………………………………. 440
10.3.15 Electric / hydraulic flowchart “Clam open” (FSA)……………………………………………………… 442
10.3.16 Electric / hydraulic flowchart “Clam close” (FSA)…………………………………………………….. 444
10.3.17 Checks and adjustments of the main relief valve (MRV)…………………………………………………. 446
10.3.18 Checks and adjustments of the secondary relief valves (SRV)……………………………………………. 448
10.3.18.1 Boom cylinders, piston side (BHA & FSA), boom up………………………………………………… 448
10.3.18.2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down……………………………………………. 452
10.3.18.3 Stick cylinders, piston side (FSA), stick out…………………………………………………… 456
10.3.18.4 Stick cylinders, piston side (BHA), stick in……………………………………………………. 460
10.3.18.5 Stick cylinders, piston rod side (FSA), stick in………………………………………………… 464
10.3.18.6 Stick cylinders, piston rod side (BHA), stick out……………………………………………….. 468
10.3.18.7 Bucket cylinders, piston side (FSA), bucket fill………………………………………………… 472
10.3.18.8 Bucket cylinders, piston side (BHA), bucket fill………………………………………………… 476
10.3.18.9 Bucket cylinders, piston rod side (FSA), bucket dump…………………………………………….. 480
10.3.18.10 Bucket cylinders, piston rod side (BHA), bucket dump……………………………………………. 484
10.3.18.11 Clam cylinders, piston rod side (FSA), clam open……………………………………………….. 488
10.3.18.12 Clam cylinders, piston side (FSA), clam close………………………………………………….. 492
10.3.19 Checks and adjustments of cycle times……………………………………………………………….. 496
10.3.19.1 Checks and adjustments of boom lowering speed (FSA)……………………………………………… 496
10.3.19.2 Checks and adjustments of boom lowering speed (BHA)……………………………………………… 500
10.3.19.3 Checks and adjustments of stick retract speed (FSA)……………………………………………… 504
10.3.19.4 Checks and adjustments of stick retract speed (BHA)……………………………………………… 508
10.3.19.5 Checks and adjustments of bucket dump speed (FSA)……………………………………………….. 512
10.3.19.6 Checks and adjustments of bucket dump speed (BHA)……………………………………………….. 516
10.3.19.7 Checks and Adjustment of bucket Curl Speed (BHA)………………………………………………… 520
10.3.19.8 Checks and adjustments of clam close speed (FSA)………………………………………………… 524
10.4 Hydraulics for the slew circuit…………………………………………………………………………… 526
10.4.1 Slew circuit with variable slew motors……………………………………………………………….. 526
10.4.2 Slew motor (variable displacement)…………………………………………………………………… 530
10.4.2.1 Hydraulic slew motor – displacement control……………………………………………………… 532
10.4.3 Slew gearbox type 2063……………………………………………………………………………… 534
10.4.4 Slew gearbox type 632770……………………………………………………………………………. 536
10.4.5 Slew parking brake (on slew gear type 2063)…………………………………………………………… 538
10.4.6 Slew parking brake (on slew gear type 632770)…………………………………………………………. 540
10.4.7 Slew brake valve…………………………………………………………………………………… 542
10.4.8 Flushing circuit…………………………………………………………………………………… 546
10.4.9 Electric / hydraulic flowchart “Slew left” FSA………………………………………………………… 548
10.4.10 Electric / hydraulic flowchart “Slew left” BHA……………………………………………………….. 550
10.4.11 Electric / hydraulic flowchart “Slew right” FSA………………………………………………………. 552
10.4.12 Electric / hydraulic flowchart “Slew right” BHA………………………………………………………. 554
10.4.13 Checks and adjustments for the slew circuit………………………………………………………….. 556
10.4.13.1 Pressure checks & adjustments – double stage valve (DSV)…………………………………………. 557
10.4.13.2 Checks & adjustments – brake pilot pressure…………………………………………………….. 559
10.4.13.3 Checks & adjustments – slew speed……………………………………………………………… 561
10.4.14 Function check for the hydraulic slew brake………………………………………………………….. 562
10.4.15 Function check for the slew parking brake……………………………………………………………. 564
10.4.15.1 Parking brake release pressure check…………………………………………………………… 564
10.4.15.2 Function check of relays 56K250a & b…………………………………………………………… 565
10.5 Hydraulics for the travel circuit…………………………………………………………………………. 566
10.5.1 Travel circuit…………………………………………………………………………………….. 566
10.5.2 Travel motor………………………………………………………………………………………. 570
10.5.3 Rotary joint………………………………………………………………………………………. 572
10.5.4 Travel gearbox…………………………………………………………………………………….. 574
10.5.4.1 Travel gearbox type 2063………………………………………………………………………. 574
10.5.4.2 Travel gearbox type 631053…………………………………………………………………….. 576
10.5.5 Travel parking brake……………………………………………………………………………….. 578
10.5.5.1 Travel parking brake on travel gear type 2063……………………………………………………. 578
10.5.5.2 Travel parking brake on travel gear type 631053………………………………………………….. 579
10.5.5.3 Travel brake valve……………………………………………………………………………. 580
10.5.6 Electric / hydraulic flowchart “travel forward”……………………………………………………….. 582
10.5.7 Electric / hydraulic flowchart “travel backwards”……………………………………………………… 584
10.5.8 Checks and adjustments……………………………………………………………………………… 586
10.5.8.1 Checks and adjustments for the travel circuit……………………………………………………. 586
10.5.8.2 Function check for the travel parking brake……………………………………………………… 589
11 Hydraulic track tensioning system………………………………………………………………………………. 591
11.1 General………………………………………………………………………………………………… 592
11.2 Functional description…………………………………………………………………………………… 594
11.2.1 Hydraulic schematic for track tensioning……………………………………………………………… 595
11.3 Double stage valve………………………………………………………………………………………. 596
11.4 Tensioning cylinder……………………………………………………………………………………… 598
11.5 Adjustments / checks…………………………………………………………………………………….. 600
12 Access ladder, hydraulically operated…………………………………………………………………………… 603
12.1 Overview……………………………………………………………………………………………….. 604
12.2 Function of the hydraulically operated access ladder………………………………………………………… 606
12.3 Adjustments / checks…………………………………………………………………………………….. 612
13 Central refilling system (Service arm)………………………………………………………………………….. 615
13.1 Refilling arm location…………………………………………………………………………………… 616
13.2 Function……………………………………………………………………………………………….. 618
15 Hints for reading the electric wiring diagram……………………………………………………………………. 637
15.1 General………………………………………………………………………………………………… 638
15.2 Reference code of the electrical components………………………………………………………………… 639
15.2.1 Area code…………………………………………………………………………………………. 639
15.2.2 Component identifying letter………………………………………………………………………… 641
15.3 Graphical symbols……………………………………………………………………………………….. 642
15.4 Drawing concept…………………………………………………………………………………………. 646
15.5 Cable and connector marking………………………………………………………………………………. 656
14 Hints for reading the hydraulic diagram…………………………………………………………………………. 621
14.1 General………………………………………………………………………………………………… 622
14.2 Hydraulic symbols……………………………………………………………………………………….. 624
14.2.1 Lines, unions……………………………………………………………………………………… 625
14.2.2 Components, valves…………………………………………………………………………………. 627
14.2.3 Sensors…………………………………………………………………………………………… 627
14.2.4 Valves, valve components……………………………………………………………………………. 628
14.2.5 Pump, motor, cylinder………………………………………………………………………………. 632
16 KOMTRAX Plus & MTC control system………………………………………………………………………………. 659
16.1 General………………………………………………………………………………………………… 660
16.2 Specifications for operators……………………………………………………………………………… 662
16.2.1 Opening screen…………………………………………………………………………………….. 663
16.2.2 Main gauge screens 1 to 4…………………………………………………………………………… 664
16.2.3 Fuel consumption screen…………………………………………………………………………….. 668
16.2.4 Failure messages for the operator……………………………………………………………………. 670
16.2.5 Main gauge screens – changing of Time / SMR / Date…………………………………………………….. 672
16.2.6 Maintenance monitor………………………………………………………………………………… 674
16.2.7 Settings for operator………………………………………………………………………………. 676
16.2.8 Automatic messages…………………………………………………………………………………. 682
16.3 Tables of all provided messages…………………………………………………………………………… 684
16.3.1 Table of error codes & messages……………………………………………………………………… 685
16.3.2 Table of 7-segment error codes………………………………………………………………………. 690
16.3.3 Table of available instruction messages………………………………………………………………. 691
16.4 Flow charts (1-4) of K+ main screens………………………………………………………………………. 694
16.5 KOMTRAX Plus service level……………………………………………………………………………….. 698
16.5.1 Explanation of the button symbols (Service Level)……………………………………………………… 700
16.5.2 Service Menu Select Screen………………………………………………………………………….. 701
16.5.3 Real Time Menu Select Screen………………………………………………………………………… 702
16.5.3.1 Real Time Menu, option: 01 Engine 1…………………………………………………………….. 703
16.5.3.2 Real Time Menu, option: 02 Engine 2…………………………………………………………….. 704
16.5.3.3 Real Time Menu, option: 03 PTO 1……………………………………………………………….. 704
16.5.3.4 Real Time Menu, option: 04 PTO 2……………………………………………………………….. 704
16.5.3.5 Real Time Menu, option: 05 Hydraulic……………………………………………………………. 705
16.5.3.6 Real Time Menu, option: 06 Slew………………………………………………………………… 706
16.5.3.7 Real Time Menu, option: 07 Electrical Equipment………………………………………………….. 707
16.5.3.8 Real Time Menu, option: 08 Emergency Stop……………………………………………………….. 708
16.5.3.9 Real Time Menu, option: 09 Manual Switch………………………………………………………… 709
16.5.3.10 Real Time Menu, option: 10 Central Lube System 1………………………………………………… 710
16.5.3.11 Real Time Menu, option: 11 Slew Ring Gear Lube System……………………………………………. 711
16.5.3.12 Real Time Menu, option: 12 Central Lube System 2………………………………………………… 712
16.5.3.13 Real Time Menu, option: 13 Windscreen Wiper…………………………………………………….. 713
16.5.3.14 Real Time Menu, option: 14 Ladder……………………………………………………………… 714
16.5.3.15 Real Time Menu, option: 15 Service Arm…………………………………………………………. 715
16.5.3.16 Real Time Menu, option: 16 Pilot Control……………………………………………………….. 716
16.5.3.17 Real Time Menu, option: 17 Other Items…………………………………………………………. 717
16.5.3.18 Real Time Menu, option: 18 Output Signals………………………………………………………. 718
16.5.3.19 Output signals with deactivated MTC evaluation………………………………………………….. 721
16.5.4 PM-Clinic…………………………………………………………………………………………. 722
16.5.4.1 General……………………………………………………………………………………… 722
16.5.4.2 Power Check………………………………………………………………………………….. 723
16.5.5 Serial/GCC no. setting……………………………………………………………………………… 724
16.5.6 Memory Clear………………………………………………………………………………………. 725
16.5.6.1 Input Memory Clear ID…………………………………………………………………………. 725
16.5.6.2 Memory Clear screen…………………………………………………………………………… 726
16.5.7 Failure History……………………………………………………………………………………. 727
16.5.8 Maintenance Monitor………………………………………………………………………………… 728
16.5.9 Snapshot………………………………………………………………………………………….. 729
16.5.10 Settings…………………………………………………………………………………………. 730
16.5.10.1 Central Lubrication System (CLS 1), screen 1/10…………………………………………………. 730
16.5.10.2 Slew ring gear Lubrication System (SLS), screen 2/10…………………………………………….. 731
16.5.10.3 Central Lubrication System (CLS 2), screen 3/10…………………………………………………. 732
16.5.10.4 Qmin – Qmax setting, screen 4/10………………………………………………………………. 733
16.5.10.5 Other Settings 1/2, screen 5/10……………………………………………………………….. 733
16.5.10.6 Hydraulic Oil & PTO Gear Oil Definition Table…………………………………………………… 734
16.5.10.7 Hydraulic oil temperature charts………………………………………………………………. 734
16.5.10.8 PTO gear oil temperature charts……………………………………………………………….. 734
16.5.10.9 Other Settings 2/2, screen 6/10……………………………………………………………….. 735
16.5.10.10 PLC-evaluation ON/OFF……………………………………………………………………….. 737
16.5.10.11 Shutdown Bypass ON/OFF………………………………………………………………………. 738
16.6 Interface-connection KOMTRAX Plus controller & MTC………………………………………………………….. 742
16.6.1 KOMTRAX Plus controller…………………………………………………………………………….. 743
16.7 7-segment error code indication…………………………………………………………………………… 744
16.8 Wiring of KOMTRAX Plus controller…………………………………………………………………………. 746
16.9 MTC control system – global layout………………………………………………………………………… 750
16.9.1 MTC (Master Turbo Controller)……………………………………………………………………….. 752
16.9.1.1 MTC flowchart………………………………………………………………………………… 752
16.9.1.2 MTC features…………………………………………………………………………………. 752
16.9.1.3 MTC firmware and software……………………………………………………………………… 753
16.9.1.4 Connector & component location in the control system……………………………………………… 753
16.9.1.5 View onto the MTC unit and its connectors……………………………………………………….. 754
16.9.1.6 LED indications at the MTC…………………………………………………………………….. 755
16.10 Global layout of the internal CAN BUS…………………………………………………………………….. 756
16.10.1 General information on a CAN BUS system……………………………………………………………… 756
16.10.1.1 General CAN BUS description…………………………………………………………………… 757
16.10.1.2 CAN BUS troubleshooting………………………………………………………………………. 757
16.10.1.3 Can BUS wiring………………………………………………………………………………. 758
16.10.1.4 CAN BUS end resistor…………………………………………………………………………. 760
16.11 The nodes in the CAN BUS system………………………………………………………………………….. 762
16.11.1 Global layout…………………………………………………………………………………….. 762
16.11.2 Introduction……………………………………………………………………………………… 764
16.11.2.1 ICN-V features………………………………………………………………………………. 764
16.11.2.2 View onto an open ICN-V node with DIP switches & status LED………………………………………. 766
16.11.2.3 General information on the LED control…………………………………………………………. 767
16.11.2.4 ICN-D features………………………………………………………………………………. 768
16.11.2.5 View onto an ICN-D node without wiring…………………………………………………………. 769
16.11.2.6 View onto the Status LEDs at the ICN-D node…………………………………………………….. 770
16.11.2.7 General information on the LED control…………………………………………………………. 770
16.11.2.8 Node DIP-switches……………………………………………………………………………. 772
16.11.2.9 Detailed view onto the DIP switches……………………………………………………………. 773
16.11.3 Node box…………………………………………………………………………………………. 774
16.11.4 Node locations on the machine………………………………………………………………………. 776
16.11.4.1 Node & location chart………………………………………………………………………… 777
16.11.4.2 View onto the control components in a cab base………………………………………………….. 778
17 Lubrication system……………………………………………………………………………………………. 781
17.1 General overview – SLS & CLS1/2…………………………………………………………………………… 782
17.1.1 General description………………………………………………………………………………… 783
17.2 Basic function of the lubrication systems………………………………………………………………….. 784
17.3 Lubrication systems (SLS & CLS1/2)………………………………………………………………………… 786
17.3.1 Lubrication pump station……………………………………………………………………………. 786
17.3.2 General information on CLS1/2……………………………………………………………………….. 788
17.3.3 General information on SLS………………………………………………………………………….. 788
17.3.4 Manual lube activation……………………………………………………………………………… 788
17.4 Lubrication cycle……………………………………………………………………………………….. 789
17.4.1 Operation and control………………………………………………………………………………. 789
17.4.2 Lubrication cycle – processing………………………………………………………………………. 790
17.4.3 Time segments & switch points of a lubrication cycle…………………………………………………… 791
17.4.4 Lubrication modes………………………………………………………………………………….. 792
17.4.4.1 Automatic lubrication mode…………………………………………………………………….. 792
17.4.4.2 Manual lubrication mode……………………………………………………………………….. 792
17.4.4.3 Reduced pause time for service…………………………………………………………………. 792
17.5 Hydraulically driven lube pump……………………………………………………………………………. 794
17.5.1 Adjustment of lube pump speed……………………………………………………………………….. 796
17.5.1.1 Stroke speed adjustment……………………………………………………………………….. 797
17.5.1.2 Working pressure……………………………………………………………………………… 797
17.6 Lubricant injectors……………………………………………………………………………………… 798
17.6.1 Tightening torques for fittings at grease injectors……………………………………………………. 799
17.6.2 Description……………………………………………………………………………………….. 799
17.6.3 Adjustment of lubricant output………………………………………………………………………. 800
17.6.4 Operation principle of lubricant injectors……………………………………………………………. 802
17.6.4.1 Function description………………………………………………………………………….. 803
17.6.5 Connection of one or more injectors………………………………………………………………….. 804
17.7 Vent valve and grease outlet filter……………………………………………………………………….. 806
17.7.1 Vent valve description……………………………………………………………………………… 807
17.8 End-line switch…………………………………………………………………………………………. 808
17.8.1 Description……………………………………………………………………………………….. 809
17.8.2 CLS1/2 end-line switch adjustment……………………………………………………………………. 810
17.8.3 SLS end-line switch adjustment………………………………………………………………………. 812
17.9 Lubricant level sensors………………………………………………………………………………….. 814
17.9.1 Description……………………………………………………………………………………….. 815
17.9.1.1 Checks………………………………………………………………………………………. 815
17.10 Commissioning………………………………………………………………………………………….. 816
17.10.1 Commissioning of the CLS1/2 lubrication system……………………………………………………….. 816
17.10.2 Fine adjustment…………………………………………………………………………………… 817
17.10.3 Commissioning of the SLS lubrication system………………………………………………………….. 818
18 Deep temperature equipment (option)…………………………………………………………………………….. 821
18.1 General information……………………………………………………………………………………… 822
18.1.1 Introduction………………………………………………………………………………………. 822
18.1.2 Deep temperature components overview…………………………………………………………………. 822
18.1.3 Power supply preconditions for preheating…………………………………………………………….. 823
18.1.4 Power requirements for preheating systems…………………………………………………………….. 824
18.2 Preheating procedure…………………………………………………………………………………….. 825
18.2.1 Global flow chart of the preheating procedure…………………………………………………………. 825
18.2.2 Starting the preheating procedure……………………………………………………………………. 826
18.2.3 Preheating of operator’s cab and Diesel engine [coolant system]…………………………………………. 827
18.2.4 Preheating of lubricants and superstructure (Diesel) [electric system]…………………………………… 828
18.3 Constant heating of travel motors (TTT equipment below-40°C only)…………………………………………….. 829
18.4 Component location………………………………………………………………………………………. 830
18.4.1 Electric heating elements for hydraulic & batteries [electric machine]…………………………………… 830
18.4.2 Electric heating elements for hydraulics [Diesel machine]………………………………………………. 832
18.4.3 Electric heating elements for engines & batteries [Diesel machine]………………………………………. 834
18.5 Components of TT equipment……………………………………………………………………………….. 836
18.5.1 Preheating components on a Diesel machine…………………………………………………………….. 836
18.5.2 Preheating components on an electric machine………………………………………………………….. 837
18.5.3 Wiring Diagrams for preheating systems……………………………………………………………….. 838
18.5.3.1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3………………………………………… 838
18.5.3.2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3………………………………………… 839
18.5.3.3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3………………………………………… 840
18.5.3.4 Wiring diagram “Suction Oil Manifold Preheating”…………………………………………………. 841
18.5.3.5 Wiring diagram “PTO Preheating”………………………………………………………………… 842
18.5.3.6 Wiring diagram “Battery heater pads”……………………………………………………………. 843
40 TROUBLESHOOTING………………………………………………………………………………………………….. 845
TOC……………………………………………………………………………………………………………. 847
1 Introduction………………………………………………………………………………………………….. 873
1.1 Overview………………………………………………………………………………………………… 874
1.1.1 General advice when using troubleshooting charts……………………………………………………….. 874
1.2 General Precautions………………………………………………………………………………………. 875
2 General Information for Troubleshooting………………………………………………………………………….. 877
2.1 Preparations For Work…………………………………………………………………………………….. 878
2.2 Precautions During Work…………………………………………………………………………………… 878
2.3 Precautions When Carrying Out Any Operation…………………………………………………………………. 879
2.3.1 Precautions when carrying out removal work…………………………………………………………….. 879
2.3.2 Precautions when carrying out installation work………………………………………………………… 879
2.3.3 Precautions when completing the operation……………………………………………………………… 880
2.4 Fundamental Requirements for Troubleshooting………………………………………………………………… 881
2.4.1 Technical documentation……………………………………………………………………………… 881
2.4.2 Tools……………………………………………………………………………………………… 881
2.4.2.1 Reference Guide for Deutsch Removal Tools………………………………………………………… 884
2.4.3 Personnel………………………………………………………………………………………….. 885
2.5 Points To Remember When Trouble- shooting…………………………………………………………………… 885
2.6 Sequence Of Events In Troubleshooting………………………………………………………………………. 887
2.7 Checks Before Troubleshooting……………………………………………………………………………… 888
2.8 Handling Of Electric Equipment And Hydraulic Components………………………………………………………. 889
2.8.1 Points to remember when handling electric equipment…………………………………………………….. 889
2.8.2 Points To Remember When Handling Hydraulic Equipment……………………………………………………. 892
2.9 General working procedures………………………………………………………………………………… 894
2.9.1 Air Bleeding of Various Hydraulic Parts……………………………………………………………….. 894
2.9.2 Air bleeding from hydraulic pumps…………………………………………………………………….. 894
2.9.3 Air bleeding from hydraulic cylinders…………………………………………………………………. 894
2.10 Cylinder bypass test…………………………………………………………………………………….. 895
2.11 Basics about “How to crimp” (with strain relief)……………………………………………………………. 896
2.11.1 Crimp tool & repair kit…………………………………………………………………………….. 896
2.11.2 General…………………………………………………………………………………………… 897
2.11.3 Select the required connector components……………………………………………………………… 897
2.11.4 Stripping a wire…………………………………………………………………………………… 898
2.11.5 Crimping………………………………………………………………………………………….. 899
2.11.6 Connector assembly after crimping……………………………………………………………………. 900
2.12 Cable Shielding…………………………………………………………………………………………. 901
3 Mounting Locations and Connector Types…………………………………………………………………………… 903
3.1 Superstructure…………………………………………………………………………………………… 904
3.1.1 Superstructure side view…………………………………………………………………………….. 904
3.1.2 Superstructure top view……………………………………………………………………………… 906
3.2 Location of engine electrical parts………………………………………………………………………… 908
3.2.1 Engine side view……………………………………………………………………………………. 908
3.2.2 Engine top view…………………………………………………………………………………….. 909
3.2.3 Location of engine remote oil tank sensors…………………………………………………………….. 911
3.3 Location of hydraulic components…………………………………………………………………………… 912
3.3.1 Control and filter panel engine 1 (rear)………………………………………………………………. 912
3.3.2 Valve cartridge block engine 1 (rear)…………………………………………………………………. 914
3.3.3 Control and filter panel engine 2 (front)……………………………………………………………… 916
3.3.4 Remote control valves arrangement…………………………………………………………………….. 918
3.4 View onto SLS or CLS grease barrel and lubrication cycle components……………………………………………. 920
3.5 Hydraulic oil tank & suction oil tank – Location of electrical components………………………………………. 922
3.6 Hydraulically operated access ladder……………………………………………………………………….. 924
3.7 Refilling arm……………………………………………………………………………………………. 926
3.8 Connector Types Overview………………………………………………………………………………….. 928
4 Standard Value Table for Electrical Components……………………………………………………………………. 935
5 References for Troubleshooting (CAN Bus & Node Outputs)……………………………………………………………. 949
5.1 CAN BUS Trouble or Node Output Trouble……………………………………………………………………… 950
5.1.1 Trouble CAN BUS or CAN Hardware (#D0308)………………………………………………………………. 951
5.1.2 Trouble output short circuit (#D0043)…………………………………………………………………. 952
5.2 Sequence of CAN nodes in the CAN BUS……………………………………………………………………….. 954
5.3 Troubleshooting for Relay Monitored Node Outputs…………………………………………………………….. 955
5.3.1 Relay Check………………………………………………………………………………………… 955
#D0107 – Trouble slew parking brake control 56K250a………………………………………………………….. 956
Example view onto CoDeSys Visualization screen for message #D0107………………………………………….. 958
Wiring Diagram (56K250a & 56K250b) for message #D0107…………………………………………………….. 959
5.3.2 Output Check……………………………………………………………………………………….. 960
#D0108 – Trouble slew parking brake control Output to 56K250a…………………………………………………. 961
Example view onto CoDeSys Visualization screen for message #D0108………………………………………….. 963
Wiring Diagram (56K250a & 56K250b) for message #D0108…………………………………………………….. 964
6 Tables for Testing and Troubleshooting…………………………………………………………………………… 965
6.1 Test Value Table for PT100 Temperature Sensors g Centigrade – Ohm……………………………………………… 966
6.2 Test Value Tables for Transducers………………………………………………………………………….. 967
6.2.1 Pump press. transducers……………………………………………………………………………… 967
6.2.2 Hydraulic oil pressure transducers……………………………………………………………………. 968
6.2.3 Miscellaneous Pressure Transducers……………………………………………………………………. 969
6.2.4 Temperature Transducers – signal voltage 0.5…4.5V…………………………………………………….. 970
6.2.4.1 Temperature Transducers – signal voltage 0.5…9.5V……………………………………………….. 971
6.3 Hydraulic oil temperature charts…………………………………………………………………………… 972
6.4 PTO gear oil temperature charts……………………………………………………………………………. 972
6.5 Table of Error Codes & Messages (K+ monitor)………………………………………………………………… 973
6.6 Table of 7-segment error codes…………………………………………………………………………….. 979
6.7 Table of Instruction Messages……………………………………………………………………………… 980
6.8 Table of Binary Codes…………………………………………………………………………………….. 983
6.8.1 Table of Add-On Binary Codes for #D0308……………………………………………………………….. 988
6.9 Pump & Valve Controller Fault Codes………………………………………………………………………… 989
6.10 Table of Symptom Codes…………………………………………………………………………………… 996
6.10.1 Symptoms of engines and related electrical systems…………………………………………………….. 996
6.10.2 Symptoms of Hydraulic System………………………………………………………………………… 997
6.10.3 Symptoms of mechanical system……………………………………………………………………….. 998
6.10.4 Symptoms of Additional Systems………………………………………………………………………. 998
6.11 Engine Error Codes (Tier 2)………………………………………………………………………………. 999
6.12 Power Supply…………………………………………………………………………………………….1002
6.13 Cable colour identification……………………………………………………………………………….1002
7 Troubleshooting by failure Codes…………………………………………………………………………………1003
#D0001 – Trouble Shut-Off (gate) valve………………………………………………………………………….1004
View onto the gap of proximity switch 40B031…………………………………………………………………1006
Input signal (digital) of proximity switch 40B031 on the REAL TIME MONITOR………………………………………1007
View onto the setting for SHUTDOWN BYPASS on the K+ monitor……………………………………………………1007
Wiring Diagram (40B031) for message #D0001 (Main gate valve open)………………………………………………1008
#D0004 – Trouble fuel filter…………………………………………………………………………………..1010
View onto the fuel filtration system………………………………………………………………………..1012
Wiring Diagram 1 – Control modules, LEDs, and node input for message #D0004……………………………………..1014
Wiring Diagram 2 – Fuel pump for message #D0004………………………………………………………………1015
Wiring Diagram 3 – Heating elements for the fuel filtration system……………………………………………..1016
#D0005 – Low hydraulic oil level……………………………………………………………………………….1017
Wiring Diagram, oil level label, and defined position of the attachment (#D0005)…………………………………1019
#D0007 – Trouble hydraulic oil level……………………………………………………………………………1020
Wiring Diagram of 40B004 and the defined position of the attachment (#D0007)…………………………………….1021
#D0012 – Central lubrication system grease level too low………………………………………………………….1022
#D0013 – Slew ring gear lubr. system grease level too low…………………………………………………………1022
Wiring Diagram (binary grease level sensor, refill warning) #D0012 / #D0013 / #D0202……………………………..1025
Wiring Diagram (junction box) for messages #D0012 / #D0013 / #D0202…………………………………………….1026
#D0020 – Trouble Shut-Off (gate) valve (Start blocked)……………………………………………………………1027
View onto the gap of proximity switch 40B031 (#D0020)…………………………………………………………1029
Wiring Diagram (40B031) for message #D0020 (Main gate valve closed)…………………………………………….1030
Input signal (digital) of proximity switch 40B031 on the REAL TIME MONITOR………………………………………1031
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor…………………………………………..1031
#D0031 – Set engine to low idle………………………………………………………………………………..1032
Wiring Diagram (20S030) for message #D0031…………………………………………………………………..1033
#D0032 – Trouble starter………………………………………………………………………………………1034
Wiring Diagram (Cold Start Signals) for message #D0032………………………………………………………..1035
Wiring Diagram (Engine running signals) for message #D0032…………………………………………………….1036
#D0033 – Trouble KOMTRAX Plus Controller………………………………………………………………………..1037
#D0034 – Trouble KOMTRAX Plus Display…………………………………………………………………………..1038
#D0035 – Trouble totally loss gear oil (PTO 1)…………………………………………………………………..1039
#D0036 – Trouble totally loss gear oil (PTO 2)…………………………………………………………………..1039
View onto the location of sensor 57B175-1/-2 at the PTO (#D0035 & #D0036)……………………………………….1041
Input signal (analog) of PTO 1/2 gear oil sensor 57B175-1/-2 on REAL TIME MONITOR………………………………..1042
View onto setting screens for SHUTDOWN BYPASS on K+ Plus monitor……………………………………………….1042
Wiring Diagram (57B175-1/-2) for messages #D0035 and #D0036 (example)…………………………………………..1043
#D0037 – Trouble monitoring, engine 2 speed too low………………………………………………………………1044
#D0038 – Trouble monitoring, engine 2 speed too high……………………………………………………………..1044
#D0039 – Actuate engine speed selector switch……………………………………………………………………1044
#D0040 – Emergency shut-down pump compartment……………………………………………………………………1045
Wiring Diagram (emergency circuit) for #D0040, #D0092…#D0095…………………………………………………1047
Wiring Diagram (emergency switches) for #D0040, #D0092…#D0095………………………………………………..1048
#D0041 – Emergency shut-down pump compartment……………………………………………………………………1049
Wiring Diagram (emergency circuit) for #D0041, #D0252…#D0255…………………………………………………1051
Wiring Diagram (emergency switches) for #D0041, #D0252…#D0255………………………………………………..1052
#D0043 – Trouble output short-circuit…………………………………………………………………………..1053
#D0048 – Trouble emergency safety circuit……………………………………………………………………….1054
Wiring Diagram (11K044a) for message #D0048………………………………………………………………….1055
#D0053 – Reset emergency safety circuit…………………………………………………………………………1056
#D0060 – Fire in the power house……………………………………………………………………………….1057
Wiring Diagram (fire alarm) for message #D0060……………………………………………………………….1058
#D0061 – Trouble monitoring, engine 1 speed too low………………………………………………………………1059
Input signal (digital) of 51K003b-1 & 51K003b-2 on the REAL TIME MONITOR………………………………………..1061
Wrong signal of engine 1/2 speed converter on the REAL TIME MONITOR…………………………………………….1061
Wiring Diagram (51T018-1/-2) for messages #D0061 and #D0037……………………………………………………1062
#D0062 – Trouble monitoring, engine 1 speed too high……………………………………………………………..1063
Wiring Diagram (51T018-1/-2) for messages #D0062 and #D0038……………………………………………………1064
#D0063 – Trouble monitoring hydraulic oil temp…………………………………………………………………..1065
Mounting location of 59B015………………………………………………………………………………..1066
Wiring Diagram (59B015) for message #D0063…………………………………………………………………..1067
Monitoring options for hydraulic oil temperature……………………………………………………………..1068
#D0064 – Trouble monitoring hydraulic oil level………………………………………………………………….1069
Wiring Diagram (40B004) for message #D0064…………………………………………………………………..1071
#D0065 – Very low hydraulic oil level…………………………………………………………………………..1072
View onto the hydraulic oil level label……………………………………………………………………..1072
#D0066 – Trouble hydraulic oil temperature………………………………………………………………………1073
Hydraulic oil temperature on the REAL TIME MONITOR……………………………………………………………1074
Hydraulic oil temperature charts for message #D0066…………………………………………………………..1075
#D0067 – Trouble battery voltage too high……………………………………………………………………….1076
Wiring Diagram (11T080) and component location for #D0067……………………………………………………..1077
Input signal of 11T080 on the REAL TIME MONITOR (#D0067)………………………………………………………1078
#D0069 – Trouble monitoring oil temperature gear (PTO 1)………………………………………………………….1079
Mounting location of 57B049-1/-2……………………………………………………………………………1080
Monitoring options for PTO gear oil temperature………………………………………………………………1081
Wiring Diagram (57B049-1 & 57B049-2) for messages #D0069 & #D0083………………………………………………1082
#D0070 – Trouble oil temperature gear (PTO 1)……………………………………………………………………1083
Location of PTO gear oil level dipstick and temperature sensor 57B049-1/-2………………………………………1085
PTO gear oil adjustment via K+……………………………………………………………………………..1085
#D0071 – Trouble gear lubrication (PTO 1)……………………………………………………………………….1087
Wiring Diagram (57B017-1 & 57B017-2) for messages #D0071 & #D0068………………………………………………1088
#D0072 – Trouble monitoring hydraulic oil level………………………………………………………………….1089
Wiring Diagram (40B105) and REAL TIME MONITOR for message #D0072……………………………………………….1091
#D0073 – Trouble monitoring remote engine oil level 1…………………………………………………………….1092
Wiring Diagram (63B106-1/-2) and REAL TIME MONITOR for #D0073/#D0082……………………………………………1094
#D0076 – Trouble monitoring pressure suction tank………………………………………………………………..1095
Wiring Diagram (59B162) and REAL TIME MONITOR for #D0076………………………………………………………1097
#D0079 – Trouble monitoring pressure oil cooler 1………………………………………………………………..1098
Wiring Diagram (40B165) and REAL TIME MONITOR for #D0079………………………………………………………1100
#D0080 – Trouble monitoring pressure pre-load valve………………………………………………………………1101
Wiring Diagram (40B166) and REAL TIME MONITOR for #D0080………………………………………………………1103
#D0081 – Trouble lubrication system…………………………………………………………………………….1104
Operation cycles of lubrication systems……………………………………………………………………..1105
Wiring Diagram (control signal line “bucket cut off”) for message #D0081………………………………………..1106
#D0082 – Trouble monitoring remote engine oil level 2…………………………………………………………….1107
#D0083 – Trouble monitoring oil temperature (PTO 2)………………………………………………………………1107
#D0084 – Trouble oil temperature gear (PTO 2)……………………………………………………………………1107
#D0086 – SHUTDOWN…………………………………………………………………………………………….1108
#D0087 – Stop all movements for low idle………………………………………………………………………..1109
#D0090 – Trouble power supply………………………………………………………………………………….1111
Wiring Diagram and REALT TIME MONITOR for messages #D0090 & #D0099……………………………………………..1112
#D0091 – Pilot control cut out…………………………………………………………………………………1113
#D0092 – Emergency shut-down at access ladder……………………………………………………………………1114
#D0093 – Emergency shut-down at valve block……………………………………………………………………..1114
#D0094 – Emergency shut-down at hydraulic control panel…………………………………………………………..1114
#D0095 – Emergency shut-down in cabin…………………………………………………………………………..1114
#D0096 – Pilot control cut out…………………………………………………………………………………1115
Wiring Diagram (20S094) and REAL TIME MONITOR for message #D0096……………………………………………….1116
#D0099 – Trouble power supply………………………………………………………………………………….1117
#D0100 – Maintenance Safety Switch……………………………………………………………………………..1117
Wiring Diagram (emergency line & 50S058) for message #D0100……………………………………………………1118
#D0104 – Trouble battery current……………………………………………………………………………….1119
Wiring Diagram (starter motors) for message #D0104……………………………………………………………1121
Wiring Diagram (51T017 & 71T003) for message #D0104…………………………………………………………..1122
#D0105 – Trouble battery charging current too low………………………………………………………………..1123
Wiring Diagram (11T080) for message #D0105…………………………………………………………………..1124
#D0107 – Trouble slew parking brake control 56K250a………………………………………………………………1125
Example view onto CoDeSys visualization screen for message #D0107………………………………………………1127
Wiring Diagram (56K250a & 56K250b) for message #D0107…………………………………………………………1128
#D0108 – Trouble slew parking brake control Output to 56K250a……………………………………………………..1129
Example view onto CoDeSys visualization screen for message #D0108………………………………………………1131
Wiring Diagram (56K250a & 56K250b) for message #D0108…………………………………………………………1132
#D0109 – Trouble slew parking brake control 56K250b………………………………………………………………1133
#D0110 – Trouble slew parking brake control Output to 56K250b……………………………………………………..1133
#D0111 – Trouble travel parking brake control 56K251a…………………………………………………………….1133
51K251a-1 & 51K251b-1 (relay check) on REAL TIME MONITOR………………………………………………………1133
#D0112 – Trouble travel parking brake control Output to 56K251a……………………………………………………1134
51K251a-1 & 51K251b-1 (output check) on REAL TIME MONITOR……………………………………………………..1134
#D0113 – Trouble travel parking brake control 56K251b…………………………………………………………….1135
#D0114 – Trouble travel parking brake control Output to 56K251b……………………………………………………1135
#D0115 – Trouble slew hydraulic brake control 56K252a…………………………………………………………….1136
51K252a-1 & 51K252b-1 (relay check) on REAL TIME MONITOR………………………………………………………1136
#D0116 – Trouble slew hydraulic brake control Output to 56K252a……………………………………………………1137
51K252a-1 & 51K252b-1 (output check) on REAL TIME MONITOR……………………………………………………..1137
#D0117 – Trouble slew hydraulic brake control 56K252b…………………………………………………………….1138
#D0118 – Trouble travel parking brake control Output to 56K251b……………………………………………………1138
#D0141 – Trouble monitoring X2-pressure…………………………………………………………………………1139
Wiring Diagram (57B086) for message #D0141…………………………………………………………………..1141
#D0147 – Trouble monitoring gear lubrication (PTO 1)……………………………………………………………..1142
Wiring Diagram (57B017-1/-2) for messages #D0147 & #D00150…………………………………………………….1145
#D0148 – Trouble monitoring fuel level………………………………………………………………………….1146
Wiring Diagram (31B063) for message #D0148…………………………………………………………………..1148
#D0149 – Trouble monitoring ambient temperature………………………………………………………………….1149
Wiring Diagram (13B090) and REAL TIME MONITOR for message #D0149……………………………………………….1151
#D0150 – Trouble monitoring gear lubrication (PTO 2)……………………………………………………………..1152
#D0151 – Trouble monitoring gear (PTO) oil filter 1………………………………………………………………1152
Wiring Diagram (57B027-1 & 57B027-2) for messages #D0151 and #D0193…………………………………………….1155
#D0154 – Trouble monitoring return oil filter……………………………………………………………………1156
Wiring Diagram (40B163) for message #D0154…………………………………………………………………..1158
#D0155 – Trouble monitoring leak oil filter……………………………………………………………………..1159
Wiring Diagram (40B164) for message #D0155…………………………………………………………………..1161
#D0159 – Trouble monitoring breather filter……………………………………………………………………..1162
Wiring Diagram (40B024) for message #D0159…………………………………………………………………..1164
#D0160 – Trouble monitoring engine air cleaner 1…………………………………………………………………1165
Wiring diagram (52B018-1/-2 & 52B019-1/-2) for messages #D0160 and #D0197……………………………………….1168
#D0161 – Trouble monitoring battery voltage……………………………………………………………………..1169
11T080 on the REAL TIME MONITOR…………………………………………………………………………….1170
Wiring Diagram (11T080) and component location for message #D0161………………………………………………1171
#D0162 – Trouble monitoring charging-/discharging current…………………………………………………………1172
51T017 on REAL TIME MONITOR………………………………………………………………………………..1173
Wiring Diagram (battery charging current) for message #D0162…………………………………………………..1174
#D0164 – Trouble air cleaner 1…………………………………………………………………………………1175
View onto an engine air cleaner (#D0164 & #D0198)…………………………………………………………….1176
#D0165 – Trouble breather filter hydraulic oil tank………………………………………………………………1177
Location of 40B024 and oil level label for message #D0165……………………………………………………..1178
#D0166 – Trouble oil filter gear (PTO 1)………………………………………………………………………..1179
View onto PTO gear oil filter with pressure sensor 57B027-1/-2 (#D0166 & #D0191)…………………………………1180
#D0169 – Trouble return oil filter hydraulic oil tank…………………………………………………………….1181
40B163 on REAL TIME MONITOR (#D0169)………………………………………………………………………..1182
#D0170 – Trouble leak oil filter hydraulic oil tank………………………………………………………………1183
40B164 on REAL TIME MONITOR (#D0170)………………………………………………………………………..1184
#D0176 – Trouble battery voltage too low………………………………………………………………………..1185
Wiring Diagram (71T003 & batteries) for message #D0176………………………………………………………..1186
#D0177 – Trouble battery charging circuit……………………………………………………………………….1187
Wiring Diagram (measuring points 1-4) for message #D0177………………………………………………………1188
#D0178 – Trouble battery charging current too high……………………………………………………………….1189
Wiring Diagram (51T017) for message #D0178…………………………………………………………………..1190
#D0180 – Trouble pilot pressure X2 too low………………………………………………………………………1191
Valve cartridge block with X2 pressure sensor 57B086 (X2 pressure too low)………………………………………1192
#D0181 – Trouble pilot pressure X2 too high……………………………………………………………………..1193
Valve cartridge block with X2 pressure sensor 57B086 (X2 pressure too high)……………………………………..1194
#D0184 – Central lubrication system empty……………………………………………………………………….1195
Grease level CLS 1 & SLS & CLS 2 on REAL TIME MONITOR…………………………………………………………1197
#D0185 – Trouble central lubrication system……………………………………………………………………..1198
Allocation of vent valves and end-line switches………………………………………………………………1199
Action chart for lube cycles……………………………………………………………………………….1200
View onto vent valve (62Q507a / 62Q509a / 62Q642a)……………………………………………………………1201
Wiring Diagram (60B043 & 62B046 & 80B043) for #D0185 & #D0188 & #D0203………………………………………….1202
#D0186 – Trouble central lubrication system……………………………………………………………………..1203
Allocation of vent valves………………………………………………………………………………….1203
Action chart for lube cycles……………………………………………………………………………….1204
View onto vent valve (62Q507a / 62Q509a / 62Q642a)……………………………………………………………1205
#D0187 – Slew ring gear lubrication system empty…………………………………………………………………1206
#D0188 – Trouble slew ring gear lubrication system……………………………………………………………….1206
#D0189 – Trouble slew ring gear lubrication system……………………………………………………………….1206
#D0191 – Trouble oil filter gear (PTO 2)………………………………………………………………………..1206
#D0193 – Trouble monitoring gear (PTO) oil filter 2………………………………………………………………1206
#D0197 – Trouble monitoring engine air cleaner 2…………………………………………………………………1206
#D0198 – Trouble air cleaner 2…………………………………………………………………………………1206
#D0201 – Attachment lubrication system empty…………………………………………………………………….1206
#D0202 – Attachment lubrication system grease level too low……………………………………………………….1206
#D0203- Trouble attachment lubrication system……………………………………………………………………1206
#D0204 – Trouble attachment lubrication system…………………………………………………………………..1206
#D0207 – Engine remote oil tank 1 empty…………………………………………………………………………1207
#D0208 – Engine remote oil tank 2 empty…………………………………………………………………………1207
#D0216 – Trouble software not compatible………………………………………………………………………..1208
#D0218 – Switch off all motors for running transfer pump………………………………………………………….1210
#D0220 – Trouble transfer pump motor overheated………………………………………………………………….1211
Wiring Diagram (transfer pump) for message #D0220…………………………………………………………….1212
#D0223 – Trouble starter control 51K001a-1………………………………………………………………………1213
51K001a-1 & 51K001b-1 (relay check) on REAL TIME MONITOR………………………………………………………1213
#D0224 – Trouble starter control Output to 51K001a-1……………………………………………………………..1214
51K001a-1 & 51K001b-1 (output check) on REAL TIME MONITOR……………………………………………………..1214
#D0225 – Trouble starter control 51K001b-1………………………………………………………………………1215
#D0226 – Trouble starter control Output to 51K001b-1……………………………………………………………..1215
#D0227 – Trouble starter control 51K001a-2………………………………………………………………………1215
#D0228 – Trouble starter control Output to 51K001a-2……………………………………………………………..1215
#D0229 – Trouble starter control 51K001b-2………………………………………………………………………1215
#D0230 – Trouble starter control Output to 51K001b-2……………………………………………………………..1215
#D0238 – Trouble supply by key switch 11Q044…………………………………………………………………….1216
Input signal of 11Q044 on REAL TIME MONITOR (#D0238)………………………………………………………….1216
Wiring Diagram (11Q044) for message #D0238…………………………………………………………………..1217
#D0239 – Trouble electrical matter……………………………………………………………………………..1218
Wiring Diagram – signal line 10K351…………………………………………………………………………1219
#D0240 – Trouble hydraulic oil temperature………………………………………………………………………1220
Hydraulic oil temperature charts……………………………………………………………………………1221
#D0242 – Engine 1 already running………………………………………………………………………………1222
#D0243 – Fill up fuel tank…………………………………………………………………………………….1222
#D0245 – Engine shutdown from ground……………………………………………………………………………1223
Input signal of 54S051 & 54S052 on the REAL TIME MONITOR (#D0245)………………………………………………1224
#D0246 – Hydraulic oil temperature……………………………………………………………………………..1225
#D0248 – Engine 2 already running………………………………………………………………………………1226
#D0252 – Emergency shut-down at access ladder……………………………………………………………………1226
#D0253 – Emergency shut-down at valve block……………………………………………………………………..1226
#D0254 – Emergency shut-down at hydraulic control panel…………………………………………………………..1226
#D0255 – Emergency shut-down in cabin…………………………………………………………………………..1226
#D0256 – Operator warning system……………………………………………………………………………….1226
#D0257 – Hydraulic oil temperature……………………………………………………………………………..1227
#D0261 – Maintenance Safety Switch……………………………………………………………………………..1228
#D0262 – Trouble screen at hydr. cooler entry clogged…………………………………………………………….1229
40B166 and 40B165 on REAL TIME MONITOR (#D0262)………………………………………………………………1229
Location of 40B166 and 40B165 at hydraulic oil tank (#D0262)…………………………………………………..1230
Wiring Diagram (40B166 & 40B165) for message #D0262…………………………………………………………..1231
#D0308 – Trouble CAN-BUS or CAN-Hardware………………………………………………………………………..1232
#D0309 – Trouble ladder up 56K253a……………………………………………………………………………..1235
Ladder up 56K253a & 56K253b (relay check) on REAL TIME MONITOR…………………………………………………1235
#D0310 – Trouble ladder up Output to 56K253a…………………………………………………………………….1236
Ladder up 56K253a & 56K253b (output check) on REAL TIME MONITOR………………………………………………..1236
#D0311 – Trouble ladder up redundant 56K253b…………………………………………………………………….1237
#D0312 – Trouble ladder up redundant Output to 56K253b……………………………………………………………1237
#D0313 – Trouble ladder down 56K254a……………………………………………………………………………1237
Ladder down 56K254a & 56K254b (relay check) on REAL TIME MONITOR……………………………………………….1237
#D0314 – Trouble ladder down Output to 56K254a…………………………………………………………………..1238
Ladder down 56K254a & 56K254b (output check) on REAL TIME MONITOR………………………………………………1238
#D0315 – Trouble ladder down redundant 56K254b…………………………………………………………………..1239
#D0316 – Trouble ladder down redundant Output to 56K254b………………………………………………………….1239
#D0317 – Trouble service arm up 56K255a…………………………………………………………………………1239
Service arm up 56K255a & 56K255b (relay check) on REAL TIME MONITOR…………………………………………….1239
#D0318 – Trouble service arm up Output to 56K255a………………………………………………………………..1240
Service arm up 56K255a & 56K255b (output check) on REAL TIME MONITOR……………………………………………1240
#D0319 – Trouble service arm up redundant 56K255b………………………………………………………………..1241
#D0320 – Trouble service arm up redundant Output to 56K255b……………………………………………………….1241
#D0321 – Trouble service arm down 56K256a……………………………………………………………………….1241
Service arm down 56K256a & 56K256b (relay check) on REAL TIME MONITOR…………………………………………..1241
#D0322 – Trouble service arm down Output to 56K256a………………………………………………………………1242
Service arm down 56K256a & 56K256b (output check) on REAL TIME MONITOR………………………………………….1242
#D0323 – Trouble service arm down redundant 56K256b………………………………………………………………1243
#D0324 – Trouble service arm down redundant Output to 56K256b……………………………………………………..1243
#D0331 – Automatic after_running engine 1……………………………………………………………………….1243
#D0332 – Automatic after_running engine 2……………………………………………………………………….1243
#D0333 – Trouble battery charger relay………………………………………………………………………….1244
Relay 11Q122 on TIME MONITOR……………………………………………………………………………….1244
Wiring Diagram (11Q122 & 11F019) for message #D0333…………………………………………………………..1245
#D0422 – Can-net sys (J1939)…………………………………………………………………………………..1246
Wiring Diagram (CAN BUS Quantum ↔ K+ controller) for message #D0422…………………………………………….1247
8 Troubleshooting for PUMP/VALVE controller fault codes………………………………………………………………1249
DA2UKR – Communication failure PLC <-> KOMTRAX Plus controller…………………………………………………….1250
DBB0KK – KOMTRAX Plus source voltage error………………………………………………………………………1252
Wiring Diagram K+ controller 24V supply and GND connections……………………………………………………1253
DBB0KQ – Connector sel error…………………………………………………………………………………..1254
DAFQKR – Communication failure MH800 <-> KOMTRAX Plus controller…………………………………………………..1256
Wiring Diagram for message DAFQKR…………………………………………………………………………..1257
DA2QKR – CAN2 Discon (Pump1 Con)……………………………………………………………………………….1258
Wiring Diagram for message DA2QKR…………………………………………………………………………..1259
DBZQKR – CAN2 Discon (Pump2 Con)……………………………………………………………………………….1260
Wiring Diagram for message DBZQKR…………………………………………………………………………..1261
DBWQKR – CAN2 Discon (Valve/M Con)……………………………………………………………………………..1262
Wiring Diagram for message DBWQKR…………………………………………………………………………..1263
DBXQKR – CAN2 Discon (Valve/S1 Con)…………………………………………………………………………….1264
Wiring Diagram for message DBXQKR…………………………………………………………………………..1265
DBYQKR – CAN2 Discon (Valve/S2 Con)…………………………………………………………………………….1266
Wiring Diagram for message DBYQKR…………………………………………………………………………..1267
DXAAKA – Solenoid-1(Pump-1) open circuit………………………………………………………………………..1268
DXABKA – Solenoid-2(Pump-2) open circuit………………………………………………………………………..1268
DXACKA – Solenoid-3(Pump-3) open circuit………………………………………………………………………..1268
DXADKA – Solenoid-4(Pump-4) open circuit………………………………………………………………………..1268
DXAEKA – Solenoid-5(Pump-5) open circuit………………………………………………………………………..1268
DXAFKA – Solenoid-6(Pump-6) open circuit………………………………………………………………………..1268
DXAGKA – Solenoid-7(Pump-7) open circuit………………………………………………………………………..1268
DXAHKA – Solenoid-8(Pump-8) open circuit………………………………………………………………………..1268
DXAJKA – Solenoid-9(Pump-9) open circuit………………………………………………………………………..1268
DXAKKA – Solenoid-10(Pump-10) open circuit………………………………………………………………………1268
DXALKA – Solenoid-11(Pump-11) open circuit………………………………………………………………………1268
DXAMKA – Solenoid-12(Pump-12) open circuit………………………………………………………………………1268
Wiring Diagram – EPC valve control (PUMP1 controller)…………………………………………………………1270
Wiring Diagram – EPC valve control (PUMP2 controller)…………………………………………………………1271
DXAAKB – Solenoid-1(Pump-1) short circuit……………………………………………………………………….1272
DXABKB – Solenoid-2(Pump-2) short circuit……………………………………………………………………….1272
DXACKB – Solenoid-3(Pump-3) short circuit……………………………………………………………………….1272
DXADKB – Solenoid-4(Pump-4) short circuit……………………………………………………………………….1272
DXAEKB – Solenoid-5(Pump-5) short circuit……………………………………………………………………….1272
DXAFKB – Solenoid-6(Pump-6) short circuit……………………………………………………………………….1272
DXAGKB – Solenoid-7(Pump-7) short circuit……………………………………………………………………….1272
DXAHKB – Solenoid-8(Pump-8) short circuit……………………………………………………………………….1272
DXAJKB – Solenoid-9(Pump-9) short circuit……………………………………………………………………….1272
DXAKKB – Solenoid-10(Pump-10) short circuit……………………………………………………………………..1272
DXALKB – Solenoid-11(Pump-11) short circuit……………………………………………………………………..1272
DXAMKB – Solenoid-12(Pump-12) short circuit……………………………………………………………………..1272
Wiring Diagram – EPC valve control (PUMP1 controller)…………………………………………………………1274
Wiring Diagram – EPC valve control (PUMP2 controller)…………………………………………………………1275
DHPEMA – Pump-1/2 pressure sensor abnormality……………………………………………………………………1276
DHPGMA – Pump-3/4 pressure sensor abnormality……………………………………………………………………1276
DHPJMA – Pump-5/6 pressure sensor abnormality……………………………………………………………………1276
DHPLMA – Pump-7/8 pressure sensor abnormality……………………………………………………………………1276
DHPNMA – Pump-9/10 pressure sensor abnormality…………………………………………………………………..1276
DHPQMA – Pump-11/12 pressure sensor abnormality………………………………………………………………….1276
Wiring Diagram – PWR & GND supply for pressure transducers (pumps 1…3)………………………………………..1278
Wiring Diagram – PWR & GND supply for pressure transducers (pumps 4…6)………………………………………..1279
DLE2MA – Engine speed sensor abnormality………………………………………………………………………..1280
DLE6MA – Engine2 speed sensor abnormality……………………………………………………………………….1280
Wiring Diagram – engine speed sensors……………………………………………………………………….1282
DA25KP – 5V sensor1 power abnormality…………………………………………………………………………..1283
DBZ5KP – 5V sensor1 power abnormality…………………………………………………………………………..1283
Wiring Diagram – 5V sensor power supply (PC1_5V_1) for message DA25KP…………………………………………..1284
Wiring Diagram – 5V sensor power supply (PC2_5V_1) for message DBZ5KP…………………………………………..1285
DA22KK – Pump Solenoid Power Low Error………………………………………………………………………….1286
DBZ2KK – Pump2 Solenoid Power Low Error…………………………………………………………………………1286
Wiring Diagram – PUMP1/2 solenoid power……………………………………………………………………..1287
DA29KQ – Model Selection Abnormality……………………………………………………………………………1288
DBZ9KQ – Model Selection Abnormality……………………………………………………………………………1288
Wiring Diagram – PUMP1 machine selections……………………………………………………………………1290
Wiring Diagram – PUMP2 machine selections……………………………………………………………………1291
DA2YKQ – Motor/Engine Selection Abnormality……………………………………………………………………..1292
DBZWKQ – Motor/Engine Selection Abnormality……………………………………………………………………..1292
Wiring Diagram – Motor/engine selection PUMP1 & PUMP2 controller……………………………………………….1293
DA20KQ – Pump1 Con Selection Abnormality………………………………………………………………………..1294
DBZ0KQ – Pump2 Con Selection Abnormality………………………………………………………………………..1294
Wiring Diagram – Controller selection PUMP1 & PUMP2 controller…………………………………………………1296
DA20MC – Pump1 Con Error………………………………………………………………………………………1297
DBZ0MC – Pump2 Con Error………………………………………………………………………………………1297
DGT3MA – PTO1 oil temperature sensor abnormality…………………………………………………………………1298
DGT8MA – PTO2 oil temperature sensor abnormality…………………………………………………………………1298
Wiring Diagram (57B049-1 & 57B049-2) for DGT3MA & DGT8MA & #D0069 & #D0083………………………………………1299
Mounting location of 57B049-1/2…………………………………………………………………………….1300
DGH2MA – Hydraulic oil temp sensor abnormality…………………………………………………………………..1301
Wiring Diagram (59B015) for messages DGH2MA & #D0063………………………………………………………….1302
DWNCKA – Hyd oil cooler fan pump1 solenoid open circuit…………………………………………………………..1303
DWNUKA – Hyd oil cooler fan pump2 solenoid open circuit…………………………………………………………..1303
Wiring Diagram – Hydraulic oil cooler fan pump1/2 EPC control………………………………………………….1305
DWNCKB – Hyd oil cooler fan pump1 solenoid short circuit………………………………………………………….1306
DWNUKB – Hyd oil cooler fan pump2 solenoid short circuit………………………………………………………….1306
Wiring Diagram – Hydraulic oil cooler fan pump1/2 EPC control………………………………………………….1307
DWN5KA – Radiator fan pump1 solenoid open circuit………………………………………………………………..1308
DWNTKA – Radiator fan pump2 solenoid open circuit………………………………………………………………..1308
Wiring Diagram – Radiator fan pump1/2 EPC control…………………………………………………………….1310
DWN5KB – Radiator fan pump1 solenoid short circuit……………………………………………………………….1311
DWNTKB – Radiator fan pump2 solenoid short circuit……………………………………………………………….1311
Wiring Diagram – Radiator fan pump1/2 EPC control…………………………………………………………….1312
DXQ0KA – X1 pilot pressure pump1 solenoid open circuit……………………………………………………………1313
DXQ1KA – X1 pilot pressure pump2 solenoid open circuit……………………………………………………………1313
Wiring Diagram – control oil (X1) pressure pump1/2 EPC control…………………………………………………1315
DXQ0KB – X1 pilot pressure pump1 solenoid short circuit…………………………………………………………..1316
DXQ1KB – X1 pilot pressure pump2 solenoid short circuit…………………………………………………………..1316
Wiring Diagram – control oil (X1) pressure pump1/2 EPC control…………………………………………………1317
DDABMC – Lock lever switch abnormality………………………………………………………………………….1318
Wiring Diagram – lock lever switch 20S105 (DDABMC)……………………………………………………………1319
DBW9KQ – Model Selection Abnormality……………………………………………………………………………1320
Wiring Diagram – VALVE0 machine selections…………………………………………………………………..1321
DBWZKQ – Lever control selection abnormality…………………………………………………………………….1322
Wiring Diagram – VALVE0 lever control selection………………………………………………………………1323
DBWYKQ – Attachment selection abnormality……………………………………………………………………….1324
Wiring Diagram – VALVE0 attachment selection…………………………………………………………………1325
DBW2KK – Solenoid Power Low Error(VALVE/M)………………………………………………………………………1326
Wiring Diagram for message DBW2KK…………………………………………………………………………..1329
DBW0KQ – VALVE/M Con Selection Abnormality………………………………………………………………………1330
Wiring Diagram – VALVE0 controller selection…………………………………………………………………1331
DBW0MA – VALVE/M Con Error…………………………………………………………………………………….1332
DKURMA – R lever right-left potentio abnormality…………………………………………………………………1334
Wiring Diagram – R lever right-left potentiometer input (DKURMA)……………………………………………….1335
DKUSMA – R lever right-left redu pot abnorm(VALVE/M)……………………………………………………………..1336
Wiring Diagram – R lever redundant right-left potentiometer input (DKUSMA)………………………………………1337
DKUQL8 – R lever right-left potentio error………………………………………………………………………1338
Wiring Diagram – R lever main + redundant right-left signal voltage at VALVE0……………………………………1340
DKUQL4 – R lever right-left sig. mismatch(VALVE/M)……………………………………………………………….1341
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1…………………………………………..1343
DKUNMA – R lever front-back potentio abnormality…………………………………………………………………1344
Wiring Diagram – R lever front-back potentiometer input (DKUNMA)……………………………………………….1345
DKUPMA – R lever front-back redu pot abnorm(VALVE/M)……………………………………………………………..1346
Wiring Diagram – R lever redundant front-back potentiometer input at VALVE0……………………………………..1347
DKUML8 – R lever front-back potentio error………………………………………………………………………1348
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8)…………………………………….1350
DKUML4 – R lever front-back sig. mismatch(VALVE/M)……………………………………………………………….1351
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1…………………………………………..1353
DKUXMA – L lever right-left potentio abnormality…………………………………………………………………1354
Wiring Diagram – L lever right-left potentiometer input (DKUXMA)……………………………………………….1355
DKUYMA – L lever right-left redu pot abnorm(VALVE/M)……………………………………………………………..1356
Wiring Diagram – L lever redundant right-left potentiometer input (DKUYMA)………………………………………1357
DKUWL8 – L lever right-left potentio error………………………………………………………………………1358
Wiring Diagram – L lever main + redundant right-left signal voltage at VALVE0……………………………………1360
DKUWL4 – L lever right-left sig. mismatch(VALVE/M)……………………………………………………………….1361
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1…………………………………………..1363
DKUUMA – L lever front-back potentio abnormality…………………………………………………………………1364
Wiring Diagram – L lever front-back potentiometer input (DKUUMA)……………………………………………….1365
DKUVMA – L lever front-back redu pot abnorm(VALVE/M)……………………………………………………………..1366
Wiring Diagram – L lever front-back redundant potentiometer input (VALVE0)………………………………………1367
DKUTL8 – L lever front-back potentio error………………………………………………………………………1368
Wiring Diagram – L lever front-back potentio error (DKUTL8)……………………………………………………1370
DKUTL4 – L lever front-back sig. mismatch(VALVE/M)……………………………………………………………….1371
Wiring Diagram – L lever front-back sig. mismatch(VALVE/M) for DKUTL4…………………………………………..1373
DKW1MA – R pedal potentio abnormality…………………………………………………………………………..1374
Wiring Diagram – R pedal potentio abnormality (DKW1MA)………………………………………………………..1376
DKW2MA – R pedal redundant pot abnormality(VALVE/M)………………………………………………………………1377
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA………………………………………….1379
DKW0L8 – R pedal potentio error………………………………………………………………………………..1380
Wiring Diagram – R pedal potentio error (DKW0L8)……………………………………………………………..1382
DKW0L4 – R pedal signal mismatch(VALVE/M)……………………………………………………………………….1383
Wiring Diagram – R pedal signal mismatch(VALVE/M) for DKW0L4…………………………………………………..1385
DKW4MA – L pedal potentio abnormality…………………………………………………………………………..1386
Wiring Diagram – L pedal potentio abnormality (DKW4MA)………………………………………………………..1388
DKW5MA – L pedal redundant pot abnormality(VALVE/M)………………………………………………………………1389
Wiring Diagram – L pedal redundant pot abnormality(VALVE/M) for DKW5MA………………………………………….1391
DKW3L8 – L pedal potentio error………………………………………………………………………………..1392
Wiring Diagram – L pedal potentio error (DKW3L8)……………………………………………………………..1394
DKW3L4 – L pedal signal mismatch(VALVE/M)……………………………………………………………………….1395
Wiring Diagram – L pedal signal mismatch(VALVE/M) for DKW3L4…………………………………………………..1397
DKW7MA – Clam open potentio abnormality…………………………………………………………………………1398
Wiring Diagram – Clam open potentio abnormality (DKW7MA)………………………………………………………1399
DKW8MA – Clam open redu pot abnormality(VALVE/M)…………………………………………………………………1400
Wiring Diagram – Clam open redu pot abnormality(VALVE/M) for DKW8MA…………………………………………….1401
DKW6L8 – Clam open potentio error………………………………………………………………………………1402
Wiring Diagram – Clam open potentio error (DKW6L8)……………………………………………………………1404
DKW6L4 – Clam open signal mismatch(VALVE/M)……………………………………………………………………..1405
Wiring Diagram – Clam open signal mismatch(VALVE/M) for DKW6L4…………………………………………………1407
DKWAMA – Clam close potentio abnormality………………………………………………………………………..1408
Wiring Diagram – Clam close potentio abnormality (DKWAMA)……………………………………………………..1409
DKWBMA – Clam close redundant pot abnorm(VALVE/M)………………………………………………………………..1410
Wiring Diagram – Clam close redundant pot abnorm(VALVE/M) for DKWBMA……………………………………………1411
DKW9L8 – Clam close potentio error……………………………………………………………………………..1412
Wiring Diagram – Clam close potentio error (DKW9L8)…………………………………………………………..1414
DKW9L4 – Clam close signal mismatch(VALVE/M)…………………………………………………………………….1415
Wiring Diagram – Clam close signal mismatch(VALVE/M) for DKW9L4………………………………………………..1417
DKWDMA – Hydraulic slew brake potentio abnormality……………………………………………………………….1418
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA)…………………………………………….1419
DKWEMA – Hyd. slew brake redu pot abnorm(VALVE/M)………………………………………………………………..1420
Wiring Diagram – Hyd. slew brake redu pot abnorm(VALVE/M) for DKWEMA……………………………………………1421
DKWCL8 – Hydraulic slew brake potentio error…………………………………………………………………….1422
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8)………………………………………………….1424
DKWCL4 – Hyd. slew brake sig. mismatch(VALVE/M)………………………………………………………………….1425
Wiring Diagram – Hyd. slew brake sig. mismatch(VALVE/M) for DKWCL4……………………………………………..1427
DXNHKA – Travel1 left epc solenoid open circuit………………………………………………………………….1428
DXN3KA – Stick1 epc solenoid open circuit……………………………………………………………………….1428
DXNJKA – Bucket1 epc solenoid open circuit………………………………………………………………………1428
DXN2KA – Boom1 epc solenoid open circuit………………………………………………………………………..1428
DXN5KA – Clam2 epc solenoid open circuit………………………………………………………………………..1428
DXN8KA – Bucket2 epc solenoid open circuit………………………………………………………………………1428
DXN4KA – Boom2 epc solenoid open circuit………………………………………………………………………..1428
DXN6KA – Stick2 epc solenoid open circuit……………………………………………………………………….1428
DXNKKA – Travel3 right epc solenoid open circuit…………………………………………………………………1428
DXNCKA – Boom3 epc solenoid open circuit………………………………………………………………………..1428
DXNBKA – Bucket3 epc solenoid open circuit………………………………………………………………………1428
DXNLKA – Stick3 epc solenoid open circuit……………………………………………………………………….1428
DXNMKA – Slew4 epc solenoid open circuit………………………………………………………………………..1428
Details of above 6-digit failure codes………………………………………………………………………1429
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623 (block I)……………………………………………..1430
Wiring Diagram for EPC 61K624 – 61K625 – 61K626 – 61K627 (block II)…………………………………………….1431
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 – 61K631 (block III)……………………………………………1432
Wiring Diagram for EPC 61K632 (block IV)…………………………………………………………………….1433
Monitoring screens for EPC with open circuit (block I…IV)……………………………………………………1434
DXNHKB – Travel1 left epc solenoid short circuit…………………………………………………………………1435
DXN3KB – Stick1 epc solenoid short circuit………………………………………………………………………1435
DXNJKB – Bucket1 epc solenoid short circuit……………………………………………………………………..1435
DXN2KB – Boom1 epc solenoid short circuit……………………………………………………………………….1435
DXN5KB – Clam2 epc solenoid short circuit……………………………………………………………………….1435
DXN8KB – Bucket2 epc solenoid short circuit……………………………………………………………………..1435
DXN4KB – Boom2 epc solenoid short circuit……………………………………………………………………….1435
DXN6KB – Stick2 epc solenoid short circuit………………………………………………………………………1435
DXNKKB – Travel3 right epc solenoid short circuit………………………………………………………………..1435
DXNCKB – Boom3 epc solenoid short circuit……………………………………………………………………….1435
DXNBKB – Bucket3 epc solenoid short circuit……………………………………………………………………..1435
DXNLKB – Stick3 epc solenoid short circuit………………………………………………………………………1435
DXNMKB – Slew4 epc solenoid short circuit……………………………………………………………………….1435
Details of the above 6-digit failure codes…………………………………………………………………..1436
DXNHKY – Travel1 left epc solenoid hot short circuit……………………………………………………………..1437
DXN3KY – Stick1 epc solenoid hot short circuit…………………………………………………………………..1437
DXNJKY – Bucket1 epc solenoid hot short circuit………………………………………………………………….1437
DXN2KY – Boom1 epc solenoid hot short circuit……………………………………………………………………1437
DXN5KY – Clam2 epc solenoid hot short circuit……………………………………………………………………1437
DXN8KY – Bucket2 epc solenoid hot short circuit………………………………………………………………….1437
DXN4KY – Boom2 epc solenoid hot short circuit……………………………………………………………………1437
DXN6KY – Stick2 epc solenoid hot short circuit…………………………………………………………………..1437
DXNKKY – Travel3 right epc hot solenoid short circuit…………………………………………………………….1437
DXNCKY – Boom3 epc solenoid hot short circuit……………………………………………………………………1437
DXNBKY – Bucket3 epc solenoid hot short circuit………………………………………………………………….1437
DXNLKY – Stick3 epc solenoid hot short circuit…………………………………………………………………..1437
DXNMKY – Slew4 epc solenoid hot short circuit……………………………………………………………………1437
Details of the above 6-digit failure codes…………………………………………………………………..1438
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623 (block I)……………………………………………..1439
Wiring Diagram for EPC 61K624 – 61K625 – 61K626 – 61K627 (block II)…………………………………………….1440
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 – 61K631 (block III)……………………………………………1441
Wiring Diagram for EPC 61K632 (block IV)…………………………………………………………………….1442
D5Y3KB – Boom down on/off signal short circuit…………………………………………………………………..1443
D5Y2KB – Boom up on/off signal short circuit…………………………………………………………………….1443
D5Y5KB – Stick in on/off signal short circuit……………………………………………………………………1443
D5Y4KB – Stick out on/off signal short circuit…………………………………………………………………..1443
D5Y7KB – Bucket dump on/off signal short circuit…………………………………………………………………1443
Wiring Diagram – VALVE0 controller ON/OFF signal output to node 2………………………………………………1444
DBW5MA – 5V sensor1 power abnormality…………………………………………………………………………..1445
Wiring Diagram – 5V_1 power supply and GND_1 output at VALVE0………………………………………………….1446
DBW6MA – 5V sensor2 power abnormality…………………………………………………………………………..1448
Wiring Diagram – 5V_2 power supply and GND_2 output at VALVE0………………………………………………….1449
DBX9KQ – Model Selection Abnormality……………………………………………………………………………1452
Wiring Diagram – VALVE1 machine selections…………………………………………………………………..1453
DBXZKQ – Lever Control Selection Abnormality…………………………………………………………………….1454
Wiring Diagram – VALVE1 lever control selection………………………………………………………………1455
DBXYKQ – Attachment selection abnormality……………………………………………………………………….1456
Wiring Diagram – VALVE1 attachment selection…………………………………………………………………1457
DBX2KK – Solenoid Power Low Error(VALVE/S1)……………………………………………………………………..1458
Wiring Diagram for message DBX2KK – Solenoid Power Low Error(VALVE/S1)………………………………………….1460
PPC safety circuit – Wiring Diagram overview…………………………………………………………………1461
DBX0KQ – VALVE/S1 Con Selection Abnormality……………………………………………………………………..1462
Wiring Diagram – VALVE1 controller selection…………………………………………………………………1463
DBX0MA – VALVE/S1 Con Error……………………………………………………………………………………1464
DKWHMA – R lever right-left redu pot abnorm(VALVE/S1)…………………………………………………………….1465
Wiring Diagram – R lever redundant right-left potentiometer input (DKWHMA)………………………………………1466
DKWFL4 – R lever right-left sig. mismatch(VALVE/S1)………………………………………………………………1467
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1…………………………………………..1469
DKWLMA – R lever front-back redu pot abnorm(VALVE/S1)…………………………………………………………….1470
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA)…………………………………..1471
DKWJL4 – R lever front-back sig. mismatch(VALVE/S1)………………………………………………………………1472
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1…………………………………………..1474
DKWPMA – L lever right-left redu pot abnorm(VALVE/S1)…………………………………………………………….1475
Wiring Diagram – L lever redundant right-left potentiometer input at VALVE1……………………………………..1476
DKWML4 – L lever right-left sig. mismatch(VALVE/S1)………………………………………………………………1477
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1…………………………………………..1479
DKWSMA – L lever front-back redu pot abnorm(VALVE/S1)…………………………………………………………….1480
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/S1) for DKWSMA………………………………………..1481
DKWQL4 – L lever front-back sig. mismatch(VALVE/S1)………………………………………………………………1482
Wiring Diagram – L lever front-back sig. mismatch (VALVE1) for DKWQL4…………………………………………..1484
DKWVMA – R pedal red pot abnormality(VALVE/S1)…………………………………………………………………..1485
Wiring Diagram – R pedal red pot abnormality (VALVE1) for DKWVMA……………………………………………….1486
DKWTL4 – R pedal signal mismatch(VALVE/S1)………………………………………………………………………1487
Wiring Diagram – R pedal signal mismatch(VALVE/S1) for DKWTL4………………………………………………….1489
DKWYMA – L pedal red pot abnormality(VALVE/S1)…………………………………………………………………..1490
Wiring Diagram – L pedal red pot abnormality(VALVE/S1) for DKWYMA………………………………………………1491
DKWWL4 – L pedal signal mismatch(VALVE/S1)………………………………………………………………………1492
Wiring Diagram – L pedal signal mismatch(VALVE/S1) for DKWWL4………………………………………………….1494
DKX2MA – Clam open redu pot abnormality(VALVE/S1)………………………………………………………………..1495
Wiring Diagram – Clam open redu pot abnormality(VALVE/S1)) for DKX2MA…………………………………………..1496
DKX0L4 – Clam open signal mismatch(VALVE/S1)…………………………………………………………………….1497
Wiring Diagram – Clam open signal mismatch(VALVE/S1) for DKX0L4………………………………………………..1499
DKX5MA – Clam close redu pot abnormality(VALVE/S1)……………………………………………………………….1500
Wiring Diagram – Clam close redu pot abnormality(VALVE/S1) for DKX5MA…………………………………………..1501
DKX3L4 – Clam close signal mismatch(VALVE/S1)……………………………………………………………………1502
Wiring Diagram – Clam close signal mismatch(VALVE/S1) for DKX3L4……………………………………………….1504
DKX8MA – Hyd. slew brake redu pot abnorm(VALVE/S1)……………………………………………………………….1505
Wiring Diagram – Hyd. slew brake redu pot abnorm(VALVE/S1) for DKX8MA…………………………………………..1506
DKX6L4 – Hyd. slew brake signal mismatch(VALVE/S1)……………………………………………………………….1507
Wiring Diagram – Hyd. slew brake signal mismatch(VALVE/S1) for DKX6L4…………………………………………..1509
DWKAKA – Travel1 left forward sol. open circuit………………………………………………………………….1510
DWKEKA – Travel1 left backward sol. open circuit…………………………………………………………………1510
DWBJKA – Stick1 out solenoid open circuit……………………………………………………………………….1510
DWBNKA – Stick1 in solenoid open circuit………………………………………………………………………..1510
DWASKA – Bucket1 fill solenoid open circuit……………………………………………………………………..1510
DWAWKA – Bucket1 dump solenoid open circuit……………………………………………………………………..1510
DWBAKA – Boom1 up solenoid open circuit…………………………………………………………………………1510
DWBEKA – Boom1 down solenoid open circuit……………………………………………………………………….1510
Details of above 6-digit failure codes………………………………………………………………………1510
Monitoring screens for directional solenoids – VALVE1…………………………………………………………1511
Wiring Diagram – directional solenoids at remote control block 45.1 (VALVE1)…………………………………….1512
DWKAKB – Travel1 left forward sol. short circuit…………………………………………………………………1513
DWKEKB – Travel1 left backward sol. short circuit………………………………………………………………..1513
DWBJKB – Stick1 out solenoid short circuit………………………………………………………………………1513
DWBNKB – Stick1 in solenoid short circuit……………………………………………………………………….1513
DWASKB – Bucket1 fill solenoid short circuit…………………………………………………………………….1513
DWAWKB – Bucket1 dump solenoid short circuit…………………………………………………………………….1513
DWBAKB – Boom1 up solenoid short circuit………………………………………………………………………..1513
DWBEKB – Boom1 down solenoid short circuit………………………………………………………………………1513
Details of above 6-digit failure codes………………………………………………………………………1513
Monitoring screens for directional solenoids – VALVE1…………………………………………………………1514
Wiring Diagram – directional solenoids at remote control block 45.1 (VALVE1)…………………………………….1515
DWKAKY – Travel1 left forward sol. hot short circuit……………………………………………………………..1516
DWKEKY – Travel1 left backward sol. hot short circuit…………………………………………………………….1516
DWBJKY – Stick1 out solenoid hot short circuit…………………………………………………………………..1516
DWBNKY – Stick1 in solenoid hot short circuit……………………………………………………………………1516
DWASKY – Bucket1 fill solenoid hot short circuit…………………………………………………………………1516
DWAWKY – Bucket1 dump solenoid hot short circuit…………………………………………………………………1516
DWBAKY – Boom1 up solenoid hot short circuit…………………………………………………………………….1516
DWBEKY – Boom1 down solenoid hot short circuit…………………………………………………………………..1516
Details of above 6-digit failure codes………………………………………………………………………1516
Monitoring screens for directional solenoids – VALVE1…………………………………………………………1517
Wiring Diagram – directional solenoids at remote control block 45.1 (VALVE1)…………………………………….1518
DWBXKA – Clam2 close solenoid open circuit………………………………………………………………………1519
DWBTKA – Clam2 open solenoid open circuit……………………………………………………………………….1519
DWATKA – Bucket2 fill solenoid open circuit……………………………………………………………………..1519
DWAXKA – Bucket2 dump solenoid open circuit……………………………………………………………………..1519
DWBBKA – Boom2 up solenoid open circuit…………………………………………………………………………1519
DWBFKA – Boom2 down solenoid open circuit……………………………………………………………………….1519
Details of above 6-digit failure codes………………………………………………………………………1519
Monitoring screens for directional solenoids – VALVE1…………………………………………………………1521
Wiring Diagram – directional solenoids at remote control block 45.2 (VALVE1)…………………………………….1522
DWBXKB – Clam2 close solenoid short circuit……………………………………………………………………..1523
DWBTKB – Clam2 open solenoid short circuit………………………………………………………………………1523
DWATKB – Bucket2 fill solenoid short circuit…………………………………………………………………….1523
DWAXKB – Bucket2 dump solenoid short circuit…………………………………………………………………….1523
DWBBKB – Boom2 up solenoid short circuit………………………………………………………………………..1523
DWBFKB – Boom2 down solenoid short circuit………………………………………………………………………1523
Details of above 6-digit failure codes………………………………………………………………………1523
Monitoring screens for directional solenoids – VALVE1…………………………………………………………1525
Wiring Diagram – directional solenoids at remote control block 45.2 (VALVE1)…………………………………….1526
DWBXKY – Clam2 close solenoid hot short circuit………………………………………………………………….1527
DWBTKY – Clam2 open solenoid hot short circuit…………………………………………………………………..1527
DWATKY – Bucket2 fill solenoid hot short circuit…………………………………………………………………1527
DWAXKY – Bucket2 dump solenoid hot short circuit…………………………………………………………………1527
DWBBKY – Boom2 up solenoid hot short circuit…………………………………………………………………….1527
DWBFKY – Boom2 down solenoid hot short circuit…………………………………………………………………..1527
Details of above 6-digit failure codes………………………………………………………………………1527
Monitoring screens for directional solenoids – VALVE1…………………………………………………………1528
Wiring Diagram – directional solenoids at remote control block 45.2 (VALVE1)…………………………………….1529
D5Y6KB – Bucket fill on/off signal short circuit…………………………………………………………………1530
D5Y9KB – Clam close on/off signal short circuit………………………………………………………………….1530
D5YAKB – Hyd. slew brake order signal short circuit………………………………………………………………1530
D5Y0KB – Slew left on/off signal short circuit…………………………………………………………………..1530
D5Y1KB – Slew right on/off signal short circuit………………………………………………………………….1530
Wiring Diagram – VALVE1 controller ON/OFF signal output to node 2………………………………………………1531
D5YAKY – Hyd. slew brake order signal hot short circuit…………………………………………………………..1532
Wiring Diagram – VALVE1 controller ON/OFF signal output to node 2………………………………………………1533
DBY9KQ – Model Selection Abnormality……………………………………………………………………………1534
Wiring Diagram for message DBY9KQ…………………………………………………………………………..1535
DBYZKQ – Lever Control Selection Abnormality…………………………………………………………………….1536
Wiring Diagram for message DBYZKQ…………………………………………………………………………..1537
DBYYKQ – Attachment selection abnormality……………………………………………………………………….1538
Wiring Diagram for message DBYYKQ…………………………………………………………………………..1539
DBY2KK – Solenoid Power Low Error(VALVE/S2)……………………………………………………………………..1540
Wiring Diagram for message DBY2KK – Solenoid Power Low Error(VALVE/S2)………………………………………….1542
PPC safety circuit – Wiring Diagram overview…………………………………………………………………1543
DBY0KQ – VALVE/S2 Con Selection Abnormality……………………………………………………………………..1544
Wiring Diagram for message DBY0KQ…………………………………………………………………………..1545
DBY0MA – VALVE/S2 Con Error……………………………………………………………………………………1546
DWBKKA – Stick2 out solenoid open circuit……………………………………………………………………….1547
DWBKKB – Stick2 out solenoid short circuit………………………………………………………………………1547
DWBPKA – Stick2 in solenoid open circuit………………………………………………………………………..1547
DWBPKB – Stick2 in solenoid short circuit……………………………………………………………………….1547
Details of above 6-digit failure codes………………………………………………………………………1547
Wiring Diagram – 61K627a/b open circuit or short circuit to GND………………………………………………..1549
DWBKKY – Stick2 out solenoid hot short circuit…………………………………………………………………..1550
DWBPKY – Stick2 in solenoid hot short circuit……………………………………………………………………1550
Details of above 6-digit failure codes………………………………………………………………………1550
Wiring Diagram – 61K627a/b hot short circuit…………………………………………………………………1551
DWKQKA – Travel3 right backward sol. open circuit………………………………………………………………..1552
DWKLKA – Travel3 right forward sol. open circuit…………………………………………………………………1552
DWBCKA – Boom3 up solenoid open circuit…………………………………………………………………………1552
DWBGKA – Boom3 down solenoid open circuit……………………………………………………………………….1552
DWAUKA – Bucket3 fill solenoid open circuit……………………………………………………………………..1552
DWAYKA – Bucket3 dump solenoid open circuit……………………………………………………………………..1552
DWBLKA – Stick3 out solenoid open circuit……………………………………………………………………….1552
DWBQKA – Stick3 in solenoid open circuit………………………………………………………………………..1552
DWARKA – Slew4 right solenoid open circuit………………………………………………………………………1552
DWAMKA – Slew4 left solenoid open circuit……………………………………………………………………….1552
Details of above 6-digit failure codes………………………………………………………………………1552
Monitoring screens for directional solenoids (45.3 & 43) – VALVE2………………………………………………1554
Wiring Diagram – directional solenoids at remote control blocks 45.3 & 43……………………………………….1555
DWKQKB – Travel3 right backward sol. short circuit……………………………………………………………….1556
DWKLKB – Travel3 right forward sol. short circuit………………………………………………………………..1556
DWBCKB – Boom3 up solenoid short circuit………………………………………………………………………..1556
DWBGKB – Boom3 down solenoid short circuit………………………………………………………………………1556
DWAUKB – Bucket3 fill solenoid short circuit…………………………………………………………………….1556
DWAYKB – Bucket3 dump solenoid short circuit…………………………………………………………………….1556
DWBLKB – Stick3 out solenoid short circuit………………………………………………………………………1556
DWBQKB – Stick3 in solenoid short circuit……………………………………………………………………….1556
DWARKB – Slew4 right solenoid short circuit……………………………………………………………………..1556
DWAMKB – Slew4 left solenoid short circuit………………………………………………………………………1556
Details of above 6-digit failure codes………………………………………………………………………1556
Monitoring screens for directional solenoids (45.3 & 43) – VALVE2………………………………………………1558
Wiring Diagram – directional solenoids at remote control blocks 45.3 & 43……………………………………….1559
DWKQKY – Travel3 right backward sol. hot short circuit……………………………………………………………1560
DWKLKY – Travel3 right forward sol. hot short circuit…………………………………………………………….1560
DWBCKY – Boom3 up solenoid hot short circuit…………………………………………………………………….1560
DWBGKY – Boom3 down solenoid hot short circuit…………………………………………………………………..1560
DWAUKY – Bucket3 fill solenoid hot short circuit…………………………………………………………………1560
DWAYKY – Bucket3 dump solenoid hot short circuit…………………………………………………………………1560
DWBLKY – Stick3 out solenoid hot short circuit…………………………………………………………………..1560
DWBQKY – Stick3 in solenoid hot short circuit……………………………………………………………………1560
DWARKY – Slew4 right solenoid hot short circuit………………………………………………………………….1560
DWAMKY – Slew4 left solenoid hot short circuit…………………………………………………………………..1560
Details of above 6-digit failure codes………………………………………………………………………1560
Monitoring screens for directional solenoids (45.3 & 43) – VALVE2………………………………………………1562
Wiring Diagram – directional solenoids at remote control blocks 45.3 & 43……………………………………….1563
DXEDKA – Hyd. slew brake epc sol. open circuit…………………………………………………………………..1564
DXEDKB – Hyd. slew brake epc sol. short circuit………………………………………………………………….1564
Wiring Diagram for messages DXEDKA & DXEDKB………………………………………………………………….1565
DXEDKY – Hyd. slew brake epc sol. hot short circuit………………………………………………………………1566
Wiring Diagram for message DXEDKY…………………………………………………………………………..1567
D5Z3KB – Travel right backward on/off signal short circuit………………………………………………………..1568
D5Z5KB – Travel right forward on/off signal short circuit…………………………………………………………1568
D5Z2KB – Travel left backward on/off signal short circuit…………………………………………………………1568
D5Z4KB – Travel left forward on/off signal short circuit………………………………………………………….1568
D5Y8KB – Clam open on/off signal short circuit…………………………………………………………………..1568
Wiring Diagram – VALVE2 controller ON/OFF signal output to node 2………………………………………………1569
DBZRKR – CAN1 Discon (Pump2 Con)……………………………………………………………………………….1570
Wiring Diagram for message DBZRKR…………………………………………………………………………..1571
DBWRKR – CAN1 Discon (Valve/M Con)……………………………………………………………………………..1572
Wiring Diagram for message DBWRKR…………………………………………………………………………..1573
DBXRKR – CAN1 Discon (Valve/S1 Con)…………………………………………………………………………….1574
Wiring Diagram for message DBXRKR…………………………………………………………………………..1575
DBYRKR – CAN1 Discon (Valve/S2 Con)…………………………………………………………………………….1576
Wiring Diagram for message DBYRKR…………………………………………………………………………..1577
9 Troubleshooting by Symptoms……………………………………………………………………………………..1579
9.1 Symptoms of engine and electrical system…………………………………………………………………….1580
SEL001 – Engine does not start (engine does not rotate)……………………………………………………….1580
Wiring Diagram 1 (batteries & starter motors) for symptom code SEL001……………………………………….1582
Wiring Diagram 2 (20S105) for symptom code SEL001…………………………………………………………1583
Wiring Diagram 3 (20S030) for symptom code SEL001…………………………………………………………1584
SEL002 – Engine does not start (Pre-lube does not stop)……………………………………………………….1585
SEL003 – Engine stops while in operation…………………………………………………………………….1586
View onto the fuel system water separator (SEL003)………………………………………………………..1587
SEL004 – Engine speed is hunting during boom-up movement………………………………………………………1588
SEL005 – Engine does not stop………………………………………………………………………………1590
SEL006 – Engine lacks output (low power)…………………………………………………………………….1592
Judgment Table for SEL006………………………………………………………………………………1593
SEL007 – Exhaust smoke is black…………………………………………………………………………….1594
Judgment Table for SEL007………………………………………………………………………………1595
SEL008 – Oil consumption is excessive……………………………………………………………………….1596
Judgment Table for SEL008………………………………………………………………………………1597
SEL009 – Oil becomes contaminated quickly……………………………………………………………………1598
Judgment Table for SEL009………………………………………………………………………………1599
SEL010 – Fuel consumption is excessive………………………………………………………………………1600
Judgment Table for SEL010………………………………………………………………………………1601
SEL011 – Oil is in engine coolant…………………………………………………………………………..1602
Judgment Table for SEL011………………………………………………………………………………1603
SEL012 – Oil level rises…………………………………………………………………………………..1604
Judgment Table for SEL012………………………………………………………………………………1605
SEL013 – Coolant temperature becomes too high (overheating)……………………………………………………1606
Judgment Table for SEL013………………………………………………………………………………1607
9.2 Symptoms of Hydraulic System……………………………………………………………………………….1608
SHY001 – All work equipment shows lack of power or slow movement (especially “boom up” function)…………………..1608
SHY002 – Engine speed sharply drops or engine stalls too much………………………………………………….1610
SHY003 – No work equipment, travel or slew movement…………………………………………………………..1611
SHY004 – Work equipment has too much hydraulic drift………………………………………………………….1612
SHY005 – Work equipment has time lag………………………………………………………………………..1613
SHY006 – Machine deviates during travel movement……………………………………………………………..1614
SHY007 – Hydraulic system has lack of power………………………………………………………………….1615
SHY008 – Machine does not slew……………………………………………………………………………..1616
Slew brake valve block (SHY008)…………………………………………………………………………1617
SHY009 – Slew acceleration is poor………………………………………………………………………….1618
SHY010 – Excessive overrun when stopping slew movement………………………………………………………..1620
SHY011 – Floating system without function (FSA only)………………………………………………………….1622
SHY012 – Abnormal noise coming from SRV or MRV……………………………………………………………….1623
SHY013 – Track tensioning system without function…………………………………………………………….1624
Track tensioning – overview (SHY013)…………………………………………………………………….1625
SHY014 – Ladder does not move, or slow movement………………………………………………………………1626
SHY015 – Refilling arm does not move, or slow movement………………………………………………………..1628
SHY016 – Hydraulic driven grease pump does not move…………………………………………………………..1630
SHY017 – Abnormal track chain movement during digging…………………………………………………………1632
SHY018 – Slew parking brake without function…………………………………………………………………1633
SHY019 – Travel parking brake without function……………………………………………………………….1634
9.3 Symptoms of Mechanical System………………………………………………………………………………1636
SME001 – Abnormal noise is made…………………………………………………………………………….1636
Judgment Table for SME001………………………………………………………………………………1637
SME002 – Abnormal noise around PTO / hydraulic pumps………………………………………………………….1638
SME003 – Vibration is excessive (engine mountings)……………………………………………………………1640
Judgment Table for SME003………………………………………………………………………………1641
SME004 – Vibration is excessive (engine torsion)……………………………………………………………..1642
SME005 – There is a big shock when stopping slew movement……………………………………………………..1643
SME006 – There is a big abnormal noise when moving/stopping slew movement……………………………………….1644
SME007 – Fan blades make abnormal noise……………………………………………………………………..1646
SME008 – Abnormal noise coming from a travel gearbox………………………………………………………….1647
SME009 – Abnormal noise coming from work equipment (lack of grease)…………………………………………….1649
SME010 – Abnormal idler movement……………………………………………………………………………1651
SME011 – Leak at PTO drive shaft seal……………………………………………………………………….1652
9.4 Symptoms of Additional Systems……………………………………………………………………………..1654
SAD001 – Air conditioner for cabin does not work……………………………………………………………..1654
View onto A/C unit (SAD001)…………………………………………………………………………….1655
SAD002 – Air conditioner compressor clutch is burnt…………………………………………………………..1656
View onto A/C compressor and its mounting (SAD002)………………………………………………………..1657
SAD003 – Air conditioning system defective (pipes and hoses full of moisture)……………………………………1658
View onto an A/C filling and service station……………………………………………………………..1659
SAD004 – CAN BUS failure (message #D0308 displayed)…………………………………………………………..1660
50 DISASSEMBLY & ASSEMBLY…………………………………………………………………………………………….1667
TOC…………………………………………………………………………………………………………….1669
1 Introduction…………………………………………………………………………………………………..1677
1.1 Foreword…………………………………………………………………………………………………1678
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels…………………1679
1.3 Diagrams and illustrations in this manual……………………………………………………………………1679
1.4 Procedures for disassembling and assembling in this manual…………………………………………………….1680
2 Safety………………………………………………………………………………………………………..1681
2.1 Overview…………………………………………………………………………………………………1683
2.1.1 Method of using this manual…………………………………………………………………………..1683
2.2 General precautions……………………………………………………………………………………….1685
2.2.1 General…………………………………………………………………………………………….1685
2.2.2 Personal protective clothing………………………………………………………………………….1685
2.2.3 When using a hammer………………………………………………………………………………….1686
2.2.4 Proper tools………………………………………………………………………………………..1686
2.2.5 Personnel…………………………………………………………………………………………..1686
2.2.6 Fire prevention……………………………………………………………………………………..1687
2.2.7 Unauthorized modification…………………………………………………………………………….1687
2.3 Precautions for maintenance and repair………………………………………………………………………1688
2.3.1 General precautions………………………………………………………………………………….1688
2.3.2 Keep work place clean and tidy………………………………………………………………………..1688
2.3.3 Precautions when welding……………………………………………………………………………..1689
2.3.4 Precaution with high pressure fluids…………………………………………………………………..1689
2.3.4.1 Handling high pressure hoses and pipes……………………………………………………………1689
2.3.5 Compressed air………………………………………………………………………………………1689
2.3.6 Waste materials……………………………………………………………………………………..1690
3 Superstructure…………………………………………………………………………………………………1691
3.1 Superstructure overview……………………………………………………………………………………1692
3.2 Machinery house…………………………………………………………………………………………..1694
3.2.1 Disconnection plates…………………………………………………………………………………1696
3.2.1.1 R.H.-side disconnection plate [56XH01] – port allocations…………………………………………..1696
3.2.1.2 L.H.-side disconnection plate [50XH01] – port allocations…………………………………………..1697
3.2.2 Machinery house roof…………………………………………………………………………………1698
3.2.2.1 Disassembling of the machinery house roof cover plates……………………………………………..1700
3.2.2.2 Assembling of the machinery house roof cover plates………………………………………………..1704
3.2.3 Air intake system……………………………………………………………………………………1710
3.2.3.1 Disassembling of the air intake system……………………………………………………………1710
3.2.3.2 Assembling of the air intake system………………………………………………………………1714
3.2.4 Exhaust system………………………………………………………………………………………1719
3.2.4.1 Disassembling of the exhaust system………………………………………………………………1719
3.2.4.2 Assembling of the exhaust system…………………………………………………………………1723
3.2.5 Lubrication pump station……………………………………………………………………………..1726
3.2.5.1 Disassembling of the lubrication pump station……………………………………………………..1726
3.2.5.2 Assembling of the lubricating pump station………………………………………………………..1728
3.2.6 Diesel engines………………………………………………………………………………………1730
3.2.6.1 Disassembling of the Diesel engine (engine 1 or 2)…………………………………………………1730
3.2.6.2 Assembling of the Diesel engine (engine 1 or 2)……………………………………………………1736
3.2.6.3 Disassembling of the alternator………………………………………………………………….1743
3.2.6.4 Assembling of the alternator…………………………………………………………………….1744
3.2.6.5 Disassembling of the starter motor……………………………………………………………….1745
3.2.6.6 Assembling of the starter motor………………………………………………………………….1746
3.2.7 Batteries…………………………………………………………………………………………..1747
3.2.7.1 Disassembling of the batteries…………………………………………………………………..1747
3.2.7.2 Assembling of the batteries……………………………………………………………………..1749
3.2.8 Engine cooling system………………………………………………………………………………..1751
3.2.8.1 Disassembling of the Radiator assembly……………………………………………………………1752
3.2.8.2 Assembling of the radiator assembly………………………………………………………………1755
3.2.8.3 Disassembling of the radiator fan assembly………………………………………………………..1758
3.2.8.4 Assembling of the radiator fan assembly…………………………………………………………..1761
3.2.9 Flexible drive coupling………………………………………………………………………………1764
3.2.9.1 Disassembling of the Geislinger coupling………………………………………………………….1764
3.2.9.2 Assembling of the Geislinger coupling…………………………………………………………….1766
3.2.9.3 Disassembling of the CentaFlex coupling assembly…………………………………………………..1768
3.2.9.4 Assembling of the CentaFlex coupling assembly……………………………………………………..1771
3.2.9.5 Replacing the rubber rollers of the CentaFlex coupling……………………………………………..1773
3.2.10 Main pump assemblies………………………………………………………………………………..1776
3.2.10.1 Disassembling of the main pump assemblies………………………………………………………..1777
3.2.10.2 Assembling of the main pump assemblies…………………………………………………………..1781
3.2.11 Universal pump distributor gear box (PTO)……………………………………………………………..1784
3.2.11.1 Disassembling of the universal pump distributor gear box (PTO)……………………………………..1785
3.2.11.2 Assembling of the universal pump distributor gear box (PTO)………………………………………..1789
3.2.11.3 Disassembling of the control and filter plate assemblies…………………………………………..1794
3.2.11.4 Assembling of the control and filter plate assemblies……………………………………………..1803
3.2.11.5 Disassembling of the PTO gear oil pump…………………………………………………………..1812
3.2.11.6 Assembling of the PTO gear oil pump……………………………………………………………..1814
3.3 Hydraulic system………………………………………………………………………………………….1816
3.3.1 Hydraulic oil cooler assembly…………………………………………………………………………1816
3.3.1.1 Disassembling of hydraulic cooler fan…………………………………………………………….1817
3.3.1.2 Assembling of hydraulic cooler fan……………………………………………………………….1818
3.3.1.3 Disassembling of hydraulic cooler fan motor……………………………………………………….1819
3.3.1.4 Assembling of hydraulic cooler fan motor………………………………………………………….1821
3.3.1.5 Disassembling of the hydraulic oil coolers………………………………………………………..1823
3.3.1.6 Assembling of the hydraulic oil coolers…………………………………………………………..1826
3.3.1.7 Disassembling of the hydraulic oil cooler assembly…………………………………………………1829
3.3.1.8 Assembling of the hydraulic oil cooler assembly……………………………………………………1834
3.3.2 Hydraulic oil tank…………………………………………………………………………………..1840
3.3.2.1 Disassembling of the main shut-off valve………………………………………………………….1842
3.3.2.2 Assembling of the main shut-off valve…………………………………………………………….1844
3.3.2.3 Disassembling of the hydraulic oil tank…………………………………………………………..1846
3.3.2.4 Assembling of the hydraulic oil tank……………………………………………………………..1857
3.3.3 Control frame assembly……………………………………………………………………………….1870
3.3.3.1 Disassembling of the main control valve blocks I, II and III………………………………………..1871
3.3.3.2 Assembling of the main control valve blocks I, II and III…………………………………………..1875
3.3.3.3 Disassembling of the main control valve block IV (Slewing)………………………………………….1879
3.3.3.4 Assembling of the main control valve block IV (Slewing)…………………………………………….1881
3.3.3.5 Disassembling of the high pressure filters at the main control valve blocks…………………………..1883
3.3.3.6 Assembling of the high pressure filters at the main control valve blocks……………………………..1886
3.3.3.7 Disassembling of the MRV at the main control valve blocks…………………………………………..1889
3.3.3.8 Assembling of the MRV at the main control valve blocks……………………………………………..1890
3.3.3.9 Disassembling of SRV on main control valve block…………………………………………………..1891
3.3.3.10 Assembling of SRV on main control valve blocks……………………………………………………1892
3.3.3.11 Disassembling of ACV-/SRV-block on main control valve blocks……………………………………….1893
3.3.3.12 Assembling of ACV-/SRV-block on main control valve blocks………………………………………….1894
3.3.4 Distributor Manifold…………………………………………………………………………………1896
3.3.4.1 Disassembling of throttle check valves at the distributor manifold…………………………………..1897
3.3.4.2 Assembling of throttle check valves at the distributor manifold……………………………………..1899
3.3.4.3 Disassembling of anti cavitation valves at the distributor manifold………………………………….1901
3.3.4.4 Assembling of anti cavitation valves at the distributor manifold…………………………………….1903
3.3.4.5 Disassembling of the distributor manifold…………………………………………………………1907
3.3.4.6 Assembling of the distributor manifold……………………………………………………………1910
3.4 Slew system………………………………………………………………………………………………1912
3.4.1 Slew gears………………………………………………………………………………………….1912
3.4.1.1 Disassembling of the slew gear…………………………………………………………………..1913
3.4.1.2 Assembling of the slew gear……………………………………………………………………..1916
3.4.2 Slew brake valve block……………………………………………………………………………….1920
3.4.2.1 Disassembling of the slew brake valve block……………………………………………………….1920
3.4.2.2 Assembling of the slew brake valve block………………………………………………………….1922
3.4.3 Hydraulic slew motors………………………………………………………………………………..1924
3.4.3.1 Disassembling of the slew motor………………………………………………………………….1924
3.4.3.2 Assembling of the slew motor…………………………………………………………………….1926
3.4.4 Slew parking brake…………………………………………………………………………………..1928
3.4.4.1 Disassembly of the slew parking brake of slew gear type 2063………………………………………..1929
3.4.4.2 Assembly of the slew parking brake of SLEW GEAR type 2063…………………………………………..1932
3.4.4.3 Disassembling of the slew parking brake of SLEW GEAR type 632770…………………………………….1935
3.4.4.4 Assembling of the slew parking brake of SLEW GEAR type 632770……………………………………….1939
3.4.5 Slew circle…………………………………………………………………………………………1942
3.4.5.1 Disassembling of the slew circle…………………………………………………………………1942
3.4.5.2 Assembling of the slew circle……………………………………………………………………1946
3.4.6 Slew circle lubrication pinion (dummy wheel)……………………………………………………………1947
3.4.6.1 Disassembling of the lubrication pinion assembly…………………………………………………..1948
3.4.6.2 Assembling of the lubrication pinion assembly……………………………………………………..1950
3.5 Operator’s cab……………………………………………………………………………………………1952
3.5.1 Disassembling of the operator’s cab……………………………………………………………………1953
3.5.2 Assembling of the operator’s cab………………………………………………………………………1957
3.5.3 Disassembling of the operator’s cab together with the cab support frame……………………………………1961
3.5.4 Assembling of the operator’s cab together with the cab support frame………………………………………1965
3.5.5 Cab-mounts………………………………………………………………………………………….1968
3.5.5.1 Disassembling of the cab-mounts………………………………………………………………….1968
3.5.5.2 Assembling of the cab-mounts…………………………………………………………………….1970
3.5.6 Front window………………………………………………………………………………………..1972
3.5.6.1 Disassembling of the front window………………………………………………………………..1972
3.5.6.2 Assembling of the front window…………………………………………………………………..1973
3.5.7 Operator’s seat……………………………………………………………………………………..1974
3.5.7.1 Disassembling of the operator’s seat……………………………………………………………..1974
3.5.7.2 Assembling of the operator’s seat………………………………………………………………..1975
3.6 Cab base…………………………………………………………………………………………………1976
3.6.1 Disassembling of the cab support frame…………………………………………………………………1977
3.6.2 Assembling of the cab support frame……………………………………………………………………1979
3.6.3 Disassembling of the cab base…………………………………………………………………………1981
3.6.4 Assembling of the cab base……………………………………………………………………………1984
3.7 Ladders and platforms……………………………………………………………………………………..1988
3.7.1 Hydraulic access Ladder………………………………………………………………………………1988
3.7.1.1 Disassembling of the hydraulic access ladder………………………………………………………1988
3.7.1.2 Assembling of the hydraulic access ladder…………………………………………………………1990
3.7.1.3 Disassembling of the access ladder cylinder……………………………………………………….1992
3.7.1.4 Assembling of the access ladder cylinder………………………………………………………….1994
3.7.2 Fuel tank step………………………………………………………………………………………1995
3.7.2.1 Disassembling of the fuel tank step………………………………………………………………1995
3.7.2.2 Assembling of the fuel tank step…………………………………………………………………1997
3.7.3 Access ladder platform……………………………………………………………………………….1998
3.7.3.1 Disassembling of the access ladder platform……………………………………………………….1998
3.7.3.2 Assembling of the access ladder platform………………………………………………………….2000
3.7.4 Emergency escape ladders……………………………………………………………………………..2002
3.7.4.1 Disassembling of the emergency escape ladder assembly at the cab base………………………………..2002
3.7.4.2 Assembling of the emergency escape ladder assembly at the cab base…………………………………..2003
3.7.4.3 Disassembling of the emergency escape ladder assembly at the machinery house………………………….2004
3.7.4.4 Assembling of the emergency escape ladder assembly at the machinery house…………………………….2005
3.8 Counterweight…………………………………………………………………………………………….2007
3.8.1 Disassembling of the counterweight…………………………………………………………………….2008
3.8.2 Assembling of the counterweight……………………………………………………………………….2011
3.9 Fuel tank………………………………………………………………………………………………..2016
3.9.1 General information regarding disassembling and assembling……………………………………………….2016
3.9.2 Disassembling of the fuel tank………………………………………………………………………..2018
3.9.3 Assembling of the fuel tank…………………………………………………………………………..2027
3.10 Superstructure Lifting……………………………………………………………………………………2038
3.10.1 Disassembling the superstructure from the undercarriage…………………………………………………2038
3.10.2 Assembling the superstructure onto the undercarriage……………………………………………………2041
4 Undercarriage………………………………………………………………………………………………….2045
4.1 Undercarriage overview…………………………………………………………………………………….2046
4.2 Travel system…………………………………………………………………………………………….2048
4.2.1 Crawler Track……………………………………………………………………………………….2048
4.2.1.1 Changing of the crawler track……………………………………………………………………2048
4.2.2 Sprocket assembly……………………………………………………………………………………2055
4.2.2.1 Disassembling of the sprocket assembly……………………………………………………………2055
4.2.2.2 Assembling of the sprocket assembly………………………………………………………………2060
4.2.3 Guide wheel assembly…………………………………………………………………………………2063
4.2.3.1 Disassembling of the guide wheel assembly…………………………………………………………2063
4.2.3.2 Assembling of the guide wheel assembly……………………………………………………………2066
4.2.4 Track tensioning accumulators…………………………………………………………………………2069
4.2.4.1 Disassembling of the low pressure accumulators…………………………………………………….2069
4.2.4.2 Assembling of the low pressure accumulators……………………………………………………….2071
4.2.4.3 Disassembling of the high pressure accumulators……………………………………………………2073
4.2.4.4 Assembling of the high pressure accumulators………………………………………………………2074
4.2.5 Track tensioning valve block………………………………………………………………………….2075
4.2.5.1 Disassembling of the track tensioning valve block………………………………………………….2075
4.2.5.2 Assembling of the track tensioning valve block…………………………………………………….2077
4.2.6 Track tensioning cylinders……………………………………………………………………………2078
4.2.6.1 Disassembling of the track tensioning cylinders……………………………………………………2078
4.2.6.2 Assembling of the track tensioning cylinders………………………………………………………2080
4.2.7 Replace the Hydraulic hoses of the track tensioning system……………………………………………….2083
4.2.7.1 Precursory work………………………………………………………………………………..2083
4.2.7.2 Replace the hydraulic hoses inside the undercarriage center body…………………………………….2085
4.2.7.3 Replace the hydraulic hose between undercarriage center body and crawler frame………………………..2085
4.2.7.4 Replace the hydraulic hoses inside the crawler frame……………………………………………….2087
4.2.7.5 Subsequent work………………………………………………………………………………..2087
4.2.8 Travel brake valve block (overspeed valve)……………………………………………………………..2088
4.2.8.1 Disassembling of the travel brake valve block……………………………………………………..2088
4.2.8.2 Assembling of the travel brake valve block………………………………………………………..2089
4.2.9 Travel motor………………………………………………………………………………………..2090
4.2.9.1 Disassembling of the travel motors……………………………………………………………….2090
4.2.9.2 Assembling of the travel motors………………………………………………………………….2092
4.2.10 Travel parking brake………………………………………………………………………………..2094
4.2.10.1 Disassembling of the travel parking brake of type 631053 and 2063…………………………………..2096
4.2.10.2 Assembling of the travel parking brake of type 631053 and type 2063…………………………………2100
4.2.11 Travel gearbox……………………………………………………………………………………..2105
4.2.11.1 Disassembling of the travel gearbox……………………………………………………………..2106
4.2.11.2 Assembling of the travel gearbox………………………………………………………………..2108
4.2.12 Carrier rollers…………………………………………………………………………………….2111
4.2.12.1 Disassembling of the carrier roller assembly……………………………………………………..2111
4.2.12.2 Assembling of the carrier roller assembly………………………………………………………..2113
4.2.13 Track rollers………………………………………………………………………………………2115
4.2.13.1 Disassembling of the track roller assembly……………………………………………………….2115
4.2.13.2 Assembling of the track roller assembly………………………………………………………….2117
4.2.14 Replace the hydraulic hoses of the traveling system…………………………………………………….2120
4.3 Undercarriage Center Body………………………………………………………………………………….2124
4.3.1 Disassembling of the undercarriage center body and the crawler carriers……………………………………2124
4.3.2 Assembling of the undercarriage center body and the crawler carriers………………………………………2129
4.3.2.1 Install crawler carrier mounting bolts……………………………………………………………2134
4.3.3 Rotary joint………………………………………………………………………………………..2135
4.3.3.1 Disassembling of the rotary joint………………………………………………………………..2135
4.3.3.2 Assembling of the rotary joint…………………………………………………………………..2138
5 Attachment…………………………………………………………………………………………………….2141
5.1 Attachment bearings at superstructure……………………………………………………………………….2142
5.1.1 Boom foot bearings with full floating pins……………………………………………………………..2142
5.1.1.1 Disassembling of the boom foot bearings…………………………………………………………..2143
5.1.1.2 Assembling of the boom foot bearings……………………………………………………………..2145
5.1.2 Boom cylinder foot bearings with full floating pins……………………………………………………..2148
5.1.2.1 Disassembling of the boom cylinder foot bearings – BHA arrangement…………………………………..2150
5.1.2.2 Assembling of the boom cylinder foot bearings – BHA arrangement……………………………………..2152
5.1.2.3 Disassembling of the boom cylinder foot bearings – FSA arrangement…………………………………..2155
5.1.2.4 Assembling of the boom cylinder foot bearings – FSA arrangement……………………………………..2157
5.2 Repair procedures…………………………………………………………………………………………2160
5.2.1 Replacement of bushings at the attachment………………………………………………………………2160
5.2.1.1 Removal of the bushings…………………………………………………………………………2160
5.2.1.2 Installation of the bushings…………………………………………………………………….2161
5.2.2 General installation instructions for attachment pins……………………………………………………2162
5.3 Backhoe (BHA)…………………………………………………………………………………………….2164
5.3.1 Overview……………………………………………………………………………………………2164
5.3.2 Pin Sealing bucket – Steering Rod – bucket link rod……………………………………………………..2166
5.3.3 Boom assembly……………………………………………………………………………………….2168
5.3.3.1 Disassembling of the boom……………………………………………………………………….2168
5.3.3.2 Assembling of the boom………………………………………………………………………….2170
5.3.3.3 Disassembling of the boom cylinders………………………………………………………………2172
5.3.3.4 Assembling of the boom cylinders…………………………………………………………………2176
5.3.4 Stick assembly………………………………………………………………………………………2181
5.3.4.1 Disassembling of the Stick………………………………………………………………………2181
5.3.4.2 Assembling of the Stick…………………………………………………………………………2186
5.3.4.3 Disassembling of the Stick Cylinders……………………………………………………………..2191
5.3.4.4 Assembling of the Stick cylinders………………………………………………………………..2196
5.3.5 Bucket and steering………………………………………………………………………………….2201
5.3.5.1 Disassembling of the bucket……………………………………………………………………..2201
5.3.5.2 Assembling of the bucket………………………………………………………………………..2205
5.3.5.3 Disassembling of the Bucket Cylinders…………………………………………………………….2208
5.3.5.4 Assembling of the Bucket Cylinders……………………………………………………………….2215
5.3.5.5 Disassembling of the bucket link rod……………………………………………………………..2222
5.3.5.6 Assembling of the bucket link rod………………………………………………………………..2225
5.3.5.7 Disassembling of the steering rods……………………………………………………………….2228
5.3.5.8 Assembling of the steering rods………………………………………………………………….2234
5.3.6 Hydraulic hoses at the backhoe attachment………………………………………………………………2238
5.3.6.1 Replace the boom arc hoses………………………………………………………………………2238
5.3.6.2 Replace the boom cylinder hoses………………………………………………………………….2242
5.3.6.3 Replace the stick cylinder hoses…………………………………………………………………2244
5.3.6.4 Replace the bucket cylinder hoses………………………………………………………………..2246
5.4 Front shovel (FSA)………………………………………………………………………………………..2248
5.4.1 Overview……………………………………………………………………………………………2248
5.4.2 Using the Cylinder Mounting Device for Front shovel attachments (PN 967 000 40)…………………………….2250
5.4.2.1 Designated usage……………………………………………………………………………….2251
5.4.2.2 Non-designated usage……………………………………………………………………………2251
5.4.3 Boom assembly……………………………………………………………………………………….2252
5.4.3.1 Disassembling of the boom……………………………………………………………………….2252
5.4.3.2 Assembling of the boom………………………………………………………………………….2254
5.4.3.3 Disassembling of the boom cylinders………………………………………………………………2256
5.4.3.4 Assembling of the boom cylinders…………………………………………………………………2260
5.4.4 Stick assembly………………………………………………………………………………………2266
5.4.4.1 Disassembling of the stick………………………………………………………………………2266
5.4.4.2 Assembling of the stick…………………………………………………………………………2271
5.4.4.3 Disassembling of the stick cylinders……………………………………………………………..2276
5.4.4.4 Assembling of the stick cylinders………………………………………………………………..2280
5.4.5 Bull clam bucket…………………………………………………………………………………….2284
5.4.5.1 Disassembling of the bull clam bucket…………………………………………………………….2284
5.4.5.2 Assembling of the bull clam bucket……………………………………………………………….2288
5.4.5.3 Disassembling of the bucket cylinders…………………………………………………………….2292
5.4.5.4 Assembling of the bucket cylinders……………………………………………………………….2298
5.4.5.5 Disassembling of the clam cylinders………………………………………………………………2304
5.4.5.6 Assembling of the clam cylinders…………………………………………………………………2309
5.4.6 Hydraulic hoses at the front shovel attachment………………………………………………………….2314
5.4.6.1 Replace the boom arc hoses………………………………………………………………………2314
5.4.6.2 Replace the boom cylinder hoses………………………………………………………………….2318
5.4.6.3 Replace the stick arc hoses……………………………………………………………………..2320
5.4.6.4 Replace the stick cylinder hoses…………………………………………………………………2322
5.4.6.5 Replace the bucket cylinder hoses………………………………………………………………..2324
5.4.6.6 Replace the clam cylinder hoses………………………………………………………………….2326
5.5 Ground engaging tools (GET)………………………………………………………………………………..2331
5.5.1 Replacement of the GET……………………………………………………………………………….2331
5.6 Cylinder bypass test………………………………………………………………………………………2332
6 Service Information…………………………………………………………………………………………….2333
6.1 Fluids and lubricants……………………………………………………………………………………..2334
6.2 Lifting Gears…………………………………………………………………………………………….2334
6.3 Safety hints for sling accessory……………………………………………………………………………2336
6.4 Weight tables…………………………………………………………………………………………….2337
6.4.1 Superstructure………………………………………………………………………………………2337
6.4.2 Undercarriage……………………………………………………………………………………….2339
6.4.3 Backhoe attachment (BHA)……………………………………………………………………………..2340
6.4.4 Face shovel attachment (FSA)………………………………………………………………………….2341
6.5 Torque charts according to KOMATSU company standard…………………………………………………………..2342
6.5.1 Metric standard thread……………………………………………………………………………….2342
6.5.2 Metric fine thread…………………………………………………………………………………..2343
6.5.3 Cummins motor torques – metric………………………………………………………………………..2344
6.5.4 Cummins motor torques – U.S. customary…………………………………………………………………2344
6.5.5 SAE-flange connections……………………………………………………………………………….2345
6.6 Blind plugs………………………………………………………………………………………………2346
6.6.1 Dummy plates for SAE–flanges………………………………………………………………………….2346
6.6.2 Classification of threads to the nominal width………………………………………………………….2348
6.6.3 Plugs and fittings according to DIN 2353……………………………………………………………….2349
6.7 Conversion table………………………………………………………………………………………….2350
6.7.1 Method of using the conversion table…………………………………………………………………..2350
6.7.2 Millimeter – inch & kilogram – pound…………………………………………………………………..2351
6.7.3 Liter – U.S. gallon & liter – U.K. gallon………………………………………………………………2352
6.7.4 Nm- ft.lb…………………………………………………………………………………………..2353
6.7.5 Bar – PSI – kPa – MPa………………………………………………………………………………..2354
6.7.6 Temperature…………………………………………………………………………………………2355
6.8 Tools……………………………………………………………………………………………………2356
6.8.1 Standard tool case…………………………………………………………………………………..2356
6.8.2 Used special tools (Overview)…………………………………………………………………………2358
6.9 Work instructions…………………………………………………………………………………………2361
6.9.1 Bleeding the track tensioning system…………………………………………………………………..2361
6.9.2 Hints for hydraulic hose installation………………………………………………………………….2363
6.9.3 Remove / install the crawler carrier…………………………………………………………………..2366
6.9.4 Repair procedure for the radiator assembly……………………………………………………………..2367
7 Parts & Service News……………………………………………………………………………………………2369
7.1 List of the PARTS AND SERVICE NEWS………………………………………………………………………….2370

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