Komatsu Hydraulic Mining Shovel PC7000E-6 Shop Manual – PDF DOWNLOAD

DESCRIPTION:

Komatsu Hydraulic Mining Shovel PC7000E-6 Shop Manual – PDF DOWNLOAD

SERIAL NUMBER 35003 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 PC7000E-6 Shop Manual – PDF DOWNLOAD

SHOP MANUAL PC7000E-6……………………………………………………………………………………………….. 1
00 FOREWORD & SAFETY………………………………………………………………………………………………… 3
1 Foreword……………………………………………………………………………………………………… 5
1.1 BEFORE READING THIS MANUAL………………………………………………………………………………… 6
1.1.1 CAS (Canadian Standards Association)………………………………………………………………….. 6
1.2 CONTENTS OF THIS BINDER…………………………………………………………………………………… 7
1.2.1 Contacting the Service………………………………………………………………………………. 7
1.2.2 Guarantee………………………………………………………………………………………….. 7
1.3 DIVISION OF THE BINDER……………………………………………………………………………………. 8
2 SAFETY……………………………………………………………………………………………………….. 13
TOC………………………………………………………………………………………………………… 9
2.1 SAFETY INFORMATION……………………………………………………………………………………….. 14
2.2 OVERVIEW………………………………………………………………………………………………… 15
2.2.1 NORMAL OPERATIONS…………………………………………………………………………………… 15
2.2.2 REGULAR MAINTENANCE…………………………………………………………………………………. 15
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR……………………………………………………………….. 15
2.2.4 ADDITIONAL SAFETY PRECAUTIONS………………………………………………………………………… 15
2.3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB…………………………………………………….. 16
2.3.1 SOUND……………………………………………………………………………………………… 16
2.3.2 VIBRATION………………………………………………………………………………………….. 16
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR……………………………………………………… 17
2.4.1 UNDERSTANDING THE MACHINE……………………………………………………………………………. 17
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR………………………………………………….. 17
2.4.2.1 ENSURING SAFE OPERATION………………………………………………………………………… 17
2.4.3 PREPARATIONS FOR SAFE OPERATION………………………………………………………………………. 17
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT……………………………………………………. 17
2.4.3.2 INSPECTING THE MACHINE…………………………………………………………………………. 17
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT………………………………………………… 18
2.4.3.4 KEEP MACHINE CLEAN…………………………………………………………………………….. 18
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT………………………………………………………… 18
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT………………………………………………………. 19
2.4.3.7 IF A PROBLEM IS FOUND………………………………………………………………………….. 19
2.4.4 FIRE PREVENTION…………………………………………………………………………………….. 19
2.4.4.1 PRECAUTIONS TO PREVENT FIRE…………………………………………………………………….. 19
2.4.4.2 ACTION IF FIRE OCCURS ON PC3000…………………………………………………………………. 20
2.4.4.3 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000……………………………………………. 21
2.4.4.4 EMERGENCY EXIT FROM OPERATOR’S CAB………………………………………………………………. 21
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…………………………………………………………. 22
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE…………………………………………. 22
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE………………………………………………………………… 22
2.4.5.3 NO PEOPLE ON THE ATTACHMENT…………………………………………………………………….. 22
2.4.5.4 WORKING IN HIGH PLACES…………………………………………………………………………. 22
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK……………………………………………………………….. 23
2.4.5.6 LEAVING THE MACHINE……………………………………………………………………………. 23
2.4.6 BURN PREVENTION…………………………………………………………………………………….. 23
2.4.6.1 Hot coolant…………………………………………………………………………………… 23
2.4.6.2 Hot oil………………………………………………………………………………………. 24
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…………………………………………………………………… 24
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………………………………………………………… 24
2.4.9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS…………………………………………………….. 25
2.4.9.1 UNAUTHORIZED MODIFICATION………………………………………………………………………. 25
2.4.9.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS……………………………………………………. 25
2.4.10 ELECTROMAGNETIC COMPATIBILITY (EMC)………………………………………………………………….. 25
2.4.11 PRECAUTIONS AT JOBSITE……………………………………………………………………………… 26
2.4.11.1 VISIBILITY FROM OPERATOR’S SEAT………………………………………………………………… 27
2.4.11.2 CAMERA SYSTEM WITH MONITORS……………………………………………………………………. 27
2.4.11.3 ENSURE GOOD VISIBILITY………………………………………………………………………… 27
2.4.11.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS………………………………………………………….. 27
2.4.11.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS………………………………………………………. 28
2.4.11.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES………………………………………………………….. 28
2.4.11.7 Lightning Strikes…………………………………………………………………………….. 29
2.4.11.8 WORKING ON LOOSE GROUND……………………………………………………………………….. 29
2.4.11.9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES……………………………………………………….. 30
2.4.11.10 VENTILATION OF ENCLOSED AREAS…………………………………………………………………. 31
2.4.12 STARTING motor…………………………………………………………………………………….. 32
2.4.12.1 WARNING TAG………………………………………………………………………………….. 32
2.4.12.2 CHECKS BEFORE STARTING motor…………………………………………………………………… 32
2.4.12.3 PRECAUTION WHEN STARTING motor…………………………………………………………………. 32
2.4.12.4 PRECAUTION IN COLD AREAS………………………………………………………………………. 33
2.4.13 OPERATION…………………………………………………………………………………………. 33
2.4.13.1 CHECKS BEFORE OPERATION……………………………………………………………………….. 33
2.4.13.2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE…………………………………………………. 34
2.4.13.3 PRECAUTIONS WHEN traveling…………………………………………………………………….. 35
2.4.13.4 TRAVELING ON SLOPES…………………………………………………………………………… 36
2.4.13.5 OPERATIONS ON SLOPES………………………………………………………………………….. 37
2.4.13.6 PROHIBITED OPERATIONS…………………………………………………………………………. 37
2.4.13.7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES…………………………………………………….. 38
2.4.13.8 PARKING THE MACHINE…………………………………………………………………………… 38
2.4.13.9 TRANSPORTATION……………………………………………………………………………….. 38
2.5 PRECAUTION FOR MAINTENANCE………………………………………………………………………………… 39
2.5.1 GENERAL PRECAUTIONS…………………………………………………………………………………. 39
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…………………………………… 40
2.5.1.2 STOP motor FOR MAINTENANCE……………………………………………………………………… 41
2.5.1.3 WARNING TAG…………………………………………………………………………………… 42
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY…………………………………………………………………… 43
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS………………………………………………………….. 43
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING……………………………………………. 44
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS………………………………………………………. 44
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT……………………………………………. 45
2.5.1.9 NOISE………………………………………………………………………………………… 45
2.5.1.10 WHEN USING A HAMMER…………………………………………………………………………… 45
2.5.1.11 PROPER TOOLS…………………………………………………………………………………. 46
2.5.1.12 ACCUMULATOR………………………………………………………………………………….. 46
2.5.1.13 PERSONNEL……………………………………………………………………………………. 46
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………………………………………………………….. 47
2.5.2.1 PRECAUTION WHEN WELDING………………………………………………………………………… 47
2.5.2.2 BATTERY HANDLING………………………………………………………………………………. 47
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID………………………………………………………………….. 48
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE……………………………………………………………… 49
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…………………………………………………………… 50
2.5.3.3 REPLACEMENT OF HOSE LINES………………………………………………………………………. 50
2.5.3.4 INSPECTION OF HOSE LINES……………………………………………………………………….. 50
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………………………………………………….. 51
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE……………………………………………………………………. 51
2.5.3.7 AIR CONDITIONING MAINTENANCE……………………………………………………………………. 51
2.5.3.8 COMPRESSED AIR………………………………………………………………………………… 52
2.5.3.9 WASTE MATERIALS……………………………………………………………………………….. 52
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS……………………………………………… 53
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM……………………………………………………………………. 53
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS………………………………………….. 53
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…………………………………………………………. 53
2.7 SPECIAL SAFETY EQUIPMENT………………………………………………………………………………….. 54
2.7.1 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB………………………………………………. 55
2.7.2 OBJECT HANDLING…………………………………………………………………………………….. 55
2.7.3 LIGHTING…………………………………………………………………………………………… 55
2.7.4 WARNING BEACON……………………………………………………………………………………… 55
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…………………………………………….. 55
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)……………………………………….. 55
2.7.5.2 INSTRUCTIONS FOR USE…………………………………………………………………………… 57
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL………………………………………………….. 59
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS……………….. 59
2.7.5.5 INSTRUCTIONS FOR USE…………………………………………………………………………… 61
2.8 HIGH VOLTAGE SAFETY INSTRUCTIONS FOR MACHINES WITH ELECTRIC MOTOR……………………………………………… 63
2.8.1 QUALIFICATION OF PERSONNEL…………………………………………………………………………… 63
2.8.2 ELECTRICAL TOOLS……………………………………………………………………………………. 63
2.8.3 GENERAL PREPARATION BEFORE WORKING ON ELECTRICAL EQUIPMENT………………………………………………. 64
2.8.4 CONNECTION OF PILOT LINE (GROUND CHECK WIRE)…………………………………………………………… 64
2.8.5 PREPARATION BEFORE WORKING ON THE CABLE DRUM…………………………………………………………… 64
2.8.6 PREPARATION BEFORE WORKING ON THE CABLE GUIDE………………………………………………………….. 65
2.8.7 MODIFICATION OF THE ELECTRICAL SYSTEM…………………………………………………………………. 65
2.8.8 FIRE………………………………………………………………………………………………. 65
2.8.9 GENERAL INSTRUCTIONS………………………………………………………………………………… 66
2.8.10 GROUNDING PROCEDURE FOR THE HIGH VOLTAGE SYSTEM……………………………………………………….. 66
2.8.10.1 INTRODUCTION…………………………………………………………………………………. 66
2.8.10.2 GENERAL PREPARATION BEFORE WORKING ON ELECTRICAL EQUIPMENT………………………………………… 67
2.8.10.3 WORKING EQUIPMENT & PERSONAL PROTECTION…………………………………………………………. 67
2.8.10.4 SPECIAL TOOLS REQUIRED………………………………………………………………………… 67
2.8.10.5 PERSONAL PROTECTION EQUIPMENT (PPE)…………………………………………………………….. 68
2.8.10.6 PREPARING THE MACHINE FOR HIGH VOLTAGE MAINTENANCE……………………………………………….. 68
2.8.10.7 POWER DISCONNECTION AND EARTHING……………………………………………………………….. 69
2.8.10.8 THE THREE STEPS To DEACTIVATE POWER…………………………………………………………….. 70
2.8.10.9 EARTHING PROCEDURES IN THE HV CABINET…………………………………………………………… 72
2.8.10.10 THREE STEPS TO RECONNECTING THE POWER AFTER MAINTENANCE WORK……………………………………… 80
2.8.10.11 Step 1, inserting the key…………………………………………………………………….. 80
2.8.10.12 Step 2, Switching earthing off………………………………………………………………… 80
2.8.10.13 Step 3, Switching load on…………………………………………………………………….. 81
01 SPECIFICATION……………………………………………………………………………………………………. 83
PC7000E-6………………………………………………………………………………………………………. 84
10 STRUCTURE & FUNCTION……………………………………………………………………………………………… 93
TOC……………………………………………………………………………………………………………. 95
1 Introduction………………………………………………………………………………………………….. 109
1.1 Foreword………………………………………………………………………………………………… 110
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels………………… 111
1.3 Explanation of abbreviations………………………………………………………………………………. 112
1.4 Diagrams and illustrations in this manual…………………………………………………………………… 113
2 Specifications………………………………………………………………………………………………… 115
2.1 Lifting Gears……………………………………………………………………………………………. 116
2.2 Safety hints for sling accessory…………………………………………………………………………… 118
2.3 Standard Tightening Torque Chart…………………………………………………………………………… 119
2.4 Conversion Table…………………………………………………………………………………………. 120
2.5 Blind plugs……………………………………………………………………………………………… 126
2.6 Classification of threads to the nominal width………………………………………………………………. 128
2.7 Plugs and fittings according to ISO 8434-1 / DIN 2353………………………………………………………… 129
3 Main assembly groups…………………………………………………………………………………………… 131
3.1 General layout…………………………………………………………………………………………… 132
3.2 Superstructure…………………………………………………………………………………………… 134
3.2.1 Superstructure side view…………………………………………………………………………….. 134
3.2.2 Superstructure top view……………………………………………………………………………… 136
3.3 Machinery house………………………………………………………………………………………….. 138
3.4 Hydraulic oil tank……………………………………………………………………………………….. 140
3.5 Hydraulic oil cooler……………………………………………………………………………………… 142
3.6 High voltage switch cabinet……………………………………………………………………………….. 144
3.7 Cab support……………………………………………………………………………………………… 150
3.7.1 View into cab base………………………………………………………………………………….. 156
3.8 Operator’s cab…………………………………………………………………………………………… 158
3.9 Main control blocks (FSA)…………………………………………………………………………………. 160
3.10 Slew machinery………………………………………………………………………………………….. 162
3.10.1 Slew gear type 2063 / Slew motor type A6VLM…………………………………………………………… 162
3.10.2 Slew gear type 632770 / Slew motor type A6VLM…………………………………………………………. 164
3.11 Slip ring unit & Rotary joint…………………………………………………………………………….. 166
3.11.1 Slip Ring Unit in Detail……………………………………………………………………………. 168
3.12 Undercarriage…………………………………………………………………………………………… 170
3.13 Slew ring………………………………………………………………………………………………. 172
3.14 Attachment……………………………………………………………………………………………… 174
3.14.1 Front Shovel Attachment (FSA)……………………………………………………………………….. 174
3.14.2 Back hoe Attachment (BHA)…………………………………………………………………………… 176
3.15 Counterweight…………………………………………………………………………………………… 178
3.16 PPC safety circuit………………………………………………………………………………………. 180
4 Drive………………………………………………………………………………………………………… 183
4.1 Electric drive – Safety and operation instruction documents…………………………………………………… 184
4.2 Prime drive assembly……………………………………………………………………………………… 186
4.3 Electric motor…………………………………………………………………………………………… 188
4.3.1 Attaching parts…………………………………………………………………………………….. 188
4.3.2 Grease equipment for motor bearings…………………………………………………………………… 190
4.3.3 Monitoring the motor bearing temperature………………………………………………………………. 192
4.3.4 Monitoring the motor winding temperature………………………………………………………………. 194
4.3.5 Temperature signal conversion………………………………………………………………………… 196
4.3.6 Anti-condensation heater…………………………………………………………………………….. 197
4.3.7 Ventilation………………………………………………………………………………………… 198
4.3.8 Checking the bearing condition……………………………………………………………………….. 199
4.4 Capacitor mounting location……………………………………………………………………………….. 200
4.4.1 Capacitor assembly………………………………………………………………………………….. 201
4.5 Initial Start-up procedure………………………………………………………………………………… 204
4.5.1 Main supply cable…………………………………………………………………………………… 205
4.5.2 Machine configuration (via CoDeSys)…………………………………………………………………… 206
4.5.3 Motor protection relays (type Multilin 369)……………………………………………………………. 210
4.5.4 Motor alignment…………………………………………………………………………………….. 212
4.5.5 Motor rotation direction…………………………………………………………………………….. 214
4.5.6 Starting & Re-starting the electric motor……………………………………………………………… 214
4.5.7 Supervision during the first motor running period………………………………………………………. 215
4.6 Flexible coupling………………………………………………………………………………………… 216
4.6.1 Description of the flexible coupling………………………………………………………………….. 218
4.6.2 Coupling inspection…………………………………………………………………………………. 219
4.6.2.1 Work to be performed during visual inspection…………………………………………………….. 219
4.6.3 Coupling replacement information……………………………………………………………………… 219
4.6.4 Coupling run-out……………………………………………………………………………………. 219
4.7 Pump distributor gearbox (PTO)…………………………………………………………………………….. 220
4.7.1 PTO oil filling, oil level, and ventilation……………………………………………………………. 222
4.7.2 Pump spline lubrication……………………………………………………………………………… 224
4.7.2.1 Oil level in the main pump & gear oil pump drive shaft housing……………………………………… 225
4.7.3 PTO lubrication and cooling………………………………………………………………………….. 226
4.7.3.1 Hydraulic components and schematic of cooling circuit-1……………………………………………. 226
4.7.3.2 Schematic overview – PTO gear oil cooling circuit-1……………………………………………….. 228
4.7.3.3 Checks and adjustments…………………………………………………………………………. 230
4.8 Hydraulic pumps – location, drive speed and flow rates……………………………………………………….. 232
5 Hydraulic oil tank…………………………………………………………………………………………….. 237
5.1 General layout…………………………………………………………………………………………… 238
5.2 Hydraulic oil tank, location of the electric equipment……………………………………………………….. 240
5.3 Suction oil tank with strainers……………………………………………………………………………. 242
5.4 Return oil collector pipe with strainer…………………………………………………………………….. 244
5.5 Back pressure valve………………………………………………………………………………………. 246
5.6 Transfer pump……………………………………………………………………………………………. 248
5.7 Return & leak oil filter………………………………………………………………………………….. 250
5.8 Breather filter………………………………………………………………………………………….. 252
6 Hydraulic oil cooling………………………………………………………………………………………….. 255
6.1 Overall view of the hydraulic oil cooling…………………………………………………………………… 256
6.2 Function of the hydraulic oil cooling circuit……………………………………………………………….. 258
6.3 Adjustment of the back pressure valve………………………………………………………………………. 260
6.4 Stepless cooler fan RPM control……………………………………………………………………………. 262
6.4.1 Pressure limiting valves…………………………………………………………………………….. 264
6.4.2 Components of the fan drive circuits………………………………………………………………….. 266
6.4.3 Fan pump type HPV190………………………………………………………………………………… 268
6.5 Oil cooler fan speed testing/adjustment…………………………………………………………………….. 270
6.5.1 Testing & readjustment procedure……………………………………………………………………… 272
6.5.2 Basic adjustment procedure…………………………………………………………………………… 273
6.6 OC fan resonance speed adjustment………………………………………………………………………….. 274
6.6.1 Hydraulic oil temperature charts……………………………………………………………………… 276
7 Controlling…………………………………………………………………………………………………… 277
7.1 General layout…………………………………………………………………………………………… 278
7.2 Control and filter panels – location of components…………………………………………………………… 280
7.2.1 Control and filter panel motor-1 (rear)……………………………………………………………….. 280
7.2.2 Valve cartridge block motor-1 (rear)………………………………………………………………….. 282
7.2.3 Control and filter panel motor-2 (front)………………………………………………………………. 284
7.3 Pilot pressure supply and adjustments………………………………………………………………………. 286
7.3.1 Pilot pressure control (PPC) circuit………………………………………………………………….. 286
7.3.2 Pilot pressure operating the main block spools…………………………………………………………. 288
7.3.3 Checks and adjustment of pilot pressure……………………………………………………………….. 290
7.3.4 Remote control valves arrangement…………………………………………………………………….. 292
7.4 Function of the electro hydraulic control system…………………………………………………………….. 294
7.4.1 Illustration of the joystick signal flow (example)……………………………………………………… 296
7.5 Hand lever (joystick) control……………………………………………………………………………… 298
7.5.1 Voltage supply of hand lever 20S020…………………………………………………………………… 299
7.5.2 Direction signal course from hand lever to controllers………………………………………………….. 300
7.5.3 Double ratiometric* output diagram……………………………………………………………………. 301
7.6 Foot pedal control……………………………………………………………………………………….. 302
7.6.1 Voltage supply of foot lever 20S021a………………………………………………………………….. 304
7.6.2 Direction signal course from foot pedal to controllers………………………………………………….. 305
7.6.3 Double ratiometric* output diagram for 2 direction pedal………………………………………………… 306
7.6.4 Single ratiometric* output diagram for 1 direction pedal………………………………………………… 307
7.7 Hand lever & foot pedal monitoring…………………………………………………………………………. 308
7.7.1 Lever monitoring screens (example)……………………………………………………………………. 310
7.7.2 Solenoid valve monitoring screen (example)…………………………………………………………….. 312
7.8 Valve solenoid adjustment…………………………………………………………………………………. 314
7.8.1 Overview sol min/max current & adjustment range………………………………………………………… 315
7.9 ACCEL & DECEL time adjustment……………………………………………………………………………… 316
7.9.1 Accel & Decel times…………………………………………………………………………………. 316
8 Components……………………………………………………………………………………………………. 319
8.1 Main control blocks and high pressure screens (FSA)………………………………………………………….. 320
8.2 Main control blocks with valves and HP screens (FSA)…………………………………………………………. 322
8.3 Main control blocks with valves and HP screens (BHA)…………………………………………………………. 324
8.4 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA)……………………………. 326
8.5 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA)……………………………. 328
8.6 Restrictor block with secondary relief valve………………………………………………………………… 330
8.7 Anti-cavitation valve (ACV) block………………………………………………………………………….. 332
8.7.1 Single ACV block on the manifold……………………………………………………………………… 332
8.7.2 Double ACV block on the manifold……………………………………………………………………… 334
8.8 Remote control valves…………………………………………………………………………………….. 336
8.9 4/3 Directional solenoid valves……………………………………………………………………………. 338
8.10 Proportional solenoid valves……………………………………………………………………………… 340
8.11 High-pressure screen…………………………………………………………………………………….. 342
8.12 Control blocks and valves………………………………………………………………………………… 344
8.12.1 Main control blocks I, II, III (4 spool blocks)……………………………………………………….. 344
8.12.1.1 Spin lock for valve blocks (ND52)………………………………………………………………. 345
8.12.2 Hydraulic diagram of a 4-spool valve block……………………………………………………………. 346
8.12.3 Spool types……………………………………………………………………………………….. 347
8.12.4 Spool positions (control block)……………………………………………………………………… 350
8.12.5 MRV, SRV, and ACV………………………………………………………………………………….. 352
8.12.6 Load holding valve…………………………………………………………………………………. 354
8.12.7 Main control block IV (slew)………………………………………………………………………… 356
8.13 Travel brake valve………………………………………………………………………………………. 358
8.14 Pressure reducing valve………………………………………………………………………………….. 360
8.15 4/2 Directional valves…………………………………………………………………………………… 362
8.16 Pressure double stage valve………………………………………………………………………………. 364
8.17 Hydraulic cylinder………………………………………………………………………………………. 366
8.17.1 Hydraulic cylinder – Chesterton® 11KE sealing…………………………………………………………. 366
8.17.2 Cylinder data markings……………………………………………………………………………… 369
9 Main hydraulic pumps, pump regulation, valve control & monitoring system…………………………………………….. 371
9.1 General…………………………………………………………………………………………………. 372
9.1.1 Pump data………………………………………………………………………………………….. 374
9.2 Main pumps………………………………………………………………………………………………. 378
9.2.1 Hydraulic pump type HPV375+375……………………………………………………………………….. 378
9.2.1.1 Main pump sectional drawings……………………………………………………………………. 380
9.2.2 Servo valve………………………………………………………………………………………… 382
9.2.2.1 VC valve  servo piston………………………………………………………………………… 383
9.2.3 EPC valve………………………………………………………………………………………….. 388
9.3 Electronic pump regulation system………………………………………………………………………….. 390
9.3.1 Cut-off function……………………………………………………………………………………. 392
9.3.2 Slew control……………………………………………………………………………………….. 393
9.3.3 Temperature control…………………………………………………………………………………. 393
9.3.4 Diagnostics and monitoring…………………………………………………………………………… 393
9.3.5 Hydraulic oil temperature charts……………………………………………………………………… 394
9.3.6 PTO gear oil temperature charts………………………………………………………………………. 394
9.4 Pump & valve controllers………………………………………………………………………………….. 396
9.5 Multimonitor…………………………………………………………………………………………….. 398
9.5.1 Service menu screen…………………………………………………………………………………. 401
9.6 Service menu – 01 Monitoring………………………………………………………………………………. 401
9.6.1 Monitoring PUMP 1 controller…………………………………………………………………………. 402
9.6.2 Monitoring PUMP 2 controller…………………………………………………………………………. 403
9.6.3 Monitoring VALVE 0 controller………………………………………………………………………… 404
9.6.4 Monitoring VALVE 1 controller………………………………………………………………………… 406
9.6.5 Monitoring VALVE 2 controller………………………………………………………………………… 407
9.6.6 Monitoring all controllers…………………………………………………………………………… 407
9.7 Using Multimonitor functions for monitoring…………………………………………………………………. 408
9.7.1 Hold function………………………………………………………………………………………. 408
9.8 Service menu – 02 Abnormality Record……………………………………………………………………….. 409
9.8.1 To delete any failure record from the display………………………………………………………….. 410
9.8.2 Troubleshooting procedures…………………………………………………………………………… 410
9.8.3 Failure codes for pump & valve controllers & system connections………………………………………….. 411
9.9 Service menu – 03 Default…………………………………………………………………………………. 419
9.10 Service menu – 04 Adjustment……………………………………………………………………………… 420
9.10.1 Adjustments for PUMP 1 controller……………………………………………………………………. 420
9.10.2 Adjustments for PUMP 2 controller……………………………………………………………………. 422
9.10.3 Adjustments for VALVE 0 controller…………………………………………………………………… 424
9.10.4 Adjustments for VALVE 2 controller…………………………………………………………………… 425
9.10.5 Details on the adjustable parameters…………………………………………………………………. 426
9.10.5.1 PUMP 1 controller…………………………………………………………………………….. 426
9.10.5.2 PUMP 2 controller…………………………………………………………………………….. 428
9.10.5.3 VALVE0 controller…………………………………………………………………………….. 429
9.10.5.4 VALVE 1 & 2 controller………………………………………………………………………… 432
9.10.6 Description of the Primary P-Factor………………………………………………………………….. 433
9.10.7 Pump1…6F/R Solenoid Min. Current Adjustment…………………………………………………………. 434
9.10.8 Pump1…6F/R Solenoid Max. Current Adjustment…………………………………………………………. 435
9.11 Accel & Decel time adjustment…………………………………………………………………………….. 436
9.11.1 Accel & Decel times………………………………………………………………………………… 436
9.12 Service menu – 05 Controller Setting………………………………………………………………………. 438
9.13 Controller replacement procedure………………………………………………………………………….. 438
9.13.1 Controller Setting → Wiring Input Check………………………………………………………………. 438
9.13.2 Controller Setting → Memory…………………………………………………………………………. 442
9.13.3 Confirmation………………………………………………………………………………………. 444
9.14 Service menu – 06 Option Setting………………………………………………………………………….. 445
9.15 Service menu – 07 Display Setup…………………………………………………………………………… 446
9.16 Checks and adjustments…………………………………………………………………………………… 448
9.16.1 Motor power check………………………………………………………………………………….. 448
9.16.2 Cut-off function check……………………………………………………………………………… 452
9.16.2.1 Cut-off for clam close (FSA only)………………………………………………………………. 453
9.17 Electronic load limiting control………………………………………………………………………….. 454
9.17.1 Load limiting control input signals at PUMP1/2 controllers……………………………………………… 455
9.17.2 Load limiting control output signals from PUMP1 controller to main pumps 1…3……………………………. 456
9.17.3 Signal rectifier module (12T431)…………………………………………………………………….. 458
9.17.4 Checks and adjustment of 12T431……………………………………………………………………… 460
9.17.4.1 Testing the signal rectifier 12T431 for voltage………………………………………………….. 461
9.17.4.2 Testing the signal rectifier 12T431 for current………………………………………………….. 461
10 Operating hydraulics………………………………………………………………………………………….. 463
10.1 General………………………………………………………………………………………………… 464
10.1.1 Allocation of pumps and main valve blocks…………………………………………………………….. 466
10.2 Spool functions (FSA)……………………………………………………………………………………. 468
10.2.1 Floating function for boom and stick cylinders………………………………………………………… 468
10.2.2 Spool functions (BHA)………………………………………………………………………………. 470
10.3 Hydraulics for the attachment cylinders……………………………………………………………………. 472
10.3.1 Electric / hydraulic flowchart “Boom UP” (FSA)………………………………………………………… 472
10.3.2 Electric / hydraulic flowchart “boom up” (BHA)………………………………………………………… 474
10.3.3 Electric / hydraulic flowchart “boom down” (FSA), single movement and Auto-float ON……………………….. 476
10.3.4 Electric / hydraulic flowchart “boom down” (FSA), Auto-float OFF – button 20S095 pressed and single movement…. 478
10.3.5 Electric / hydraulic flowchart “Boom down” (BHA)………………………………………………………. 480
10.3.6 Electric / hydraulic flowchart “Stick out” (FSA)………………………………………………………. 482
10.3.7 Electric / hydraulic flowchart “Stick out” (BHA)………………………………………………………. 484
10.3.8 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float ON and single movement………………………… 486
10.3.9 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float OFF – 20S098 pressed & single movement………….. 488
10.3.10 Electric / hydraulic flowchart “Stick in” (BHA)………………………………………………………. 490
10.3.11 Electric / hydraulic flowchart “Bucket fill” (FSA)……………………………………………………. 492
10.3.12 Electric / hydraulic flowchart “Bucket fill” (BHA)……………………………………………………. 494
10.3.13 Electric / hydraulic flowchart “Bucket dump” (FSA)……………………………………………………. 496
10.3.14 Electric / hydraulic flowchart “Bucket dump” (BHA)……………………………………………………. 498
10.3.15 Electric / hydraulic flowchart “Clam open” (FSA)……………………………………………………… 500
10.3.16 Electric / hydraulic flowchart “Clam close” (FSA)…………………………………………………….. 502
10.3.17 Checks and adjustments of the main relief valve (MRV)…………………………………………………. 504
10.3.18 Checks and adjustments of the secondary relief valves (SRV)……………………………………………. 506
10.3.18.1 Boom cylinders, piston side (BHA & FSA), boom up………………………………………………… 506
10.3.18.2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down……………………………………………. 510
10.3.18.3 Stick cylinders, piston side (FSA), stick out…………………………………………………… 514
10.3.18.4 Stick cylinders, piston side (BHA), stick in……………………………………………………. 518
10.3.18.5 Stick cylinders, piston rod side (FSA), stick in………………………………………………… 522
10.3.18.6 Stick cylinders, piston rod side (BHA), stick out……………………………………………….. 526
10.3.18.7 Bucket cylinders, piston side (FSA), bucket fill………………………………………………… 530
10.3.18.8 Bucket cylinders, piston side (BHA), bucket fill………………………………………………… 534
10.3.18.9 Bucket cylinders, piston rod side (FSA), bucket dump…………………………………………….. 538
10.3.18.10 Bucket cylinders, piston rod side (BHA), bucket dump……………………………………………. 542
10.3.18.11 Clam cylinders, piston rod side (FSA), clam open……………………………………………….. 546
10.3.18.12 Clam cylinders, piston side (FSA), clam close………………………………………………….. 550
10.3.19 Checks and adjustments of cycle times……………………………………………………………….. 554
10.3.19.1 Checks and adjustments of boom lowering speed (FSA)……………………………………………… 554
10.3.19.2 Checks and adjustments of boom lowering speed (BHA)……………………………………………… 558
10.3.19.3 Checks and adjustments of stick retract speed (FSA)……………………………………………… 562
10.3.19.4 Checks and adjustments of stick retract speed (BHA)……………………………………………… 566
10.3.19.5 Checks and adjustments of bucket dump speed (FSA)……………………………………………….. 570
10.3.19.6 Checks and adjustments of bucket dump speed (BHA)……………………………………………….. 574
10.3.19.7 Checks and adjustments of bucket curl speed (BHA)……………………………………………….. 578
10.3.19.8 Checks and adjustments of clam close speed (FSA)………………………………………………… 582
10.4 Hydraulics for the slew circuit…………………………………………………………………………… 584
10.4.1 Slew circuit with variable slew motors……………………………………………………………….. 584
10.4.2 Slew motor (variable displacement)…………………………………………………………………… 588
10.4.2.1 Hydraulic slew motor – displacement control……………………………………………………… 590
10.4.3 Slew gearbox type 2063……………………………………………………………………………… 592
10.4.4 Slew gearbox type 632770……………………………………………………………………………. 594
10.4.5 Slew parking brake (on slew gear type 2063)…………………………………………………………… 596
10.4.6 Slew parking brake (on slew gear type 632770)…………………………………………………………. 598
10.4.7 Slew brake valve…………………………………………………………………………………… 600
10.4.8 Flushing circuit…………………………………………………………………………………… 604
10.4.9 Electric / hydraulic flowchart “Slew left” FSA………………………………………………………… 606
10.4.10 Electric / hydraulic flowchart “Slew left” BHA……………………………………………………….. 608
10.4.11 Electric / hydraulic flowchart “Slew right” FSA………………………………………………………. 610
10.4.12 Electric / hydraulic flowchart “Slew right” BHA………………………………………………………. 612
10.4.13 Checks and adjustments for the slew circuit………………………………………………………….. 614
10.4.13.1 Pressure checks & adjustments – double stage valve (DSV)…………………………………………. 615
10.4.13.2 Checks & adjustments – brake pilot pressure…………………………………………………….. 617
10.4.13.3 Checks & adjustments – slew speed……………………………………………………………… 619
10.4.14 Function check for the hydraulic slew brake………………………………………………………….. 620
10.4.15 Function check for the slew parking brake……………………………………………………………. 622
10.4.15.1 Parking brake release pressure check…………………………………………………………… 622
10.4.15.2 Function check of relays 56K250a & b…………………………………………………………… 623
10.5 Hydraulics for the travel circuit…………………………………………………………………………. 624
10.5.1 Travel circuit…………………………………………………………………………………….. 624
10.5.2 Travel motor………………………………………………………………………………………. 628
10.5.3 Rotary joint………………………………………………………………………………………. 630
10.5.4 Travel gearbox…………………………………………………………………………………….. 632
10.5.4.1 Travel gearbox Type 2063………………………………………………………………………. 632
10.5.4.2 Travel gearbox type 631053…………………………………………………………………….. 634
10.5.5 Travel parking brake……………………………………………………………………………….. 636
10.5.5.1 Travel parking brake on travel gear type 2063……………………………………………………. 636
10.5.5.2 Travel parking brake on travel gear type 631053………………………………………………….. 637
10.5.5.3 Travel brake valve……………………………………………………………………………. 638
10.5.6 Electric / hydraulic flowchart “travel forward”……………………………………………………….. 640
10.5.7 Electric / hydraulic flowchart “travel backwards”……………………………………………………… 642
10.5.8 Checks and adjustments……………………………………………………………………………… 644
10.5.8.1 Checks and adjustments for the travel circuit……………………………………………………. 644
10.5.8.2 Function check for the travel parking brake……………………………………………………… 647
11 Hydraulic track tensioning system………………………………………………………………………………. 649
11.1 General………………………………………………………………………………………………… 650
11.2 Functional description…………………………………………………………………………………… 652
11.2.1 Hydraulic schematic for track tensioning……………………………………………………………… 653
11.3 Double stage valve………………………………………………………………………………………. 654
11.4 Tensioning cylinder……………………………………………………………………………………… 656
11.5 Adjustments / checks…………………………………………………………………………………….. 658
12 Stairway, hydraulically operated……………………………………………………………………………….. 661
12.1 Overview……………………………………………………………………………………………….. 662
12.2 Function of the hydraulically operated stairway…………………………………………………………….. 664
12.3 Adjustments / checks…………………………………………………………………………………….. 670
13 Central refilling system………………………………………………………………………………………. 673
13.1 Central refilling equipment………………………………………………………………………………. 674
13.2 Central refilling system overview…………………………………………………………………………. 676
14 Hints for reading the hydraulic diagram…………………………………………………………………………. 679
14.1 General………………………………………………………………………………………………… 680
14.2 Hydraulic symbols……………………………………………………………………………………….. 682
14.2.1 Lines, unions……………………………………………………………………………………… 683
14.2.2 Components, valves…………………………………………………………………………………. 685
14.2.3 Sensors…………………………………………………………………………………………… 685
14.2.4 Valves, valve components……………………………………………………………………………. 686
14.2.5 Pump, motor, cylinder………………………………………………………………………………. 690
15 Hints for reading the electric Wiring Diagram……………………………………………………………………. 695
15.1 General………………………………………………………………………………………………… 696
15.2 Reference code of the electrical components………………………………………………………………… 697
15.2.1 Area code…………………………………………………………………………………………. 697
15.2.2 Component identifying letter………………………………………………………………………… 698
15.3 Graphical symbols……………………………………………………………………………………….. 699
15.4 Concept of the Wiring Diagram…………………………………………………………………………….. 703
15.4.1 Cover page of the Komatsu W/D……………………………………………………………………….. 703
15.4.2 Example 1 from the schematics in the W/D……………………………………………………………… 705
15.4.3 Example 2 from the schematics in the W/D……………………………………………………………… 707
15.4.4 Table of contents in the W/D (page 1 of 2)……………………………………………………………. 709
15.4.5 Location list……………………………………………………………………………………… 711
15.4.6 Cross reference list for electr. components in the W/D…………………………………………………. 712
15.4.7 Cross reference list for terminals in the W/D…………………………………………………………. 714
15.4.8 Cross reference list for connectors in the W/D………………………………………………………… 716
15.4.9 Cross reference list for terminal boards in the W/D……………………………………………………. 718
15.4.10 Connection table………………………………………………………………………………….. 720
15.5 Cable and connector marking………………………………………………………………………………. 722
15.6 Cable color identification……………………………………………………………………………….. 724
16 KOMTRAX Plus & MTC control system………………………………………………………………………………. 725
16.1 General………………………………………………………………………………………………… 726
16.1.1 CAN overview 1…………………………………………………………………………………….. 726
16.1.2 CAN overview 2…………………………………………………………………………………….. 727
16.1.3 Description……………………………………………………………………………………….. 728
16.2 Specifications for operators……………………………………………………………………………… 730
16.2.1 Opening screen…………………………………………………………………………………….. 731
16.2.2 Main gauge screens 1 to 3…………………………………………………………………………… 732
16.2.3 Energy consumption screen…………………………………………………………………………… 736
16.2.4 Failure messages for the operator……………………………………………………………………. 738
16.2.5 Main gauge screens – Changing of Time / SMR / Date…………………………………………………….. 740
16.2.6 Maintenance monitor………………………………………………………………………………… 742
16.2.7 Settings for operator………………………………………………………………………………. 744
16.2.8 Automatic messages…………………………………………………………………………………. 750
16.3 Table of all provided messages……………………………………………………………………………. 752
16.3.1 Table of Error Codes & messages……………………………………………………………………… 753
16.3.2 Table of available Instruction Messages………………………………………………………………. 759
16.4 Flow charts (1…4) of KOMTRAX Plus main screens……………………………………………………………. 762
16.5 KOMTRAX Plus service level……………………………………………………………………………….. 766
16.5.1 Explanation of the button symbols (Service Level)……………………………………………………… 768
16.5.2 Service Menu Select Screen………………………………………………………………………….. 769
16.5.3 Real Time Menu Select Screen………………………………………………………………………… 770
16.5.3.1 Real Time Menu, option: 01 Motor 1……………………………………………………………… 771
16.5.3.2 Real Time Menu, option: 02 Motor 2……………………………………………………………… 772
16.5.3.3 Real Time Menu, option: 03 PTO 1……………………………………………………………….. 772
16.5.3.4 Real Time Menu, option: 04 PTO 2……………………………………………………………….. 772
16.5.3.5 Real Time Menu, option: 05 Hydraulic……………………………………………………………. 773
16.5.3.6 Real Time Menu, option: 06 Slew………………………………………………………………… 774
16.5.3.7 Real Time Menu, option: 07 Electrical Equipment………………………………………………….. 775
16.5.3.8 Real Time Menu, option: 08 Emergency Stop……………………………………………………….. 776
16.5.3.9 Real Time Menu, option: 09 Heater………………………………………………………………. 777
16.5.3.10 Real Time Menu, option: 10 Manual Switch……………………………………………………….. 778
16.5.3.11 Real Time Menu, option: 11 Central Lube System 1………………………………………………… 779
16.5.3.12 Real Time Menu, option: 12 Slew Ring Gear Lube System……………………………………………. 780
16.5.3.13 Real Time Menu, option: 13 Central Lube System 2………………………………………………… 781
16.5.3.14 Real Time Menu, option: 14 Cable drum………………………………………………………….. 782
16.5.3.15 Real Time Menu, option: 15 Windscreen Wiper…………………………………………………….. 783
16.5.3.16 Real Time Menu, option: 16 Ladder (stairway)……………………………………………………. 784
16.5.3.17 Real Time Menu, option: 17 Service Arm…………………………………………………………. 785
16.5.3.18 Real Time Menu, option: 18 Pilot Control……………………………………………………….. 786
16.5.3.19 Real Time Menu, option: 19 Other Items…………………………………………………………. 787
16.5.3.20 Real Time Menu, option: 20 Output Signals………………………………………………………. 788
16.5.3.21 Output signals with deactivated MTC evaluation………………………………………………….. 791
16.5.4 PM-Clinic…………………………………………………………………………………………. 792
16.5.4.1 General……………………………………………………………………………………… 792
16.5.4.2 Power Check………………………………………………………………………………….. 793
16.5.5 Serial/GCC no. setting……………………………………………………………………………… 794
16.5.6 Memory Clear………………………………………………………………………………………. 795
16.5.6.1 Input Memory Clear ID…………………………………………………………………………. 795
16.5.6.2 Memory Clear screen…………………………………………………………………………… 796
16.5.7 Failure History……………………………………………………………………………………. 797
16.5.8 Maintenance Monitor………………………………………………………………………………… 798
16.5.9 Snapshot………………………………………………………………………………………….. 799
16.5.10 Setting………………………………………………………………………………………….. 800
16.5.10.1 Central Lubrication System (CLS 1), screen 1/12…………………………………………………. 800
16.5.10.2 Slew ring gear Lubrication System (SLS), screen 2/12…………………………………………….. 801
16.5.10.3 Central Lubrication System (CLS 2), screen 3/12…………………………………………………. 802
16.5.10.4 Qmin – Qmax setting, screen 4/12………………………………………………………………. 803
16.5.10.5 Other Settings 1/2, screen 5/12……………………………………………………………….. 803
16.5.10.6 Hydraulic Oil & PTO Gear Oil Definition Table…………………………………………………… 804
16.5.10.7 Hydraulic oil temperature charts………………………………………………………………. 804
16.5.10.8 PTO gear oil temperature charts……………………………………………………………….. 804
16.5.10.9 Other Settings 2/2, screen 6/12……………………………………………………………….. 805
16.5.10.10 PLC-evaluation ON/OFF……………………………………………………………………….. 807
16.5.10.11 Shutdown Bypass ON/OFF………………………………………………………………………. 808
16.6 Interface-Connection KOMTRAX Plus controller & MTC………………………………………………………….. 812
16.6.1 KOMTRAX Plus controller…………………………………………………………………………….. 813
16.7 7-segment error code indication…………………………………………………………………………… 814
16.8 View onto the KOMTRAX Plus controller……………………………………………………………………… 816
16.9 MTC control system – global layout………………………………………………………………………… 818
16.9.1 MTC (Master Turbo Controller)……………………………………………………………………….. 820
16.9.1.1 MTC flowchart………………………………………………………………………………… 820
16.9.1.2 MTC features…………………………………………………………………………………. 820
16.9.1.3 MTC firmware and software……………………………………………………………………… 821
16.9.1.4 Connector and component location in the control system……………………………………………. 821
16.9.1.5 View onto the MTC unit and its connectors……………………………………………………….. 822
16.9.1.6 LED indications at the MTC…………………………………………………………………….. 823
16.10 Global layout of the internal CAN BUS…………………………………………………………………….. 824
16.10.1 General information on a CAN BUS system……………………………………………………………… 824
16.10.1.1 General CAN BUS description…………………………………………………………………… 825
16.10.1.2 CAN BUS troubleshooting………………………………………………………………………. 825
16.10.1.3 CAN BUS wiring………………………………………………………………………………. 826
16.10.1.4 CAN BUS end resistor…………………………………………………………………………. 828
16.11 The nodes in the CAN BUS system………………………………………………………………………….. 830
16.11.1 Global layout…………………………………………………………………………………….. 830
16.11.2 Introduction……………………………………………………………………………………… 832
16.11.2.1 ICN-V features………………………………………………………………………………. 832
16.11.2.2 View onto an open ICN-V node with DIP switches & status LED………………………………………. 834
16.11.2.3 General information on the LED control…………………………………………………………. 835
16.11.2.4 ICN-D features………………………………………………………………………………. 836
16.11.2.5 View onto an ICN-D node without wiring…………………………………………………………. 837
16.11.2.6 View onto the Status LEDs at the ICN-D node…………………………………………………….. 838
16.11.2.7 General information on the LED control…………………………………………………………. 838
16.11.2.8 Node DIP-switches……………………………………………………………………………. 840
16.11.2.9 Detailed view onto the DIP switches……………………………………………………………. 841
16.11.3 Node box…………………………………………………………………………………………. 842
16.11.4 Node location on the machine……………………………………………………………………….. 844
16.11.4.1 Node & location chart………………………………………………………………………… 845
16.11.5 View onto the control components in a cab base……………………………………………………….. 846
17 Lubrication system……………………………………………………………………………………………. 849
17.1 General overview – SLS & CLS1/2…………………………………………………………………………… 850
17.1.1 General description………………………………………………………………………………… 851
17.2 Basic function of the lubrication systems………………………………………………………………….. 852
17.3 Lubrication systems (SLS & CLS1/2)………………………………………………………………………… 854
17.3.1 Lubrication pump station……………………………………………………………………………. 854
17.3.2 General Information on CLS1/2……………………………………………………………………….. 856
17.3.3 General information on SLS………………………………………………………………………….. 856
17.3.4 Manual lube activation……………………………………………………………………………… 856
17.4 Lubrication cycle……………………………………………………………………………………….. 857
17.4.1 Operation and control………………………………………………………………………………. 857
17.4.2 Lubrication cycle – processing………………………………………………………………………. 858
17.4.3 Time segments & switch points of a lubrication cycle…………………………………………………… 859
17.4.4 Lubrication modes………………………………………………………………………………….. 860
17.4.4.1 Automatic lubrication mode…………………………………………………………………….. 860
17.4.4.2 Manual lubrication mode……………………………………………………………………….. 860
17.4.4.3 Reduced pause time for service…………………………………………………………………. 860
17.5 Hydraulically driven lube pump……………………………………………………………………………. 862
17.5.1 Adjustment of lube pump speed……………………………………………………………………….. 864
17.5.1.1 Stroke speed adjustment……………………………………………………………………….. 865
17.5.1.2 Working pressure……………………………………………………………………………… 865
17.6 Lubricant injectors……………………………………………………………………………………… 866
17.6.1 Tightening torques for fittings at grease injectors……………………………………………………. 867
17.6.2 Description……………………………………………………………………………………….. 867
17.6.3 Adjustment of the lubricant output…………………………………………………………………… 868
17.6.4 Operation principle of lubricant injectors……………………………………………………………. 870
17.6.4.1 Function description………………………………………………………………………….. 871
17.6.5 Connection of one or more injectors………………………………………………………………….. 872
17.7 Vent valve and grease outlet filter……………………………………………………………………….. 874
17.7.1 Vent valve description……………………………………………………………………………… 875
17.8 End-line switch…………………………………………………………………………………………. 876
17.8.1 Description……………………………………………………………………………………….. 877
17.8.2 CLS1/2 end-line switch adjustment……………………………………………………………………. 878
17.8.3 SLS end-line switch adjustment………………………………………………………………………. 880
17.9 Lubricant level sensors………………………………………………………………………………….. 882
17.9.1 Description……………………………………………………………………………………….. 883
17.9.1.1 Checks………………………………………………………………………………………. 883
17.10 Commissioning………………………………………………………………………………………….. 884
17.10.1 Commissioning of the CLS1/2 lubrication system……………………………………………………….. 884
17.10.2 Fine adjustment…………………………………………………………………………………… 885
17.10.3 Commissioning of the SLS lubrication system………………………………………………………….. 886
18 Deep temperature equipment (option)…………………………………………………………………………….. 889
18.1 General information……………………………………………………………………………………… 890
18.1.1 Introduction………………………………………………………………………………………. 890
18.1.2 Deep temperature components overview…………………………………………………………………. 890
18.1.3 Power supply preconditions for preheating…………………………………………………………….. 891
18.1.4 Power requirements for preheating systems…………………………………………………………….. 892
18.2 Preheating procedure…………………………………………………………………………………….. 893
18.2.1 Global flow chart of the preheating procedure…………………………………………………………. 893
18.2.2 Starting the preheating procedure……………………………………………………………………. 894
18.2.3 Preheating of operator’s cab and Diesel engine [coolant system]…………………………………………. 895
18.2.4 Preheating of lubricants and superstructure (Diesel) [electric system]…………………………………… 896
18.3 Constant heating of travel motors (TTT equipment below-40°C only)…………………………………………….. 897
18.4 Component location………………………………………………………………………………………. 898
18.4.1 Electric heating elements for hydraulic & batteries [electric machine]…………………………………… 898
18.4.2 Electric heating elements for hydraulics [Diesel machine]………………………………………………. 900
18.4.3 Electric heating elements for engines & batteries [Diesel machine]………………………………………. 902
18.5 Components of TT equipment……………………………………………………………………………….. 904
18.5.1 Preheating components on a Diesel machine…………………………………………………………….. 904
18.5.2 Preheating components on an electric machine………………………………………………………….. 905
18.5.3 Wiring Diagrams for preheating systems……………………………………………………………….. 906
18.5.3.1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3………………………………………… 906
18.5.3.2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3………………………………………… 907
18.5.3.3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3………………………………………… 908
18.5.3.4 Wiring diagram “Suction Oil Manifold Preheating”…………………………………………………. 909
18.5.3.5 Wiring diagram “PTO Preheating”………………………………………………………………… 910
18.5.3.6 Wiring diagram “Battery heater pads”……………………………………………………………. 911
19 Cable guide & Cable drum………………………………………………………………………………………. 913
19.1 General layout of the cable guide…………………………………………………………………………. 914
19.1.1 Safety……………………………………………………………………………………………. 915
19.2 General layout of the cable drum………………………………………………………………………….. 916
19.2.1 Safety……………………………………………………………………………………………. 918
19.3 Service switch………………………………………………………………………………………….. 920
19.4 Drive system……………………………………………………………………………………………. 922
19.4.1 Drive motor……………………………………………………………………………………….. 924
19.4.2 Connecting the drive motor………………………………………………………………………….. 926
19.4.3 Drive motor resistor……………………………………………………………………………….. 926
19.4.4 Drive torque regulation…………………………………………………………………………….. 926
19.4.5 Cable strain………………………………………………………………………………………. 927
19.4.6 Chain lubrication & chain tension……………………………………………………………………. 928
19.5 Drum Body………………………………………………………………………………………………. 930
19.5.1 Slip ring assembly…………………………………………………………………………………. 931
19.5.2 Carbon graphite brushes…………………………………………………………………………….. 931
19.5.3 Location of dryer and heater units in the drum body……………………………………………………. 932
19.5.4 Dryer system………………………………………………………………………………………. 933
19.6 High voltage interlock system…………………………………………………………………………….. 934
19.7 Switch boxes for the cable drum…………………………………………………………………………… 936
19.7.1 Install and connect the cable……………………………………………………………………….. 938
19.7.2 Winding up the cable……………………………………………………………………………….. 940
19.8 Cable guide drive mechanism………………………………………………………………………………. 942
19.8.1 Proximity switches on the cable guide drive mechanism………………………………………………….. 944
19.8.2 Cable deflection & drum full/empty control……………………………………………………………. 946
19.8.2.1 Monitoring the drum min/max winding status………………………………………………………. 948
19.8.3 Checks and adjustments……………………………………………………………………………… 950
19.9 Travel motion control……………………………………………………………………………………. 952
19.9.1 Ground contact control……………………………………………………………………………… 953
19.10 Overview on switches & control elements on the cable drum…………………………………………………… 954
19.11 Slew angle monitoring & Attention message…………………………………………………………………. 956
19.12 Commissioning cable drum………………………………………………………………………………… 958
19.12.1 Cable drum configuration for the MTC (CoDeSys)……………………………………………………….. 960
19.12.2 Lubricate drum drive side bearing with grease………………………………………………………… 962
19.12.3 Tool set for manual motor rotation………………………………………………………………….. 962
19.12.4 Cable drum maintenance…………………………………………………………………………….. 962
19.13 Shovel relocation………………………………………………………………………………………. 963
40 TROUBLESHOOTING………………………………………………………………………………………………….. 965
TOC……………………………………………………………………………………………………………. 967
1 Introduction………………………………………………………………………………………………….. 995
1.1 Overview………………………………………………………………………………………………… 996
1.1.1 General advice when using troubleshooting charts……………………………………………………….. 996
1.2 General Precautions………………………………………………………………………………………. 997
2 General Information for Troubleshooting………………………………………………………………………….. 999
2.1 Preparations For Work……………………………………………………………………………………..1000
2.2 Precautions During Work……………………………………………………………………………………1000
2.3 Precautions When Carrying Out Any Operation………………………………………………………………….1001
2.3.1 Precautions when carrying out removal work……………………………………………………………..1001
2.3.2 Precautions when carrying out installation work…………………………………………………………1001
2.3.3 Precautions when completing the operation………………………………………………………………1002
2.4 Fundamental Requirements for Troubleshooting…………………………………………………………………1003
2.4.1 Technical documentation………………………………………………………………………………1003
2.4.2 Tools………………………………………………………………………………………………1003
2.4.2.1 Reference Guide for Deutsch Removal Tools…………………………………………………………1007
2.4.3 Personnel…………………………………………………………………………………………..1008
2.5 Points To Remember When Trouble- shooting……………………………………………………………………1008
2.6 Sequence Of Events In Troubleshooting……………………………………………………………………….1010
2.7 Checks Before Troubleshooting………………………………………………………………………………1011
2.8 Handling Of Electric Equipment And Hydraulic Components……………………………………………………….1012
2.8.1 Points to remember when handling electric equipment……………………………………………………..1012
2.8.2 Points To Remember When Handling Hydraulic Equipment…………………………………………………….1015
2.9 General working procedures…………………………………………………………………………………1017
2.9.1 Air Bleeding of Various Hydraulic Parts………………………………………………………………..1017
2.9.2 Air bleeding from the hydraulic pumps………………………………………………………………….1017
2.9.3 Air bleeding from hydraulic cylinders………………………………………………………………….1017
2.10 Cylinder bypass test……………………………………………………………………………………..1018
2.11 Basics about “How to crimp” (with strain relief)…………………………………………………………….1019
2.11.1 Crimp tool & repair kit……………………………………………………………………………..1019
2.11.2 General……………………………………………………………………………………………1020
2.11.3 Select the required connector components………………………………………………………………1020
2.11.4 Stripping a wire……………………………………………………………………………………1021
2.11.5 Crimping…………………………………………………………………………………………..1022
2.11.6 Connector assembly after crimping…………………………………………………………………….1023
2.12 Cable Shielding………………………………………………………………………………………….1024
3 Mounting Locations and Connector Types……………………………………………………………………………1025
3.1 Superstructure……………………………………………………………………………………………1026
3.1.1 General layout (FSA & BHA)……………………………………………………………………………1026
3.1.2 Superstructure side view……………………………………………………………………………..1028
3.1.3 Superstructure top view………………………………………………………………………………1030
3.2 Machinery house…………………………………………………………………………………………..1032
3.3 Slip ring unit & Rotary joint………………………………………………………………………………1034
3.3.1 Slip Ring Unit in Detail……………………………………………………………………………..1036
3.4 Capacitor………………………………………………………………………………………………..1038
3.5 High Voltage Switch Cabinet – view 1………………………………………………………………………..1040
3.6 Cab support………………………………………………………………………………………………1046
3.6.1 View into cab base…………………………………………………………………………………..1052
3.7 Arrangement of Slew Angle Sensor……………………………………………………………………………1054
3.7.1 Slew angle sensor in the Wiring Diagram………………………………………………………………..1055
3.8 Location of hydraulic components……………………………………………………………………………1056
3.8.1 Location of Control Blocks……………………………………………………………………………1056
3.8.2 Control and filter panel motor 1 (rear)………………………………………………………………..1058
3.8.3 Valve cartridge block motor-1 (rear)…………………………………………………………………..1060
3.8.4 Control and filter panel motor-2 (front)……………………………………………………………….1062
3.8.5 Remote control valves arrangement……………………………………………………………………..1064
3.9 View onto the SLS or CLS1/2 grease barrel and the lubrication cycle components…………………………………..1066
3.10 Hydraulic oil tank & suction oil tank – Location of electrical components………………………………………1068
3.11 Hydraulically operated stairway……………………………………………………………………………1070
3.12 Central refilling equipment……………………………………………………………………………….1072
3.13 Connector Types Overview………………………………………………………………………………….1074
4 Standard Value Table for Electrical Components…………………………………………………………………….1081
5 References for Troubleshooting (CAN Bus & Node Outputs)…………………………………………………………….1097
5.1 CAN BUS trouble or Node Output Trouble………………………………………………………………………1098
5.1.1 Trouble CAN BUS or CAN Hardware (#D0308)……………………………………………………………….1099
5.1.2 Trouble output short circuit (#D0043)………………………………………………………………….1100
5.2 Sequence of CAN nodes in the CAN BUS………………………………………………………………………..1102
5.3 Troubleshooting for Relay Monitored Node Outputs……………………………………………………………..1103
5.3.1 Relay Check…………………………………………………………………………………………1103
#D0107 – Trouble slew parking brake control 56K250a………………………………………………………………1104
Example view onto CoDeSys visualization screen for message #D0107………………………………………………1106
Wiring Diagram (56K250a & 56K250b) for message #D0107…………………………………………………………1107
5.3.2 Output Check………………………………………………………………………………………..1108
#D0108 – Trouble slew parking brake control Output to 56K250a……………………………………………………..1109
Example view onto CoDeSys visualization screen for message #D0108………………………………………………1111
Wiring Diagram (56K250a & 56K250b) for message #D0108…………………………………………………………1112
6 Tables for Testing and Troubleshooting……………………………………………………………………………1113
6.1 Test Value Tables for Transducers…………………………………………………………………………..1114
6.1.1 Pump Press. transducers………………………………………………………………………………1114
6.1.2 Hydraulic oil pressure transducers…………………………………………………………………….1115
6.1.3 Miscellaneous Pressure Transducers…………………………………………………………………….1116
6.1.4 Temperature Transducers (signal voltage 0.5…4.5V)……………………………………………………..1117
6.1.4.1 Temperature Transducers – signal voltage 0.5…9.5V………………………………………………..1118
6.2 Test Value Table for PT100 Temperature Sensors g Centigrade – Ohm………………………………………………1119
6.3 Hydraulic oil temperature charts……………………………………………………………………………1120
6.4 PTO gear oil temperature charts…………………………………………………………………………….1120
6.5 Table of Trouble Codes (K+ monitor)…………………………………………………………………………1121
6.6 Table of 7-segment error codes……………………………………………………………………………..1127
6.7 Table of Instruction Messages………………………………………………………………………………1128
6.8 Table of Binary Codes……………………………………………………………………………………..1131
6.8.1 Table of Add-On Binary Codes for #D0308………………………………………………………………..1136
6.9 Pump & Valve Controller Fault Codes…………………………………………………………………………1137
6.10 Table of symptom codes……………………………………………………………………………………1145
6.10.1 Symptoms of E-motors and related parts………………………………………………………………..1145
6.10.2 Symptoms of Hydraulic System…………………………………………………………………………1145
6.10.3 Symptoms of mechanical system………………………………………………………………………..1146
6.10.4 Symptoms of Additional Systems……………………………………………………………………….1146
6.11 Power Supply…………………………………………………………………………………………….1147
6.12 Cable colour identification……………………………………………………………………………….1147
7 Troubleshooting by failure codes…………………………………………………………………………………1149
#D0001 – Trouble Shut-Off (gate) valve………………………………………………………………………….1150
View onto the gap of proximity switch 40B031…………………………………………………………………1152
Input signal (digital) of proximity switch 40B031 on REAL TIME MONITOR………………………………………….1153
View onto setting for SHUTDOWN BYPASS on K+ monitor…………………………………………………………..1153
Wiring Diagram (40B031) for message #D0001 (Main gate valve closed)…………………………………………….1154
#D0005 – Low hydraulic oil level……………………………………………………………………………….1155
Wiring Diagram, oil level label, and defined attachment position (#D0005)……………………………………….1157
#D0007 – Trouble hydraulic oil level……………………………………………………………………………1158
Wiring Diagram of 40B004 and defined attachment position (#D0007)………………………………………………1159
#D0012 – Central lubrication system grease level too low………………………………………………………….1160
#D0013 – Slew ring gear lubr. system grease level too low…………………………………………………………1160
Wiring Diagram (binary grease level sensor, refill warning) #D0012 / #D0013 / #D0202……………………………..1163
Wiring Diagram (junction box) for messages #D0012 / #D0013 / #D0202…………………………………………….1164
#D0020 – Trouble Shut-Off (gate) valve (Start blocked)……………………………………………………………1165
View onto gap of proximity switch 40B031 (#D0020)…………………………………………………………….1167
Wiring Diagram (40B031) for message #D0020 (Main gate valve closed)…………………………………………….1168
Input signal (digital) of proximity switch 40B031 on REAL TIME MONITOR………………………………………….1169
View onto setting for SHUTDOWN BYPASS on KOMTRAX Plus monitor………………………………………………….1169
#D0033 – Trouble KOMTRAX Plus Controller………………………………………………………………………..1170
#D0034 – Trouble KOMTRAX Plus Display…………………………………………………………………………..1171
#D0035 – Trouble totally loss gear oil (PTO 1)…………………………………………………………………..1172
#D0036 – Trouble totally loss gear oil (PTO 2)…………………………………………………………………..1172
View onto the location of sensor 57B175-1/-2 at the PTO (#D0035 & #D0036)……………………………………….1174
Input signal (analog) of PTO-1/2 gear oil sensor 57B175-1/-2 on REAL TIME MONITOR………………………………..1175
View onto setting screens for SHUTDOWN BYPASS on K+ monitor……………………………………………………1175
Wiring Diagram (57B175-1/-2) for messages #D0035 and #D0036 (example drawing)……………………………………1176
#D0040 – Emergency shut-down pump compartment……………………………………………………………………1177
Emergency circuit line for #D0040, #D0092, #D0093, #D0094, #D0095, #D0097, #D0354………………………………..1179
Digital inputs of emergency stop switches……………………………………………………………………1180
#D0041 – Emergency shut-down pump compartment……………………………………………………………………1181
Emergency circuit line for #D0041, #D0252, #D0253, #D0254, #D0255, #D0258, #D0355………………………………..1183
Digital inputs of emergency stop switches……………………………………………………………………1184
#D0043 – Trouble output short-circuit…………………………………………………………………………..1185
#D0046 – Reverse travel cut out bypassed by horn…………………………………………………………………1186
D#0047 – Travel cut out by cable drum…………………………………………………………………………..1188
Screenshot and Wiring Diagram for monitoring motor temperature (D#0047)…………………………………………1189
#D0048 – Trouble emergency safety circuit……………………………………………………………………….1190
Wiring Diagram (11K044a) for message #D0048………………………………………………………………….1191
#D0049 – Trouble cab heating 1…………………………………………………………………………………1192
#D0050 – Trouble cab heating 2…………………………………………………………………………………1192
View onto heater air inlet & outlet grids in operator’s cab……………………………………………………1193
Wiring Diagram – cab heater 1 and 2…………………………………………………………………………1194
Wiring Diagram – control of heater overheat protection (100°C)…………………………………………………1195
#D0051 – Trouble cab heating 1…………………………………………………………………………………1196
#D0052 – Trouble cab heating 2…………………………………………………………………………………1196
View onto heater air inlet & outlet grids in operator’s cab……………………………………………………1197
Wiring Diagram – cab heater 1 and 2…………………………………………………………………………1198
Wiring Diagram – control of heater overheat protection (60°C)………………………………………………….1199
#D0053 – Reset emergency safety circuit…………………………………………………………………………1200
#D0055 – Trouble monitoring cable drum motor temperature………………………………………………………….1202
Wiring Diagram (91B979 & 95B980) for message #D0055…………………………………………………………..1203
#D0059 – Fire in the switch cabinet…………………………………………………………………………….1204
Wiring Diagram for fire warning system………………………………………………………………………1205
#D0060 – Fire in the power house……………………………………………………………………………….1206
Wiring Diagram for fire warning system………………………………………………………………………1207
#D0063 – Trouble monitoring hydraulic oil temp…………………………………………………………………..1208
Mounting location of 59B015………………………………………………………………………………..1209
Wiring Diagram (59B015) for message #D0063…………………………………………………………………..1210
Monitoring options for hydraulic oil temperature……………………………………………………………..1211
#D0064 – Trouble monitoring hydraulic oil level………………………………………………………………….1212
Wiring Diagram (40B004) for message #D0064…………………………………………………………………..1214
#D0065 – Very low hydraulic oil level…………………………………………………………………………..1215
View onto hydraulic oil level label…………………………………………………………………………1215
#D0066 – Trouble hydraulic oil temperature………………………………………………………………………1216
Hydraulic oil temperature on REAL TIME MONITOR……………………………………………………………….1217
Hydraulic oil temperature charts for message #D0066…………………………………………………………..1218
#D0067 – Trouble battery voltage too high……………………………………………………………………….1219
Wiring Diagram (11T080) and component location for #D0067……………………………………………………..1220
Input signal of 11T080 on REAL TIME MONITOR (#D0067)………………………………………………………….1221
#D0069 – Trouble monitoring oil temperature gear (PTO 1)………………………………………………………….1222
Mounting location of 57B049-1/-2……………………………………………………………………………1223
Monitoring options for PTO 1 gear oil temperature…………………………………………………………….1224
Wiring Diagram (57B049-1 & 57B049-2) for messages #D0069 & #D0083………………………………………………1225
#D0070 – Trouble oil temperature gear (PTO 1)……………………………………………………………………1226
Location of PTO gear oil level dipstick and temperature sensor 57B049-1/-2………………………………………1228
PTO gear oil adjustment via K+……………………………………………………………………………..1228
#D0071 – Trouble gear lubrication (PTO 1)……………………………………………………………………….1230
Wiring Diagram and location (57B017-1 & 57B017-2) for #D0071 & #D0068…………………………………………..1231
#D0072 – Trouble monitoring hydraulic oil level………………………………………………………………….1232
Wiring Diagram (40B105) and REAL TIME MONITOR for message #D0072……………………………………………….1233
#D0076 – Trouble monitoring pressure suction tank………………………………………………………………..1234
Wiring Diagram (59B162) and REAL TIME MONITOR for #D0076………………………………………………………1235
#D0079 – Trouble monitoring pressure oil cooler 1………………………………………………………………..1236
Wiring Diagram (40B165) and REAL TIME MONITOR for #D0079………………………………………………………1237
#D0080 – Trouble monitoring pressure pre-load valve………………………………………………………………1238
Wiring Diagram (40B166) and REAL TIME MONITOR for #D0080………………………………………………………1239
#D0081 – Trouble lubrication system…………………………………………………………………………….1240
Operation cycles of lubrication systems……………………………………………………………………..1241
Wiring Diagram (control signal line “bucket cut off”) for message #D0081………………………………………..1242
#D0083 – Trouble monitoring oil temperature (PTO 2)………………………………………………………………1242
#D0084 – Trouble oil temperature gear (PTO 2)……………………………………………………………………1242
#D0086 – SHUTDOWN…………………………………………………………………………………………….1243
#D0090 – Trouble power supply………………………………………………………………………………….1244
Wiring Diagram and REALT TIME MONITOR for messages #D0090 & #D0099……………………………………………..1245
Wiring Diagram (battery chargers) for messages #D0090 & #D0099…………………………………………………1246
#D0091 – Pilot control cut out…………………………………………………………………………………1248
#D0092 – Emergency shut-down at access ladder……………………………………………………………………1249
#D0093 – Emergency shut-down at valve block……………………………………………………………………..1249
#D0094 – Emergency shut-down at hydraulic control panel…………………………………………………………..1249
#D0095 – Emergency shut-down in cabin…………………………………………………………………………..1249
#D0097 – Emergency shut-down at counterweight……………………………………………………………………1249
#D0099 – Trouble power supply………………………………………………………………………………….1250
#D0100 – Maintenance Safety Switch……………………………………………………………………………..1250
Wiring Diagram (emergency line with 50S058) for message #D0100…………………………………………………1251
#D0107 – Trouble slew parking brake control 56K250a………………………………………………………………1252
Example view onto CoDeSys visualization screen for message #D0107………………………………………………1254
Wiring Diagram (56K250a & 56K250b) for message #D0107…………………………………………………………1255
#D0108 – Trouble slew parking brake control Output to 56K250a……………………………………………………..1256
Example view onto the CoDeSys visualization screen for message #D0108…………………………………………..1258
Wiring Diagram (56K250a & 56K250b) for message #D0108…………………………………………………………1259
#D0109 – Trouble slew parking brake control 56K250b………………………………………………………………1259
#D0110 – Trouble slew parking brake control Output to 56K250b……………………………………………………..1259
#D0111 – Trouble travel parking brake control 56K251a…………………………………………………………….1260
51K251a-1 & 51K251b-1 (relay check) on REAL TIME MONITOR………………………………………………………1260
#D0112 – Trouble travel parking brake control Output to 56K251a……………………………………………………1261
51K251a-1 & 51K251b-1 (output check) on REAL TIME MONITOR……………………………………………………..1261
#D0113 – Trouble travel parking brake control 56K251b…………………………………………………………….1262
#D0114 – Trouble travel parking brake control Output to 56K251b……………………………………………………1262
#D0115 – Trouble slew hydraulic brake control 56K252a…………………………………………………………….1262
51K252a-1 & 51K252b-1 (relay check) on REAL TIME MONITOR………………………………………………………1262
#D0116 – Trouble slew hydraulic brake control Output to 56K252a……………………………………………………1263
51K252a-1 & 51K252b-1 (output check) on REAL TIME MONITOR……………………………………………………..1263
#D0117 – Trouble slew hydraulic brake control 56K252b…………………………………………………………….1263
#D0118 – Trouble travel parking brake control Output to 56K251b……………………………………………………1263
#D0141 – Trouble monitoring X2-pressure…………………………………………………………………………1264
Wiring Diagram (57B086) and monitoring screen for message #D0141……………………………………………….1265
#D0147 – Trouble monitoring gear lubrication (PTO 1)……………………………………………………………..1266
#D0149 – Trouble monitoring ambient temperature………………………………………………………………….1270
Wiring Diagram (13B090) and REAL TIME MONITOR for message #D0149……………………………………………….1271
#D0150 – Trouble monitoring gear lubrication (PTO 2)……………………………………………………………..1272
#D0151 – Trouble monitoring gear (PTO) oil filter 1………………………………………………………………1272
Wiring Diagram (57B027-1 & 57B027-2) for messages #D0151 and #D0193…………………………………………….1274
#D0154 – Trouble monitoring return oil filter……………………………………………………………………1275
Wiring Diagram (40B163) and monitoring screen for message #D0154……………………………………………….1277
#D0155 – Trouble monitoring leak oil filter……………………………………………………………………..1278
Wiring Diagram (40B164) and monitoring screen for message #D0155……………………………………………….1280
#D0159 – Trouble monitoring breather filter……………………………………………………………………..1281
Wiring Diagram and monitoring screen for message #D0159……………………………………………………….1283
#D0161 – Trouble monitoring battery voltage……………………………………………………………………..1284
11T080 on the REAL TIME MONITOR…………………………………………………………………………….1285
Wiring Diagram (11T080) and component location for message #D0161………………………………………………1286
#D0165 – Trouble breather filter hydraulic oil tank………………………………………………………………1288
Location of 40B024 and oil level label for message #D0165……………………………………………………..1289
#D0166 – Trouble oil filter gear (PTO 1)………………………………………………………………………..1290
View onto PTO gear oil filter with pressure sensor 57B027-1/-2 (#D0166 & #D0191)…………………………………1291
#D0169 – Trouble return oil filter hydraulic oil tank…………………………………………………………….1292
40B163 on REAL TIME MONITOR (#D0169)………………………………………………………………………..1293
#D0170 – Trouble leak oil filter hydraulic oil tank………………………………………………………………1294
40B164 on the REAL TIME MONITOR (#D0170)…………………………………………………………………….1295
#D0176 – Trouble battery voltage too low………………………………………………………………………..1296
Real Time Monitor (11T080) for message #D0176………………………………………………………………..1297
Wiring Diagram (11T080) and component location for message #D0176………………………………………………1298
Wiring Diagram (battery chargers) for message #D0176………………………………………………………….1299
#D0180 – Trouble pilot pressure X2 too low………………………………………………………………………1300
Valve cartridge block with X2 pressure sensor 57B086 for message #D0180…………………………………………1301
#D0181 – Trouble pilot pressure X2 too high……………………………………………………………………..1302
Valve cartridge block with X2 pressure sensor 57B086 (X2 pressure too high)……………………………………..1303
#D0184 – Central lubrication system empty……………………………………………………………………….1304
Grease level CLS 1 & SLS & CLS 2 on REAL TIME MONITOR…………………………………………………………1306
#D0185 – Trouble central lubrication system……………………………………………………………………..1307
Allocation of vent valves and end-line switches………………………………………………………………1308
Action chart for lube cycles……………………………………………………………………………….1309
View onto the vent valve (62Q507a / 62Q509a / 62Q642a)………………………………………………………..1310
Wiring Diagram (60B043 & 62B046 & 80B043) for #D0185 & #D0188 & #D0203………………………………………….1311
#D0186 – Trouble central lubrication system……………………………………………………………………..1312
Allocation of vent valves………………………………………………………………………………….1312
Action chart for lube cycles……………………………………………………………………………….1313
View onto vent valve (62Q507a / 62Q509a / 62Q642a)……………………………………………………………1314
#D0187 – Slew ring gear lubrication system empty…………………………………………………………………1315
#D0188 – Trouble slew ring gear lubrication system……………………………………………………………….1315
#D0189 – Trouble slew ring gear lubrication system……………………………………………………………….1315
#D0191 – Trouble oil filter gear (PTO 2)………………………………………………………………………..1315
#D0193 – Trouble monitoring gear (PTO) oil filter 2………………………………………………………………1315
#D0201 – Attachment lubrication system empty…………………………………………………………………….1315
#D0202 – Attachment lubrication system grease level too low……………………………………………………….1315
#D0203- Trouble attachment lubrication system……………………………………………………………………1315
#D0204 – Trouble attachment lubrication system…………………………………………………………………..1315
#D0210 – Trouble electric motor 1 winding temperature…………………………………………………………….1316
#D0211 – Trouble electric motor 2 winding temperature…………………………………………………………….1316
Wiring Diagram (motor 1 winding temperature monitoring) for #D0210……………………………………………..1317
Wiring Diagram (motor 2 winding temperature monitoring) for #D0211……………………………………………..1318
REAL TIME MONITOR for motor 1/2 winding temperature, #D0210 & #D0211……………………………………………1319
#D0212 – Trouble electric motor 1 bearing temperature…………………………………………………………….1320
#D0213 – Trouble electric motor 2 bearing temperature…………………………………………………………….1320
REAL TIME MONITOR for motor 1/2 bearing temperature, #D0212 & #D0213……………………………………………1321
Wiring Diagram (motor 1/2 bearing temperature monitoring) for #D0212 & #D0213……………………………………1322
#D0214 – Trouble transformer 1 temperature………………………………………………………………………1323
#D0215 – Trouble transformer 2 temperature………………………………………………………………………1323
Wiring Diagram (temperature control for transformer A), message #D0214………………………………………….1324
REAL TIME MONITOR (net-line voltage & transformer temperature) for #D0214 & 215………………………………….1325
#D0216 – Trouble software not compatible………………………………………………………………………..1326
#D0218 – Switch off all motors for running transfer pump………………………………………………………….1327
#D0220 – Trouble transfer pump motor overheated………………………………………………………………….1328
Wiring Diagram (transfer pump) for message #D0220…………………………………………………………….1329
#D0238 – Trouble supply by key switch 11Q044…………………………………………………………………….1330
Input signal of 11Q044 on REAL TIME MONITOR (#D0238)………………………………………………………….1330
Wiring Diagram (11Q044) for message #D0238…………………………………………………………………..1331
#D0239 – Trouble electrical matter……………………………………………………………………………..1332
Wiring Diagram (signal input at node 02, X3.08) for message #D0239……………………………………………..1334
#D0240 – Trouble hydraulic oil temperature………………………………………………………………………1336
Hydraulic oil temperature charts……………………………………………………………………………1337
#D0241 – Motor 1 already running……………………………………………………………………………….1338
#D0244 – Motor shutdown from ground…………………………………………………………………………….1339
Input signal of 54S007 & 54S008 on REAL TIME MONITOR (#D0244)………………………………………………….1340
#D0246 – Hydraulic oil temperature……………………………………………………………………………..1341
#D0252 – Emergency shut-down at access ladder……………………………………………………………………1342
#D0253 – Emergency shut-down at valve block……………………………………………………………………..1342
#D0254 – Emergency shut-down at hydraulic control panel…………………………………………………………..1342
#D0255 – Emergency shut-down in cabin…………………………………………………………………………..1342
#D0256 – Operator warning system……………………………………………………………………………….1342
#D0257 – Hydraulic oil temperature……………………………………………………………………………..1343
#D0258 – Emergency shut-down at counterweight……………………………………………………………………1343
#D0261 – Maintenance Safety Switch……………………………………………………………………………..1344
#D0262 – Trouble screen at hydr. cooler entry clogged…………………………………………………………….1345
40B166 and 40B165 on REAL TIME MONITOR (#D0262)………………………………………………………………1345
Location of 40B166 and 40B165 at the hydraulic oil tank (message #D0262)………………………………………..1346
Wiring Diagram (40B166 & 40B165) for message #D0262…………………………………………………………..1347
#D0263 – Trouble monitoring motor 1 bearing temperature…………………………………………………………..1348
#D0264 – Trouble monitoring motor 2 bearing temperature…………………………………………………………..1348
View onto terminal box motor 1……………………………………………………………………………..1349
Wiring Diagram (motor 1/2 bearing temperature) for #D0263 & #D0264……………………………………………..1350
#D0265 – Trouble monitoring emergency voltage……………………………………………………………………1351
Wiring Diagram and monitoring (12T082) for message #D0265……………………………………………………..1353
#D0266 – Trouble emergency voltage too high……………………………………………………………………..1354
Wiring Diagram and monitoring (12T082) for message #D0266……………………………………………………..1355
Wiring Diagram (13T003) for message #D0266…………………………………………………………………..1356
#D0267 – Trouble emergency voltage too low………………………………………………………………………1357
Wiring Diagram and monitoring (12T082) for message #D0267……………………………………………………..1358
Wiring Diagram (13T003) for message #D0267…………………………………………………………………..1359
#D0270 – Trouble monitoring motor 1 current……………………………………………………………………..1360
#D0271 – Trouble monitoring motor 2 current……………………………………………………………………..1360
Wiring Diagram (12T431) for messages #D0270 and #D0271………………………………………………………..1363
#D0272 – Trouble monitoring high voltage………………………………………………………………………..1364
Wiring Diagram (12T431) for messages #D0272………………………………………………………………….1366
#D0274 – Trouble monitoring motor 1 winding temperature…………………………………………………………..1368
#D0276 – Trouble monitoring motor 2 winding temperature…………………………………………………………..1368
View onto terminal box motor 1……………………………………………………………………………..1369
Wiring Diagram (motor 1 winding temp. monitoring) for message #D0274……………………………………………1370
Wiring Diagram (motor 2 winding temp. monitoring) for message #D0276……………………………………………1371
#D0277 – Trouble high voltage capacitor 1……………………………………………………………………….1372
Wiring Diagram capacitor pressure monitoring and monitoring screen (motor 1)…………………………………….1373
#D0278 – Earth fault tripped…………………………………………………………………………………..1374
#D0281 – Ground leakage tripped………………………………………………………………………………..1375
Wiring Diagram and monitoring screen (12F431) for message #D0281……………………………………………….1375
#D0283 – Trouble monitoring motor 1 power……………………………………………………………………….1376
#D0284 – Trouble monitoring motor 2 power……………………………………………………………………….1376
Copy from User Instruction 12P004-1/-2………………………………………………………………………1377
Example view onto 12P004-1/-2………………………………………………………………………………1378
Wiring Diagram (12P004-1 & 12P004-2) for messages #D0283 & #D0284………………………………………………1379
#D0285 – Trouble motor 1………………………………………………………………………………………1380
#D0286 – Trouble motor 2………………………………………………………………………………………1380
Wiring Diagram (motor protection relays & node inputs) for message #D0285/286……………………………………1381
Wiring Diagram (motor 1/2 protection relay) for messages #D0285/286…………………………………………….1382
#D0287 – Trouble 3 phase current rotation direction………………………………………………………………1383
Wiring Diagram and phase sequence relay monitoring for message #D0287…………………………………………..1384
#D0288 – Trouble restart motor 1, temperature too high……………………………………………………………1385
#D0289 – Trouble restart motor 2, temperature too high……………………………………………………………1385
#D0290 – Trouble motor main relay 1…………………………………………………………………………….1386
Wiring Diagram (12K460/12K461) for messages #D0290 & #D0306……………………………………………………1387
Wiring Diagram (12K403a) for messages #D0290 & #D0306…………………………………………………………1388
Wiring Diagram (signal input 32Q701-1/-2) for messages #D0290 & #D0306………………………………………….1389
#D0291 – Reverse travel cut out by cable drum……………………………………………………………………1390
Wiring Diagram (91B904a, 91B911, 91B919) for message #D0291……………………………………………………1391
#D0292 – Reverse travel left track cut out by cable drum………………………………………………………….1392
#D0293 – Reverse travel right track cut out by cable drum…………………………………………………………1392
Wiring Diagram (diagonal cable pull) for messages #D0292 & #D0293………………………………………………1393
#D0294 – Forward travel cut out by cable drum……………………………………………………………………1394
Wiring Diagram (91B904b) for message #D0294………………………………………………………………….1395
#D0295 – Trouble temperature cab base…………………………………………………………………………..1396
Cab base temperature on REAL TIME MONITOR (#D0295)……………………………………………………………1396
Wiring Diagram (12B001 and 32B802) for messages #D0295 and #D0296………………………………………………1397
#D0296 – Trouble temperature high voltage cabinet………………………………………………………………..1398
HV-cabinet temperature on REAL TIME MONITOR (#D0296)………………………………………………………….1398
#D0301 – Trouble high voltage supply was interrupted……………………………………………………………..1399
Motor voltage (12T431-3) on REAL TIME MONITOR (#D0301)………………………………………………………..1399
Wiring Diagram 12T431 – HV monitoring at pin 16………………………………………………………………1400
Wiring Diagram 12T431 (continued) for message #D0301………………………………………………………….1401
#D0304 – Start Motor 1 blocked…………………………………………………………………………………1402
#D0305 – Start Motor 2 blocked…………………………………………………………………………………1402
#D0307 – Attention ! Cable drum !………………………………………………………………………………1403
#D0308 – Trouble CAN-BUS or CAN-Hardware………………………………………………………………………..1404
#D0309 – Trouble ladder up 56K253a……………………………………………………………………………..1407
Ladder (stairway) up 56K253a & 56K253b (relay check) on REAL TIME MONITOR……………………………………….1407
#D0310 – Trouble ladder up Output to 56K253a…………………………………………………………………….1408
Ladder (stairway) up 56K253a & 56K253b (output check) on REAL TIME MONITOR………………………………………1408
#D0311 – Trouble ladder up redundant 56K253b…………………………………………………………………….1409
#D0312 – Trouble ladder up redundant Output to 56K253b……………………………………………………………1409
#D0313 – Trouble ladder down 56K254a……………………………………………………………………………1409
Ladder (stairway) down 56K254a & 56K254b (relay check) on REAL TIME MONITOR……………………………………..1409
#D0314 – Trouble ladder down Output to 56K254a…………………………………………………………………..1410
Ladder (stairway) down 56K254a & 56K254b (output check) on REAL TIME MONITOR…………………………………….1410
#D0315 – Trouble ladder down redundant 56K254b…………………………………………………………………..1410
#D0316 – Trouble ladder down redundant Output to 56K254b………………………………………………………….1410
#D0329 – Protection switch tripped……………………………………………………………………………..1411
Additional protection switches on REAL TIME MONITOR (#D0329)…………………………………………………..1411
#D0334 -Trouble cab heater contactor……………………………………………………………………………1412
Wiring Diagram for cab heating – 3 step heater regulation……………………………………………………..1413
Wiring Diagram – additional cab heater (20E002) at cab wall……………………………………………………1414
Wiring Diagram – operation panel 20S026a…………………………………………………………………….1415
#D0335 -Trouble cab heater safety relay…………………………………………………………………………1416
Wiring Diagram (heater safety relays) for message #D0335………………………………………………………1418
Temperature control (100°C) for heater on cabin wall………………………………………………………….1419
#D0337 – Trouble motor on control 12K408a-1……………………………………………………………………..1420
12K408a-1/-2 & 12K408b-1/-2 (relay check) on REAL TIME MONITOR…………………………………………………1420
#D0338 – Trouble motor on control Output to 12K408a-1…………………………………………………………….1421
12K408a-1/-2 & 12K408b-1/-2 (output check) on REAL TIME MONITOR………………………………………………..1421
#D0354 – Emergency shut-down cable drum…………………………………………………………………………1422
#D0355 – Emergency shut-down cable drum…………………………………………………………………………1422
#D0356 – Trouble monitoring slew speed………………………………………………………………………….1422
Slew speed (11B144) on REAL TIME MONITOR…………………………………………………………………….1422
Wiring Diagram (11B144) for message #D0356…………………………………………………………………..1423
#D0357 – Trouble monitoring slew angle………………………………………………………………………….1424
Slew angle (11B145) on REAL TIME MONITOR…………………………………………………………………….1424
Wiring Diagram (11B145) for message #D0357…………………………………………………………………..1425
8 Troubleshooting for PUMP/VALVE controller fault codes………………………………………………………………1427
DA2UKR – Communication failure PLC <-> KOMTRAX Plus controller…………………………………………………….1428
DBB0KK – KOMTRAX Plus source voltage error………………………………………………………………………1430
Wiring Diagram K+ controller 24V supply and GND connections……………………………………………………1431
DBB0KQ – Connector sel error…………………………………………………………………………………..1432
DAFQKR – Communication failure MH800 <-> KOMTRAX Plus controller…………………………………………………..1434
Wiring Diagram for message DAFQKR…………………………………………………………………………..1435
DA2QKR – CAN2 Discon (Pump1 Con)……………………………………………………………………………….1436
Wiring Diagram for message DA2QKR…………………………………………………………………………..1437
DBZQKR – CAN2 Discon (Pump2 Con)……………………………………………………………………………….1438
Wiring Diagram for message DBZQKR…………………………………………………………………………..1439
DBWQKR – CAN2 Discon (Valve/M Con)……………………………………………………………………………..1440
Wiring Diagram for message DBWQKR…………………………………………………………………………..1441
DBXQKR – CAN2 Discon (Valve/S1 Con)…………………………………………………………………………….1442
Wiring Diagram for message DBXQKR…………………………………………………………………………..1443
DBYQKR – CAN2 Discon (Valve/S2 Con)…………………………………………………………………………….1444
Wiring Diagram for message DBYQKR…………………………………………………………………………..1445
DXAAKA – Solenoid-1(Pump-1) open circuit………………………………………………………………………..1446
DXABKA – Solenoid-2(Pump-2) open circuit………………………………………………………………………..1446
DXACKA – Solenoid-3(Pump-3) open circuit………………………………………………………………………..1446
DXADKA – Solenoid-4(Pump-4) open circuit………………………………………………………………………..1446
DXAEKA – Solenoid-5(Pump-5) open circuit………………………………………………………………………..1446
DXAFKA – Solenoid-6(Pump-6) open circuit………………………………………………………………………..1446
DXAGKA – Solenoid-7(Pump-7) open circuit………………………………………………………………………..1446
DXAHKA – Solenoid-8(Pump-8) open circuit………………………………………………………………………..1446
DXAJKA – Solenoid-9(Pump-9) open circuit………………………………………………………………………..1446
DXAKKA – Solenoid-10(Pump-10) open circuit………………………………………………………………………1446
DXALKA – Solenoid-11(Pump-11) open circuit………………………………………………………………………1446
DXAMKA – Solenoid-12(Pump-12) open circuit………………………………………………………………………1446
Wiring Diagram – EPC valve control (PUMP1 controller)…………………………………………………………1448
Wiring Diagram – EPC valve control (PUMP2 controller)…………………………………………………………1449
DXAAKB – Solenoid-1(Pump-1) short circuit……………………………………………………………………….1450
DXABKB – Solenoid-2(Pump-2) short circuit……………………………………………………………………….1450
DXACKB – Solenoid-3(Pump-3) short circuit……………………………………………………………………….1450
DXADKB – Solenoid-4(Pump-4) short circuit……………………………………………………………………….1450
DXAEKB – Solenoid-5(Pump-5) short circuit……………………………………………………………………….1450
DXAFKB – Solenoid-6(Pump-6) short circuit……………………………………………………………………….1450
DXAGKB – Solenoid-7(Pump-7) short circuit……………………………………………………………………….1450
DXAHKB – Solenoid-8(Pump-8) short circuit……………………………………………………………………….1450
DXAJKB – Solenoid-9(Pump-9) short circuit……………………………………………………………………….1450
DXAKKB – Solenoid-10(Pump-10) short circuit……………………………………………………………………..1450
DXALKB – Solenoid-11(Pump-11) short circuit……………………………………………………………………..1450
DXAMKB – Solenoid-12(Pump-12) short circuit……………………………………………………………………..1450
Wiring Diagram – EPC valve control (PUMP1 controller)…………………………………………………………1452
Wiring Diagram – EPC valve control (PUMP2 controller)…………………………………………………………1453
DHPEMA – Pump-1/2 pressure sensor abnormality……………………………………………………………………1454
DHPGMA – Pump-3/4 pressure sensor abnormality……………………………………………………………………1454
DHPJMA – Pump-5/6 pressure sensor abnormality……………………………………………………………………1454
DHPLMA – Pump-7/8 pressure sensor abnormality……………………………………………………………………1454
DHPNMA – Pump-9/10 pressure sensor abnormality…………………………………………………………………..1454
DHPQMA – Pump-11/12 pressure sensor abnormality………………………………………………………………….1454
Wiring Diagram – PWR & GND supply for pressure transducers (pumps 1…3)………………………………………..1456
Wiring Diagram – PWR & GND supply for pressure transducers (pumps 4…6)………………………………………..1457
DA25KP – 5V sensor1 power abnormality…………………………………………………………………………..1458
DBZ5KP – 5V sensor1 power abnormality…………………………………………………………………………..1458
Wiring Diagram – 5V sensor power supply (PC1_5V_1) for message DA25KP…………………………………………..1459
Wiring Diagram – 5V sensor power supply (PC2_5V_1) for message DBZ5KP…………………………………………..1460
DA22KK – Pump Solenoid Power Low Error………………………………………………………………………….1461
DBZ2KK – Pump2 Solenoid Power Low Error…………………………………………………………………………1461
Wiring Diagram – PUMP1/2 solenoid power……………………………………………………………………..1462
DA29KQ – Model Selection Abnormality……………………………………………………………………………1463
DBZ9KQ – Model Selection Abnormality……………………………………………………………………………1463
Wiring Diagram – PUMP1 machine selections……………………………………………………………………1465
Wiring Diagram – PUMP2 machine selections……………………………………………………………………1466
DA2YKQ – Motor/Engine Selection Abnormality……………………………………………………………………..1467
DBZWKQ – Motor/Engine Selection Abnormality……………………………………………………………………..1467
Wiring Diagram – Motor/engine selection PUMP1 controller………………………………………………………1468
Wiring Diagram – Motor/engine selection PUMP2 controller………………………………………………………1469
DA20KQ – Pump1 Con Selection Abnormality………………………………………………………………………..1470
DBZ0KQ – Pump2 Con Selection Abnormality………………………………………………………………………..1470
Wiring Diagram – Controller selection PUMP1 controller………………………………………………………..1472
Wiring Diagram – Controller selection PUMP2 controller………………………………………………………..1473
DA2XKQ – Motor1 Frequency Select Abnormality…………………………………………………………………….1474
DBZXKQ – Motor2 Frequency Select Abnormality…………………………………………………………………….1474
Wiring Diagram – Controller selection PUMP1 controller (frequency)……………………………………………..1476
Wiring Diagram – Controller selection PUMP2 controller (frequency)……………………………………………..1477
DA20MC – Pump1 Con Error………………………………………………………………………………………1478
DBZ0MC – Pump2 Con Error………………………………………………………………………………………1478
DGT3MA – PTO1 oil temperature sensor abnormality…………………………………………………………………1479
DGT8MA – PTO2 oil temperature sensor abnormality…………………………………………………………………1479
Wiring Diagram (57B049-1 & 57B049-2) for DGT3MA & DGT8MA & #D0069 & #D0083………………………………………1480
Mounting location of 57B049-1/2…………………………………………………………………………….1481
DGH2MA – Hydraulic oil temp sensor abnormality…………………………………………………………………..1482
Wiring Diagram (59B015) for messages DGH2MA & #D0063………………………………………………………….1483
DJK3MA – Motor voltage sensor abnormality……………………………………………………………………….1484
Wiring Diagram (12T431) for messages DJK3MA & #D0272………………………………………………………….1485
DJK4MA – Motor1 current sensor abnormality………………………………………………………………………1486
DJK6MA – Motor2 current sensor abnormality………………………………………………………………………1486
Wiring Diagram (12T431) for messages DJK4MA, DJK6MA & #D0270, #D0271……………………………………………1487
G@00KP – Motor1 voltage low error………………………………………………………………………………1488
Wiring Diagram (12T431) for message G@00KP…………………………………………………………………..1490
DWNCKA – Hyd oil cooler fan pump1 solenoid open circuit…………………………………………………………..1491
DWNUKA – Hyd oil cooler fan pump2 solenoid open circuit…………………………………………………………..1491
Wiring Diagram – Hydraulic oil cooler fan pump1/2 EPC control………………………………………………….1493
DWNCKB – Hyd oil cooler fan pump1 solenoid short circuit………………………………………………………….1494
DWNUKB – Hyd oil cooler fan pump2 solenoid short circuit………………………………………………………….1494
Wiring Diagram – Hydraulic oil cooler fan pump1/2 EPC control………………………………………………….1495
DXQ0KA – X1 pilot pressure pump1 solenoid open circuit……………………………………………………………1496
DXQ1KA – X1 pilot pressure pump2 solenoid open circuit……………………………………………………………1496
Wiring Diagram – control oil (X1) pressure pump1/2 EPC control…………………………………………………1498
DXQ0KB – X1 pilot pressure pump1 solenoid short circuit…………………………………………………………..1500
DXQ1KB – X1 pilot pressure pump2 solenoid short circuit…………………………………………………………..1500
Wiring Diagram – control oil (X1) pressure pump1/2 EPC control…………………………………………………1501
DDABMC – Lock lever switch abnormality………………………………………………………………………….1502
Wiring Diagram – lock lever switch 20S105 (DDABMC)……………………………………………………………1503
DBW9KQ – Model Selection Abnormality……………………………………………………………………………1504
Wiring Diagram – VALVE0 machine selection……………………………………………………………………1505
DBWZKQ – Lever control selection abnormality…………………………………………………………………….1506
Wiring Diagram – VALVE0 lever control selection………………………………………………………………1507
DBWYKQ – Attachment selection abnormality……………………………………………………………………….1508
Wiring Diagram – VALVE0 attachment selection…………………………………………………………………1509
DBW2KK – Solenoid Power Low Error(VALVE/M)………………………………………………………………………1510
Wiring Diagram for message DBW2KK…………………………………………………………………………..1512
DBW0KQ – VALVE/M Con Selection Abnormality………………………………………………………………………1514
Wiring Diagram – VALVE0 controller selection…………………………………………………………………1515
DBW0MA – VALVE/M Con Error…………………………………………………………………………………….1516
DKURMA – R lever right-left potentio abnormality…………………………………………………………………1518
Wiring Diagram – R lever right-left potentiometer input (DKURMA)……………………………………………….1519
DKUSMA – R lever right-left redu pot abnorm(VALVE/M)……………………………………………………………..1520
Wiring Diagram – R lever redundant right-left potentiometer input (DKUSMA)………………………………………1521
DKUQL8 – R lever right-left potentio error………………………………………………………………………1522
Wiring Diagram – R lever main + redundant right-left signal voltage at VALVE0……………………………………1524
DKUQL4 – R lever right-left sig. mismatch(VALVE/M)……………………………………………………………….1525
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1…………………………………………..1527
DKUNMA – R lever front-back potentio abnormality…………………………………………………………………1528
Wiring Diagram – R lever front-back potentiometer input (DKUNMA)……………………………………………….1529
DKUPMA – R lever front-back redu pot abnorm(VALVE/M)……………………………………………………………..1530
Wiring Diagram – R lever redundant front-back potentiometer input at VALVE0……………………………………..1531
DKUML8 – R lever front-back potentio error………………………………………………………………………1532
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8)…………………………………….1534
DKUML4 – R lever front-back sig. mismatch(VALVE/M)……………………………………………………………….1535
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1…………………………………………..1537
DKUXMA – L lever right-left potentio abnormality…………………………………………………………………1538
Wiring Diagram – L lever right-left potentiometer input (DKUXMA)……………………………………………….1539
DKUYMA – L lever right-left redu pot abnorm(VALVE/M)……………………………………………………………..1540
Wiring Diagram – L lever redundant right-left potentiometer input (DKUYMA)………………………………………1541
DKUWL8 – L lever right-left potentio error………………………………………………………………………1542
Wiring Diagram – L lever main + redundant right-left signal voltage at VALVE0……………………………………1544
DKUWL4 – L lever right-left sig. mismatch(VALVE/M)……………………………………………………………….1545
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1…………………………………………..1547
DKUUMA – L lever front-back potentio abnormality…………………………………………………………………1548
Wiring Diagram – L lever front-back potentiometer input (DKUUMA)……………………………………………….1549
DKUVMA – L lever front-back redu pot abnorm(VALVE/M)……………………………………………………………..1550
Wiring Diagram – L lever front-back redundant potentiometer input (VALVE0)………………………………………1551
DKUTL8 – L lever front-back potentio error………………………………………………………………………1552
Wiring Diagram – L lever front-back potentio error (DKUTL8)……………………………………………………1554
DKUTL4 – L lever front-back sig. mismatch(VALVE/M)……………………………………………………………….1555
Wiring Diagram – L lever front-back sig. mismatch(VALVE/M) for DKUTL4…………………………………………..1557
DKW1MA – R pedal potentio abnormality…………………………………………………………………………..1558
Wiring Diagram – R pedal potentio abnormality (DKW1MA)………………………………………………………..1559
DKW2MA – R pedal redundant pot abnormality(VALVE/M)………………………………………………………………1560
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA………………………………………….1561
DKW0L8 – R pedal potentio error………………………………………………………………………………..1562
Wiring Diagram – R pedal potentio error (DKW0L8)……………………………………………………………..1563
DKW0L4 – R pedal signal mismatch(VALVE/M)……………………………………………………………………….1564
Wiring Diagram – R pedal signal mismatch(VALVE/M) for DKW0L4…………………………………………………..1566
DKW4MA – L pedal potentio abnormality…………………………………………………………………………..1568
Wiring Diagram – L pedal potentio abnormality (DKW4MA)………………………………………………………..1569
DKW5MA – L pedal redundant pot abnormality(VALVE/M)………………………………………………………………1570
Wiring Diagram – L pedal redundant pot abnormality(VALVE/M) for DKW5MA………………………………………….1571
DKW3L8 – L pedal potentio error………………………………………………………………………………..1572
Wiring Diagram – L pedal potentio error (DKW3L8)……………………………………………………………..1573
DKW3L4 – L pedal signal mismatch(VALVE/M)……………………………………………………………………….1574
Wiring Diagram – L pedal signal mismatch(VALVE/M) for DKW3L4…………………………………………………..1576
DKW7MA – Clam open potentio abnormality…………………………………………………………………………1578
Wiring Diagram – Clam open potentio abnormality (DKW7MA)………………………………………………………1579
DKW8MA – Clam open redu pot abnormality(VALVE/M)…………………………………………………………………1580
Wiring Diagram – Clam open redu pot abnormality(VALVE/M) for DKW8MA…………………………………………….1581
DKW6L8 – Clam open potentio error………………………………………………………………………………1582
Wiring Diagram – Clam open potentio error (DKW6L8)……………………………………………………………1583
DKW6L4 – Clam open signal mismatch(VALVE/M)……………………………………………………………………..1584
Wiring Diagram – Clam open signal mismatch(VALVE/M) (DKW6L4)…………………………………………………..1585
DKWAMA – Clam close potentio abnormality………………………………………………………………………..1586
Wiring Diagram – Clam close potentio abnormality (DKWAMA)……………………………………………………..1587
DKWBMA – Clam close redundant pot abnorm(VALVE/M)………………………………………………………………..1588
Wiring Diagram – Clam close redundant pot abnorm(VALVE/M) for DKWBMA……………………………………………1589
DKW9L8 – Clam close potentio error……………………………………………………………………………..1590
Wiring Diagram – Clam close potentio error (DKW9L8)…………………………………………………………..1591
DKW9L4 – Clam close signal mismatch(VALVE/M)…………………………………………………………………….1592
Wiring Diagram – Clam close signal mismatch(VALVE/M) for DKW9L4………………………………………………..1593
DKWDMA – Hydraulic slew brake potentio abnormality……………………………………………………………….1594
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA)…………………………………………….1595
DKWEMA – Hyd. slew brake redu pot abnorm(VALVE/M)………………………………………………………………..1596
Wiring Diagram – Hyd. slew brake redu pot abnorm(VALVE/M) for DKWEMA……………………………………………1597
DKWCL8 – Hydraulic slew brake potentio error…………………………………………………………………….1598
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8)………………………………………………….1599
DKWCL4 – Hyd. slew brake sig. mismatch(VALVE/M)………………………………………………………………….1600
Wiring Diagram – Hyd. slew brake sig. mismatch(VALVE/M) for DKWCL4……………………………………………..1601
DXNHKA – Travel1 left epc solenoid open circuit………………………………………………………………….1602
DXN3KA – Stick1 epc solenoid open circuit……………………………………………………………………….1602
DXNJKA – Bucket1 epc solenoid open circuit………………………………………………………………………1602
DXN2KA – Boom1 epc solenoid open circuit………………………………………………………………………..1602
DXN5KA – Clam2 epc solenoid open circuit………………………………………………………………………..1602
DXN8KA – Bucket2 epc solenoid open circuit………………………………………………………………………1602
DXN4KA – Boom2 epc solenoid open circuit………………………………………………………………………..1602
DXN6KA – Stick2 epc solenoid open circuit……………………………………………………………………….1602
DXNKKA – Travel3 right epc solenoid open circuit…………………………………………………………………1602
DXNCKA – Boom3 epc solenoid open circuit………………………………………………………………………..1602
DXNBKA – Bucket3 epc solenoid open circuit………………………………………………………………………1602
DXNLKA – Stick3 epc solenoid open circuit……………………………………………………………………….1602
DXNMKA – Slew4 epc solenoid open circuit………………………………………………………………………..1602
Details of the above 6-digit failure codes…………………………………………………………………..1603
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623 (block I)……………………………………………..1604
Wiring Diagram for EPC 61K624 – 61K625 – 61K626 – 61K627 (block II)…………………………………………….1605
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 – 61K631 (block III)……………………………………………1606
Wiring Diagram for EPC 61K632 (block IV)…………………………………………………………………….1607
Monitoring screens for EPC with open circuit (block I…IV)……………………………………………………1608
DXNHKB – Travel1 left epc solenoid short circuit…………………………………………………………………1609
DXN3KB – Stick1 epc solenoid short circuit………………………………………………………………………1609
DXNJKB – Bucket1 epc solenoid short circuit……………………………………………………………………..1609
DXN2KB – Boom1 epc solenoid short circuit……………………………………………………………………….1609
DXN5KB – Clam2 epc solenoid short circuit……………………………………………………………………….1609
DXN8KB – Bucket2 epc solenoid short circuit……………………………………………………………………..1609
DXN4KB – Boom2 epc solenoid short circuit……………………………………………………………………….1609
DXN6KB – Stick2 epc solenoid short circuit………………………………………………………………………1609
DXNKKB – Travel3 right epc solenoid short circuit………………………………………………………………..1609
DXNCKB – Boom3 epc solenoid short circuit……………………………………………………………………….1609
DXNBKB – Bucket3 epc solenoid short circuit……………………………………………………………………..1609
DXNLKB – Stick3 epc solenoid short circuit………………………………………………………………………1609
DXNMKB – Slew4 epc solenoid short circuit……………………………………………………………………….1609
Details of the above 6-digit failure codes…………………………………………………………………..1610
DXNHKY – Travel1 left epc solenoid hot short circuit……………………………………………………………..1611
DXN3KY – Stick1 epc solenoid hot short circuit…………………………………………………………………..1611
DXNJKY – Bucket1 epc solenoid hot short circuit………………………………………………………………….1611
DXN2KY – Boom1 epc solenoid hot short circuit……………………………………………………………………1611
DXN5KY – Clam2 epc solenoid hot short circuit……………………………………………………………………1611
DXN8KY – Bucket2 epc solenoid hot short circuit………………………………………………………………….1611
DXN4KY – Boom2 epc solenoid hot short circuit……………………………………………………………………1611
DXN6KY – Stick2 epc solenoid hot short circuit…………………………………………………………………..1611
DXNKKY – Travel3 right epc hot solenoid short circuit…………………………………………………………….1611
DXNCKY – Boom3 epc solenoid hot short circuit……………………………………………………………………1611
DXNBKY – Bucket3 epc solenoid hot short circuit………………………………………………………………….1611
DXNLKY – Stick3 epc solenoid hot short circuit…………………………………………………………………..1611
DXNMKY – Slew4 epc solenoid hot short circuit……………………………………………………………………1611
Details of the above 6-digit failure codes…………………………………………………………………..1612
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623 (block I)……………………………………………..1613
Wiring Diagram for EPC 61K624 – 61K625 – 61K626 – 61K627 (block II)…………………………………………….1614
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 – 61K631 (block III)……………………………………………1615
Wiring Diagram for EPC 61K632 (block IV)…………………………………………………………………….1616
D5Y3KB – Boom down on/off signal short circuit…………………………………………………………………..1617
D5Y2KB – Boom up on/off signal short circuit…………………………………………………………………….1617
D5Y5KB – Stick in on/off signal short circuit……………………………………………………………………1617
D5Y4KB – Stick out on/off signal short circuit…………………………………………………………………..1617
D5Y7KB – Bucket dump on/off signal short circuit…………………………………………………………………1617
Wiring Diagram – VALVE0 controller ON/OFF signal output to node 2………………………………………………1618
DBW5MA – 5V sensor1 power abnormality…………………………………………………………………………..1619
Wiring Diagram – 5V_1 power supply and GND_1 output at VALVE0………………………………………………….1620
DBW6MA – 5V sensor2 power abnormality…………………………………………………………………………..1622
Wiring Diagram – 5V_2 power supply and GND_2 output at VALVE0………………………………………………….1623
DBX9KQ – Model Selection Abnormality……………………………………………………………………………1626
Wiring Diagram – VALVE1 machine selections…………………………………………………………………..1627
DBXZKQ – Lever Control Selection Abnormality…………………………………………………………………….1628
Wiring Diagram – VALVE1 lever control selection………………………………………………………………1629
DBXYKQ – Attachment selection abnormality……………………………………………………………………….1630
Wiring Diagram – VALVE1 attachment selection…………………………………………………………………1631
DBX2KK – Solenoid Power Low Error(VALVE/S1)……………………………………………………………………..1632
Wiring Diagram for message DBX2KK – Solenoid Power Low Error(VALVE/S1)………………………………………….1634
Wiring Diagram for message DBX2KK – PPC safety circuit………………………………………………………..1635
DBX0KQ – VALVE/S1 Con Selection Abnormality……………………………………………………………………..1636
Wiring Diagram – VALVE1 controller selection…………………………………………………………………1637
DBX0MA – VALVE/S1 Con Error……………………………………………………………………………………1638
DKWHMA – R lever right-left redu pot abnorm(VALVE/S1)…………………………………………………………….1640
Wiring Diagram – R lever redundant right-left potentiometer input (DKWHMA)………………………………………1641
DKWFL4 – R lever right-left sig. mismatch(VALVE/S1)………………………………………………………………1642
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1…………………………………………..1643
DKWLMA – R lever front-back redu pot abnorm(VALVE/S1)…………………………………………………………….1644
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA)…………………………………..1645
DKWJL4 – R lever front-back sig. mismatch(VALVE/S1)………………………………………………………………1646
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1…………………………………………..1647
DKWPMA – L lever right-left redu pot abnorm(VALVE/S1)…………………………………………………………….1648
Wiring Diagram – L lever redundant right-left potentiometer input at VALVE1……………………………………..1649
DKWML4 – L lever right-left sig. mismatch(VALVE/S1)………………………………………………………………1650
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1…………………………………………..1651
DKWSMA – L lever front-back redu pot abnorm(VALVE/S1)…………………………………………………………….1652
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/S1) for DKWSMA………………………………………..1653
DKWQL4 – L lever front-back sig. mismatch(VALVE/S1)………………………………………………………………1654
Wiring Diagram – L lever front-back sig. mismatch (VALVE1) for DKWQL4…………………………………………..1655
DKWVMA – R pedal red pot abnormality(VALVE/S1)…………………………………………………………………..1656
Wiring Diagram – R pedal red pot abnormality (VALVE1) for DKWVMA……………………………………………….1657
DKWTL4 – R pedal signal mismatch(VALVE/S1)………………………………………………………………………1658
Wiring Diagram – R pedal signal mismatch(VALVE/S1) for DKWTL4………………………………………………….1659
DKWYMA – L pedal red pot abnormality(VALVE/S1)…………………………………………………………………..1660
Wiring Diagram – L pedal red pot abnormality(VALVE/S1) for DKWYMA………………………………………………1661
DKWWL4 – L pedal signal mismatch(VALVE/S1)………………………………………………………………………1662
Wiring Diagram – L pedal signal mismatch(VALVE/S1) for DKWWL4………………………………………………….1663
DKX2MA – Clam open redu pot abnormality(VALVE/S1)………………………………………………………………..1664
Wiring Diagram – Clam open redu pot abnormality(VALVE/S1)) for DKX2MA…………………………………………..1665
DKX0L4 – Clam open signal mismatch(VALVE/S1)…………………………………………………………………….1666
Wiring Diagram – Clam open signal mismatch(VALVE/S1) for DKX0L4………………………………………………..1667
DKX5MA – Clam close redu pot abnormality(VALVE/S1)……………………………………………………………….1668
Wiring Diagram – Clam close redu pot abnormality(VALVE/S1) for DKX5MA…………………………………………..1669
DKX3L4 – Clam close signal mismatch(VALVE/S1)……………………………………………………………………1670
Wiring Diagram – Clam close signal mismatch(VALVE/S1) for DKX3L4……………………………………………….1671
DKX8MA – Hyd. slew brake redu pot abnorm(VALVE/S1)……………………………………………………………….1672
Wiring Diagram – Hyd. slew brake redu pot abnorm(VALVE/S1) for DKX8MA…………………………………………..1673
DKX6L4 – Hyd. slew brake signal mismatch(VALVE/S1)……………………………………………………………….1674
Wiring Diagram – Hyd. slew brake signal mismatch(VALVE/S1) for DKX6L4…………………………………………..1675
DWKAKA – Travel1 left forward sol. open circuit………………………………………………………………….1676
DWKEKA – Travel1 left backward sol. open circuit…………………………………………………………………1676
DWBJKA – Stick1 out solenoid open circuit……………………………………………………………………….1676
DWBNKA – Stick1 in solenoid open circuit………………………………………………………………………..1676
DWASKA – Bucket1 fill solenoid open circuit……………………………………………………………………..1676
DWAWKA – Bucket1 dump solenoid open circuit……………………………………………………………………..1676
DWBAKA – Boom1 up solenoid open circuit…………………………………………………………………………1676
DWBEKA – Boom1 down solenoid open circuit……………………………………………………………………….1676
Details of above 6-digit failure codes………………………………………………………………………1676
Monitoring screens for directional solenoids – VALVE1…………………………………………………………1677
Wiring Diagram – directional solenoids at remote control block 45.1 (VALVE1)…………………………………….1678
DWKAKB – Travel1 left forward sol. short circuit…………………………………………………………………1679
DWKEKB – Travel1 left backward sol. short circuit………………………………………………………………..1679
DWBJKB – Stick1 out solenoid short circuit………………………………………………………………………1679
DWBNKB – Stick1 in solenoid short circuit……………………………………………………………………….1679
DWASKB – Bucket1 fill solenoid short circuit…………………………………………………………………….1679
DWAWKB – Bucket1 dump solenoid short circuit…………………………………………………………………….1679
DWBAKB – Boom1 up solenoid short circuit………………………………………………………………………..1679
DWBEKB – Boom1 down solenoid short circuit………………………………………………………………………1679
Details of above 6-digit failure codes………………………………………………………………………1679
Monitoring screens for directional solenoids – VALVE1…………………………………………………………1680
Wiring Diagram – directional solenoids at remote control block 45.1 (VALVE1)…………………………………….1681
DWKAKY – Travel1 left forward sol. hot short circuit……………………………………………………………..1682
DWKEKY – Travel1 left backward sol. hot short circuit…………………………………………………………….1682
DWBJKY – Stick1 out solenoid hot short circuit…………………………………………………………………..1682
DWBNKY – Stick1 in solenoid hot short circuit……………………………………………………………………1682
DWASKY – Bucket1 fill solenoid hot short circuit…………………………………………………………………1682
DWAWKY – Bucket1 dump solenoid hot short circuit…………………………………………………………………1682
DWBAKY – Boom1 up solenoid hot short circuit…………………………………………………………………….1682
DWBEKY – Boom1 down solenoid hot short circuit…………………………………………………………………..1682
Details of above 6-digit failure codes………………………………………………………………………1682
Monitoring screens for directional solenoids – VALVE1…………………………………………………………1683
Wiring Diagram – directional solenoids at remote control block 45.1 (VALVE1)…………………………………….1684
DWBXKA – Clam2 close solenoid open circuit………………………………………………………………………1685
DWBTKA – Clam2 open solenoid open circuit……………………………………………………………………….1685
DWATKA – Bucket2 fill solenoid open circuit……………………………………………………………………..1685
DWAXKA – Bucket2 dump solenoid open circuit……………………………………………………………………..1685
DWBBKA – Boom2 up solenoid open circuit…………………………………………………………………………1685
DWBFKA – Boom2 down solenoid open circuit……………………………………………………………………….1685
Details of above 6-digit failure codes………………………………………………………………………1685
Monitoring screens for directional solenoids – VALVE1…………………………………………………………1687
Wiring Diagram – directional solenoids at remote control block 45.2 (VALVE1)…………………………………….1688
DWBXKB – Clam2 close solenoid short circuit……………………………………………………………………..1689
DWBTKB – Clam2 open solenoid short circuit………………………………………………………………………1689
DWATKB – Bucket2 fill solenoid short circuit…………………………………………………………………….1689
DWAXKB – Bucket2 dump solenoid short circuit…………………………………………………………………….1689
DWBBKB – Boom2 up solenoid short circuit………………………………………………………………………..1689
DWBFKB – Boom2 down solenoid short circuit………………………………………………………………………1689
Details of above 6-digit failure codes………………………………………………………………………1689
Monitoring screens for directional solenoids – VALVE1…………………………………………………………1691
Wiring Diagram – directional solenoids at remote control block 45.2 (VALVE1)…………………………………….1692
DWBXKY – Clam2 close solenoid hot short circuit………………………………………………………………….1693
DWBTKY – Clam2 open solenoid hot short circuit…………………………………………………………………..1693
DWATKY – Bucket2 fill solenoid hot short circuit…………………………………………………………………1693
DWAXKY – Bucket2 dump solenoid hot short circuit…………………………………………………………………1693
DWBBKY – Boom2 up solenoid hot short circuit…………………………………………………………………….1693
DWBFKY – Boom2 down solenoid hot short circuit…………………………………………………………………..1693
Details of above 6-digit failure codes………………………………………………………………………1693
Monitoring screens for directional solenoids – VALVE1…………………………………………………………1694
Wiring Diagram – directional solenoids at remote control block 45.2 (VALVE1)…………………………………….1695
D5Y6KB – Bucket fill on/off signal short circuit…………………………………………………………………1696
D5Y9KB – Clam close on/off signal short circuit………………………………………………………………….1696
D5YAKB – Hyd. slew brake order signal short circuit………………………………………………………………1696
D5Y0KB – Slew left on/off signal short circuit…………………………………………………………………..1696
D5Y1KB – Slew right on/off signal short circuit………………………………………………………………….1696
Wiring Diagram – VALVE1 controller ON/OFF signal output to node 2………………………………………………1697
D5YAKY – Hyd. slew brake order signal hot short circuit…………………………………………………………..1698
Wiring Diagram – VALVE1 controller ON/OFF signal output to node 2………………………………………………1699
DBY9KQ – Model Selection Abnormality……………………………………………………………………………1700
Wiring Diagram for message DBY9KQ…………………………………………………………………………..1701
DBYZKQ – Lever Control Selection Abnormality…………………………………………………………………….1702
Wiring Diagram for message DBYZKQ…………………………………………………………………………..1703
DBYYKQ – Attachment selection abnormality……………………………………………………………………….1704
Wiring Diagram for message DBYYKQ…………………………………………………………………………..1705
DBY2KK – Solenoid Power Low Error(VALVE/S2)……………………………………………………………………..1706
Wiring Diagram for message DBY2KK…………………………………………………………………………..1708
Wiring Diagram for message DBy2KK – PPC safety circuit………………………………………………………..1709
DBY0KQ – VALVE/S2 Con Selection Abnormality……………………………………………………………………..1710
Wiring Diagram for message DBY0KQ…………………………………………………………………………..1711
DBY0MA – VALVE/S2 Con Error……………………………………………………………………………………1712
DWBKKA – Stick2 out solenoid open circuit……………………………………………………………………….1713
DWBKKB – Stick2 out solenoid short circuit………………………………………………………………………1713
DWBPKA – Stick2 in solenoid open circuit………………………………………………………………………..1713
DWBPKB – Stick2 in solenoid short circuit……………………………………………………………………….1713
Details of above 6-digit failure codes………………………………………………………………………1713
Wiring Diagram – 61K627a/b open circuit or short circuit to GND………………………………………………..1715
DWBKKY – Stick2 out solenoid hot short circuit…………………………………………………………………..1716
DWBPKY – Stick2 in solenoid hot short circuit……………………………………………………………………1716
Details of above 6-digit failure codes………………………………………………………………………1716
Wiring Diagram – 61K627a/b hot short circuit…………………………………………………………………1717
DWKQKA – Travel3 right backward sol. open circuit………………………………………………………………..1718
DWKLKA – Travel3 right forward sol. open circuit…………………………………………………………………1718
DWBCKA – Boom3 up solenoid open circuit…………………………………………………………………………1718
DWBGKA – Boom3 down solenoid open circuit……………………………………………………………………….1718
DWAUKA – Bucket3 fill solenoid open circuit……………………………………………………………………..1718
DWAYKA – Bucket3 dump solenoid open circuit……………………………………………………………………..1718
DWBLKA – Stick3 out solenoid open circuit……………………………………………………………………….1718
DWBQKA – Stick3 in solenoid open circuit………………………………………………………………………..1718
DWARKA – Slew4 right solenoid open circuit………………………………………………………………………1718
DWAMKA – Slew4 left solenoid open circuit……………………………………………………………………….1718
Details of above 6-digit failure codes………………………………………………………………………1718
Monitoring screens for directional solenoids (45.3 & 43) – VALVE2………………………………………………1720
Wiring Diagram – directional solenoids 61K628a/b & 61K629a/b…………………………………………………..1721
Wiring Diagram – directional solenoids 61K630a/b & 61K631a/b…………………………………………………..1722
Wiring Diagram – directional solenoids 61K632a/b……………………………………………………………..1723
DWKQKB – Travel3 right backward sol. short circuit……………………………………………………………….1724
DWKLKB – Travel3 right forward sol. short circuit………………………………………………………………..1724
DWBCKB – Boom3 up solenoid short circuit………………………………………………………………………..1724
DWBGKB – Boom3 down solenoid short circuit………………………………………………………………………1724
DWAUKB – Bucket3 fill solenoid short circuit…………………………………………………………………….1724
DWAYKB – Bucket3 dump solenoid short circuit…………………………………………………………………….1724
DWBLKB – Stick3 out solenoid short circuit………………………………………………………………………1724
DWBQKB – Stick3 in solenoid short circuit……………………………………………………………………….1724
DWARKB – Slew4 right solenoid short circuit……………………………………………………………………..1724
DWAMKB – Slew4 left solenoid short circuit………………………………………………………………………1724
Details of above 6-digit failure codes………………………………………………………………………1724
Monitoring screens for directional solenoids (45.3 & 43) – VALVE2………………………………………………1726
DWKQKY – Travel3 right backward sol. hot short circuit……………………………………………………………1728
DWKLKY – Travel3 right forward sol. hot short circuit…………………………………………………………….1728
DWBCKY – Boom3 up solenoid hot short circuit…………………………………………………………………….1728
DWBGKY – Boom3 down solenoid hot short circuit…………………………………………………………………..1728
DWAUKY – Bucket3 fill solenoid hot short circuit…………………………………………………………………1728
DWAYKY – Bucket3 dump solenoid hot short circuit…………………………………………………………………1728
DWBLKY – Stick3 out solenoid hot short circuit…………………………………………………………………..1728
DWBQKY – Stick3 in solenoid hot short circuit……………………………………………………………………1728
DWARKY – Slew4 right solenoid hot short circuit………………………………………………………………….1728
DWAMKY – Slew4 left solenoid hot short circuit…………………………………………………………………..1728
Details of above 6-digit failure codes………………………………………………………………………1728
Monitoring screens for directional solenoids (45.3 & 43) – VALVE2………………………………………………1729
DXEDKA – Hyd. slew brake epc sol. open circuit…………………………………………………………………..1730
DXEDKB – Hyd. slew brake epc sol. short circuit………………………………………………………………….1730
Wiring Diagram for messages DXEDKA & DXEDKB………………………………………………………………….1731
DXEDKY – Hyd. slew brake epc sol. hot short circuit………………………………………………………………1732
Wiring Diagram for message DXEDKY…………………………………………………………………………..1733
D5Z3KB – Travel right backward on/off signal short circuit………………………………………………………..1734
D5Z5KB – Travel right forward on/off signal short circuit…………………………………………………………1734
D5Z2KB – Travel left backward on/off signal short circuit…………………………………………………………1734
D5Z4KB – Travel left forward on/off signal short circuit………………………………………………………….1734
D5Y8KB – Clam open on/off signal short circuit…………………………………………………………………..1734
Wiring Diagram – VALVE2 controller ON/OFF signal output to node 2………………………………………………1735
DBZRKR – CAN1 Discon (Pump2 Con)……………………………………………………………………………….1736
Wiring Diagram for message DBZRKR…………………………………………………………………………..1737
DBWRKR – CAN1 Discon (Valve/M Con)……………………………………………………………………………..1738
Wiring Diagram for message DBWRKR…………………………………………………………………………..1739
DBXRKR – CAN1 Discon (Valve/S1 Con)…………………………………………………………………………….1740
Wiring Diagram for message DBXRKR…………………………………………………………………………..1741
DBYRKR – CAN1 Discon (Valve/S2 Con)…………………………………………………………………………….1742
Wiring Diagram for message DBYRKR…………………………………………………………………………..1743
9 Troubleshooting by Symptoms……………………………………………………………………………………..1745
9.1 Symptoms of E-motors and related parts………………………………………………………………………1746
SEM001 – Starting E-motor(s) is not possible…………………………………………………………………1746
Wiring Diagram (main key switch & start buttons) for SEM001………………………………………………..1747
SEM002 – Stopping E-motor(s) is not possible…………………………………………………………………1748
Wiring Diagram (motor stop switches) for SEM002…………………………………………………………..1749
SEM003 – E-motor has excessive vibration…………………………………………………………………….1750
View onto the coupling for SEM003……………………………………………………………………….1751
SEM004 – Abnormal noise coming from E-motor(s)……………………………………………………………….1752
SEM005 – E-motor lacks output (low power)……………………………………………………………………1754
View onto PM CLINIC sheet (power check) for SEM005………………………………………………………..1755
SEM007 – Motor shuts down during start………………………………………………………………………1756
Wiring Diagram – Motor protection relay 12F404-1/-2 for message SEM007………………………………………1757
SEM008 – Substation main circuit breaker tripped……………………………………………………………..1758
Net-line supply overview (SEM008)……………………………………………………………………….1758
Electric energy consumption (SEM008)…………………………………………………………………….1759
Motor current overview with soft start (SEM008)…………………………………………………………..1759
9.2 Symptoms of the Hydraulic System……………………………………………………………………………1760
SHY001 – All work equipment shows lack of power or slow movement (especially “boom up” function)…………………..1760
SHY002 – No work equipment, travel or slew movement…………………………………………………………..1762
SHY003 – Work equipment has too much hydraulic drift………………………………………………………….1763
SHY004 – Work equipment has big time lag…………………………………………………………………….1764
SHY005 – Machine deviates during travel movement……………………………………………………………..1765
SHY006 – Machine does not slew……………………………………………………………………………..1766
Slew brake valve block (SHY006)…………………………………………………………………………1767
SHY007 – Slew acceleration is poor………………………………………………………………………….1768
SHY008 – Excessive overrun when stopping slew movement………………………………………………………..1770
SHY009 – Floating system without function (FSA only)………………………………………………………….1772
SHY010 – Abnormal noise coming from SRV or MRV……………………………………………………………….1773
SHY011 – Track tensioning system without function…………………………………………………………….1774
Track tensioning – overview (SHY011)…………………………………………………………………….1775
SHY012 – Stairway does not move, or slow movement…………………………………………………………….1776
SHY013 – Hydraulic driven grease pump does not move…………………………………………………………..1778
SHY014 – Abnormal track chain movement during digging…………………………………………………………1780
SHY015 – Slew parking brake without function…………………………………………………………………1781
SHY016 – Travel parking brake without function……………………………………………………………….1782
9.3 Symptoms of Mechanical System………………………………………………………………………………1784
SME001 – Abnormal noise around PTO / hydraulic pumps………………………………………………………….1784
SME002 – There is a big shock when stopping slew movement……………………………………………………..1786
SME003 – There is a big abnormal noise when moving/stopping slew movement……………………………………….1788
SME004 – Abnormal noise coming from a travel gearbox………………………………………………………….1790
SME005 – Abnormal noise coming from the work equipment (lack of grease)…………………………………………1792
SME006 – Abnormal idler movement……………………………………………………………………………1794
SME007 – Leak at the PTO drive shaft seal……………………………………………………………………1796
9.4 Symptoms of Additional Systems……………………………………………………………………………..1798
SAD001 – Air conditioner for cabin does not work……………………………………………………………..1798
View onto the A/C unit (SAD001)…………………………………………………………………………1799
SAD002 – Air conditioner LV cabinet does not work…………………………………………………………….1800
SAD003 – Air conditioner HV cabinet does not work…………………………………………………………….1800
View onto an A/C filling and service station……………………………………………………………..1801
SAD004 – CAN BUS failure (message #D0308 displayed)…………………………………………………………..1802
50 DISASSEMBLY & ASSEMBLY…………………………………………………………………………………………….1809
TOC
……………………………………………………………………………………………………………1811
1 Introduction…………………………………………………………………………………………………..1819
1.1 Foreword…………………………………………………………………………………………………1820
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels…………………1821
1.3 Diagrams and illustrations in this manual……………………………………………………………………1821
1.4 Procedures for disassembling and assembling in this manual…………………………………………………….1822
2 Safety………………………………………………………………………………………………………..1823
2.1 Overview…………………………………………………………………………………………………1825
2.1.1 Method of using this manual…………………………………………………………………………..1825
2.2 General precautions……………………………………………………………………………………….1827
2.2.1 General…………………………………………………………………………………………….1827
2.2.2 Personal protective clothing………………………………………………………………………….1827
2.2.3 When using a hammer………………………………………………………………………………….1828
2.2.4 Proper tools………………………………………………………………………………………..1828
2.2.5 Personnel…………………………………………………………………………………………..1828
2.2.6 Fire prevention……………………………………………………………………………………..1829
2.2.7 Unauthorized modification…………………………………………………………………………….1829
2.3 Precautions for maintenance and repair………………………………………………………………………1830
2.3.1 General precautions………………………………………………………………………………….1830
2.3.2 Keep work place clean and tidy………………………………………………………………………..1830
2.3.3 Precautions when welding……………………………………………………………………………..1831
2.3.4 Precaution with high pressure fluids…………………………………………………………………..1831
2.3.4.1 Handling high pressure hoses and pipes……………………………………………………………1831
2.3.5 Compressed air………………………………………………………………………………………1831
2.3.6 Waste materials……………………………………………………………………………………..1832
3 Superstructure…………………………………………………………………………………………………1833
3.1 Superstructure overview……………………………………………………………………………………1834
3.2 Machinery house…………………………………………………………………………………………..1836
3.2.1 Disconnection plates…………………………………………………………………………………1838
3.2.1.1 R.H.-side disconnection plate [56XH01] – port allocations…………………………………………..1838
3.2.1.2 L.H.-side disconnection plate [58XH01] – connector allocations………………………………………1839
3.2.2 Machinery house roof…………………………………………………………………………………1840
3.2.2.1 Disassembling of the machinery house roof cover plates……………………………………………..1842
3.2.2.2 Assembling of the machinery house roof cover plates………………………………………………..1846
3.2.3 Lubrication pump station……………………………………………………………………………..1852
3.2.3.1 Disassembling of the lubrication pump station……………………………………………………..1852
3.2.3.2 Assembling of the lubricating pump station………………………………………………………..1854
3.2.4 Electric motors……………………………………………………………………………………..1856
3.2.4.1 Disassembling of the electric motor (motor 1 or 2)…………………………………………………1856
3.2.4.2 Assembling of thE electriC motor (motor 1 or 2)……………………………………………………1860
3.2.5 Final alignment of the electric motors…………………………………………………………………1864
3.2.5.1 Disassembling of the capacitor assembly…………………………………………………………..1868
3.2.5.2 Assembling of the capacitor assembly……………………………………………………………..1870
3.2.6 Batteries…………………………………………………………………………………………..1871
3.2.6.1 Disassembling of the batteries…………………………………………………………………..1871
3.2.6.2 Assembling of the batteries……………………………………………………………………..1873
3.2.7 Flexible drive coupling………………………………………………………………………………1875
3.2.7.1 Disassembling of the CENTALINK coupling…………………………………………………………..1875
3.2.7.2 Assembling of the CENTALINK coupling……………………………………………………………..1877
3.2.8 Main pump assemblies…………………………………………………………………………………1880
3.2.8.1 Disassembling of the main pump assemblies…………………………………………………………1881
3.2.8.2 Assembling of the main pump assemblies……………………………………………………………1885
3.2.9 Universal pump distributor gear box (PTO)………………………………………………………………1888
3.2.9.1 Disassembling of the universal pump distributor gear box (PTO)………………………………………1889
3.2.9.2 Assembling of the universal pump distributor gear box (PTO)…………………………………………1892
3.2.9.3 Disassembling of the control and filter plate assemblies……………………………………………1896
3.2.9.4 Assembling of the control and filter plate assemblies………………………………………………1905
3.2.9.5 Disassembling of the PTO gear oil pump……………………………………………………………1913
3.2.9.6 Assembling of the PTO gear oil pump………………………………………………………………1915
3.3 Hydraulic system………………………………………………………………………………………….1918
3.3.1 Hydraulic oil cooler assembly…………………………………………………………………………1918
3.3.1.1 Disassembling of hydraulic cooler fan…………………………………………………………….1919
3.3.1.2 Assembling of hydraulic cooler fan……………………………………………………………….1920
3.3.1.3 Disassembling of hydraulic cooler fan motor……………………………………………………….1921
3.3.1.4 Assembling of hydraulic cooler fan motor………………………………………………………….1923
3.3.1.5 Disassembling of the hydraulic oil coolers………………………………………………………..1925
3.3.1.6 Assembling of the hydraulic oil coolers…………………………………………………………..1928
3.3.1.7 Disassembling of the hydraulic oil cooler assembly…………………………………………………1931
3.3.1.8 Assembling of the hydraulic oil cooler assembly……………………………………………………1936
3.3.2 Hydraulic oil tank…………………………………………………………………………………..1942
3.3.2.1 Disassembling of the main shut-off valve………………………………………………………….1944
3.3.2.2 Assembling of the main shut-off valve…………………………………………………………….1946
3.3.2.3 Disassembling of the hydraulic oil tank…………………………………………………………..1948
3.3.2.4 Assembling of the hydraulic oil tank……………………………………………………………..1959
3.3.3 Control frame assembly……………………………………………………………………………….1972
3.3.3.1 Disassembling of the main control valve blocks I, II and III………………………………………..1973
3.3.3.2 Assembling of the main control valve blocks I, II and III…………………………………………..1977
3.3.3.3 Disassembling of the main control valve block IV (Slewing)………………………………………….1981
3.3.3.4 Assembling of the main control valve block IV (Slewing)…………………………………………….1983
3.3.3.5 Disassembling of the high pressure filters at the main control valve blocks…………………………..1985
3.3.3.6 Assembling of the high pressure filters at the main control valve blocks……………………………..1988
3.3.3.7 Disassembling of the MRV at the main control valve blocks…………………………………………..1991
3.3.3.8 Assembling of the MRV at the main control valve blocks……………………………………………..1992
3.3.3.9 Disassembling of SRV on main control valve block…………………………………………………..1993
3.3.3.10 Assembling of SRV on main control valve blocks……………………………………………………1994
3.3.3.11 Disassembling of ACV-/SRV-block on main control valve blocks……………………………………….1995
3.3.3.12 Assembling of ACV-/SRV-block on main control valve blocks………………………………………….1996
3.3.4 Distributor Manifold…………………………………………………………………………………1998
3.3.4.1 Disassembling of throttle check valves at the distributor manifold…………………………………..1999
3.3.4.2 Assembling of throttle check valves at the distributor manifold……………………………………..2001
3.3.4.3 Disassembling of anti cavitation valves at the distributor manifold………………………………….2003
3.3.4.4 Assembling of anti cavitation valves at the distributor manifold…………………………………….2005
3.3.4.5 Disassembling of the distributor manifold…………………………………………………………2009
3.3.4.6 Assembling of the distributor manifold……………………………………………………………2012
3.4 Slew system………………………………………………………………………………………………2014
3.4.1 Slew gears………………………………………………………………………………………….2014
3.4.1.1 Disassembling of the slew gear…………………………………………………………………..2015
3.4.1.2 Assembling of the slew gear……………………………………………………………………..2018
3.4.2 Slew brake valve block……………………………………………………………………………….2022
3.4.2.1 Disassembling of the slew brake valve block……………………………………………………….2022
3.4.2.2 Assembling of the slew brake valve block………………………………………………………….2024
3.4.3 Hydraulic slew motors………………………………………………………………………………..2026
3.4.3.1 Disassembling of the slew motor………………………………………………………………….2026
3.4.3.2 Assembling of the slew motor…………………………………………………………………….2028
3.4.4 Slew parking brake…………………………………………………………………………………..2030
3.4.4.1 Disassembly of the slew parking brake (id code GFB 174)…………………………………………….2031
3.4.4.2 Assembly of the slew parking brake (id code GFB 174)……………………………………………….2034
3.4.4.3 Disassembling of the slew parking brake (id code 89DS03)……………………………………………2037
3.4.4.4 Assembling of the slew parking brake (id code 89DS03)………………………………………………2040
3.4.5 Slew circle…………………………………………………………………………………………2043
3.4.5.1 Disassembling of the slew circle…………………………………………………………………2043
3.4.5.2 Assembling of the slew circle……………………………………………………………………2047
3.4.6 Slew circle lubrication pinion (dummy wheel)……………………………………………………………2049
3.4.6.1 Disassembling of the lubrication pinion assembly…………………………………………………..2049
3.4.6.2 Assembling of the lubrication pinion assembly……………………………………………………..2051
3.5 Operator’s cab……………………………………………………………………………………………2052
3.5.1 Disassembling of the operator’s cab……………………………………………………………………2053
3.5.2 Assembling of the operator’s cab………………………………………………………………………2057
3.5.3 Disassembling of the operator’s cab together with the cab support frame……………………………………2061
3.5.4 Assembling of the operator’s cab together with the cab support frame………………………………………2065
3.5.5 Cab-mounts………………………………………………………………………………………….2068
3.5.5.1 Disassembling of the cab-mounts………………………………………………………………….2068
3.5.5.2 Assembling of the cab-mounts…………………………………………………………………….2070
3.5.6 Front window………………………………………………………………………………………..2072
3.5.6.1 Disassembling of the front window………………………………………………………………..2072
3.5.6.2 Assembling of the front window…………………………………………………………………..2073
3.5.7 Operator’s seat……………………………………………………………………………………..2074
3.5.7.1 Disassembling of the operator’s seat……………………………………………………………..2074
3.5.7.2 Assembling of the operator’s seat………………………………………………………………..2075
3.6 Cab base (Medium voltage switch cabinet)…………………………………………………………………….2076
3.6.1 Disassembling of the cab support frame…………………………………………………………………2077
3.6.2 Assembling of the cab support frame……………………………………………………………………2079
3.6.3 Disassembling of the cab base…………………………………………………………………………2081
3.6.4 Assembling of the cab base……………………………………………………………………………2084
3.7 Ladders, stairways and platforms……………………………………………………………………………2088
3.7.1 Hydraulically operated stairway……………………………………………………………………….2088
3.7.1.1 Disassembling of the hydraulically operated stairway……………………………………………….2088
3.7.1.2 Assembling of the hydraulically operated stairway………………………………………………….2090
3.7.1.3 Disassembling of the stairway cylinder……………………………………………………………2092
3.7.1.4 Assembling of the stairway cylinder………………………………………………………………2094
3.7.2 High voltage switch cabinet stairway…………………………………………………………………..2095
3.7.2.1 Disassembling of the high voltage switch cabinet stairway…………………………………………..2095
3.7.2.2 Assembling of the high voltage switch cabinet stairway……………………………………………..2097
3.7.3 stairway platform……………………………………………………………………………………2098
3.7.3.1 Disassembling of the stairway platform……………………………………………………………2098
3.7.3.2 Assembling of the stairway platform………………………………………………………………2101
3.7.4 Emergency escape ladders……………………………………………………………………………..2104
3.7.4.1 Disassembling of the emergency escape ladder assembly at the cab base………………………………..2104
3.7.4.2 Assembling of the emergency escape ladder assembly at the cab base…………………………………..2105
3.7.4.3 Disassembling of the emergency escape ladder assembly at the machinery house………………………….2106
3.7.4.4 Assembling of the emergency escape ladder assembly at the machinery house…………………………….2107
3.8 Counterweight…………………………………………………………………………………………….2109
3.8.1 Disassembling of the counterweight…………………………………………………………………….2110
3.8.2 Assembling of the counterweight……………………………………………………………………….2113
3.9 high voltage switch cabinet………………………………………………………………………………..2118
3.9.1 General information regarding disassembling and assembling……………………………………………….2118
3.9.2 Disassembling of the high voltage switch cabinet………………………………………………………..2121
3.9.3 Assembling of the high voltage switch cabinet…………………………………………………………..2130
3.10 Slip ring unit…………………………………………………………………………………………..2138
3.10.1 Disassembling of the slip ring unit…………………………………………………………………..2138
3.10.2 Assembling of the slip ring unit……………………………………………………………………..2141
3.11 Superstructure Lifting……………………………………………………………………………………2144
3.11.1 Disassembling the superstructure from the undercarriage…………………………………………………2144
3.11.2 Assembling the superstructure onto the undercarriage……………………………………………………2148
4 Undercarriage………………………………………………………………………………………………….2151
4.1 Undercarriage overview…………………………………………………………………………………….2152
4.1.0.1 Changing of the crawler track……………………………………………………………………….2154
4.1.1 Sprocket assembly……………………………………………………………………………………2161
4.1.1.1 Disassembling of the sprocket assembly……………………………………………………………2161
4.1.1.2 Assembling of the sprocket assembly………………………………………………………………2166
4.1.2 Guide wheel assembly…………………………………………………………………………………2169
4.1.2.1 Disassembling of the guide wheel assembly…………………………………………………………2169
4.1.2.2 Assembling of the guide wheel assembly……………………………………………………………2172
4.1.3 Track tensioning accumulators…………………………………………………………………………2175
4.1.3.1 Disassembling of the low pressure accumulators…………………………………………………….2175
4.1.3.2 Assembling of the low pressure accumulators……………………………………………………….2177
4.1.3.3 Disassembling of the high pressure accumulators……………………………………………………2179
4.1.3.4 Assembling of the high pressure accumulators………………………………………………………2180
4.1.4 Track tensioning valve block………………………………………………………………………….2181
4.1.4.1 Disassembling of the track tensioning valve block………………………………………………….2181
4.1.4.2 Assembling of the track tensioning valve block…………………………………………………….2183
4.1.5 Track tensioning cylinders……………………………………………………………………………2184
4.1.5.1 Disassembling of the track tensioning cylinders……………………………………………………2184
4.1.5.2 Assembling of the track tensioning cylinders………………………………………………………2186
4.1.6 Replace the Hydraulic hoses of the track tensioning system……………………………………………….2189
4.1.6.1 Precursory work………………………………………………………………………………..2189
4.1.6.2 Replace the hydraulic hoses inside the undercarriage center body…………………………………….2191
4.1.6.3 Replace the hydraulic hose between undercarriage center body and crawler frame………………………..2191
4.1.6.4 Replace the hydraulic hoses inside the crawler frame……………………………………………….2193
4.1.6.5 Subsequent work………………………………………………………………………………..2193
4.1.7 Travel brake valve block (overspeed valve)……………………………………………………………..2194
4.1.7.1 Disassembling of the travel brake valve block……………………………………………………..2194
4.1.7.2 Assembling of the travel brake valve block………………………………………………………..2195
4.1.8 Travel motor………………………………………………………………………………………..2196
4.1.8.1 Disassembling of the travel motors……………………………………………………………….2196
4.1.8.2 Assembling of the travel motors………………………………………………………………….2198
4.1.9 Travel parking brake…………………………………………………………………………………2200
4.1.9.1 Disassembling of the travel parking brake (id code ZHP 5.36 and id code GFA 350)………………………2202
4.1.9.2 Assembling of the travel parking brake (id code ZHP 5.36 and id code GFA 350)…………………………2206
4.1.10 Travel gearbox……………………………………………………………………………………..2211
4.1.10.1 Disassembling of the travel gearbox……………………………………………………………..2212
4.1.10.2 Assembling of the travel gearbox………………………………………………………………..2214
4.1.11 Carrier rollers…………………………………………………………………………………….2217
4.1.11.1 Disassembling of the carrier roller assembly……………………………………………………..2217
4.1.11.2 Assembling of the carrier roller assembly………………………………………………………..2219
4.1.12 Track rollers………………………………………………………………………………………2221
4.1.12.1 Disassembling of the track roller assembly……………………………………………………….2221
4.1.12.2 Assembling of the track roller assembly………………………………………………………….2223
4.1.13 Replace the hydraulic hoses of the traveling system…………………………………………………….2226
4.2 Undercarriage Center Body………………………………………………………………………………….2230
4.2.1 Disassembling of the undercarriage center body and the crawler carriers……………………………………2230
4.2.2 Assembling of the undercarriage center body and the crawler carriers………………………………………2235
4.2.2.1 Install crawler carrier mounting bolts……………………………………………………………2240
4.2.3 Rotary joint………………………………………………………………………………………..2241
4.2.3.1 Disassembling of the rotary joint………………………………………………………………..2241
4.2.3.2 Assembling of the rotary joint…………………………………………………………………..2245
4.3 Cable drum assembly……………………………………………………………………………………….2248
4.3.1 Disassembling of the cable drum assembly……………………………………………………………….2249
4.3.2 Assembling of the cable drum assembly………………………………………………………………….2251
5 Attachment…………………………………………………………………………………………………….2255
5.1 Attachment bearings at superstructure……………………………………………………………………….2256
5.1.1 Boom foot bearings with full floating pins……………………………………………………………..2256
5.1.1.1 Disassembling of the boom foot bearings…………………………………………………………..2257
5.1.1.2 Assembling of the boom foot bearings……………………………………………………………..2259
5.1.2 Boom cylinder foot bearings with full floating pins……………………………………………………..2262
5.1.2.1 Disassembling of the boom cylinder foot bearings – BHA arrangement…………………………………..2264
5.1.2.2 Assembling of the boom cylinder foot bearings – BHA arrangement……………………………………..2266
5.1.2.3 Disassembling of the boom cylinder foot bearings – FSA arrangement…………………………………..2269
5.1.2.4 Assembling of the boom cylinder foot bearings – FSA arrangement……………………………………..2271
5.2 Repair procedures…………………………………………………………………………………………2274
5.2.1 Replacement of bushings at the attachment………………………………………………………………2274
5.2.1.1 Removal of the bushings…………………………………………………………………………2274
5.2.1.2 Installation of the bushings…………………………………………………………………….2275
5.2.2 General installation instructions for attachment pins……………………………………………………2276
5.3 Backhoe (BHA)…………………………………………………………………………………………….2278
5.3.1 Overview……………………………………………………………………………………………2278
5.3.2 Pin Sealing bucket – Steering Rod – bucket link rod……………………………………………………..2280
5.3.3 Boom assembly……………………………………………………………………………………….2282
5.3.3.1 Disassembling of the boom……………………………………………………………………….2282
5.3.3.2 Assembling of the boom………………………………………………………………………….2284
5.3.3.3 Disassembling of the boom cylinders………………………………………………………………2286
5.3.3.4 Assembling of the boom cylinders…………………………………………………………………2290
5.3.4 Stick assembly………………………………………………………………………………………2295
5.3.4.1 Disassembling of the Stick………………………………………………………………………2295
5.3.4.2 Assembling of the Stick…………………………………………………………………………2300
5.3.4.3 Disassembling of the Stick Cylinders……………………………………………………………..2305
5.3.4.4 Assembling of the Stick cylinders………………………………………………………………..2310
5.3.5 Bucket and steering………………………………………………………………………………….2315
5.3.5.1 Disassembling of the bucket……………………………………………………………………..2315
5.3.5.2 Assembling of the bucket………………………………………………………………………..2319
5.3.5.3 Disassembling of the Bucket Cylinders…………………………………………………………….2322
5.3.5.4 Assembling of the Bucket Cylinders……………………………………………………………….2329
5.3.5.5 Disassembling of the bucket link rod……………………………………………………………..2336
5.3.5.6 Assembling of the bucket link rod………………………………………………………………..2339
5.3.5.7 Disassembling of the steering rods……………………………………………………………….2342
5.3.5.8 Assembling of the steering rods………………………………………………………………….2348
5.3.6 Hydraulic hoses at the backhoe attachment………………………………………………………………2352
5.3.6.1 Replace the boom arc hoses………………………………………………………………………2352
5.3.6.2 Replace the boom cylinder hoses………………………………………………………………….2356
5.3.6.3 Replace the stick cylinder hoses…………………………………………………………………2358
5.3.6.4 Replace the bucket cylinder hoses………………………………………………………………..2360
5.4 Front shovel (FSA)………………………………………………………………………………………..2362
5.4.1 Overview……………………………………………………………………………………………2362
5.4.2 Using the Cylinder Mounting Device for Front shovel attachments (PN 967 000 40)…………………………….2364
5.4.2.1 Designated usage……………………………………………………………………………….2365
5.4.2.2 Non-designated usage……………………………………………………………………………2365
5.4.3 Boom assembly……………………………………………………………………………………….2366
5.4.3.1 Disassembling of the boom……………………………………………………………………….2366
5.4.3.2 Assembling of the boom………………………………………………………………………….2368
5.4.3.3 Disassembling of the boom cylinders………………………………………………………………2370
5.4.3.4 Assembling of the boom cylinders…………………………………………………………………2374
5.4.4 Stick assembly………………………………………………………………………………………2380
5.4.4.1 Disassembling of the stick………………………………………………………………………2380
5.4.4.2 Assembling of the stick…………………………………………………………………………2385
5.4.4.3 Disassembling of the stick cylinders……………………………………………………………..2390
5.4.4.4 Assembling of the stick cylinders………………………………………………………………..2394
5.4.5 Bull clam bucket…………………………………………………………………………………….2398
5.4.5.1 Disassembling of the bull clam bucket…………………………………………………………….2398
5.4.5.2 Assembling of the bull clam bucket……………………………………………………………….2402
5.4.5.3 Disassembling of the bucket cylinders…………………………………………………………….2406
5.4.5.4 Assembling of the bucket cylinders……………………………………………………………….2412
5.4.5.5 Disassembling of the clam cylinders………………………………………………………………2418
5.4.5.6 Assembling of the clam cylinders…………………………………………………………………2423
5.4.6 Hydraulic hoses at the front shovel attachment………………………………………………………….2428
5.4.6.1 Replace the boom arc hoses………………………………………………………………………2428
5.4.6.2 Replace the boom cylinder hoses………………………………………………………………….2432
5.4.6.3 Replace the stick arc hoses……………………………………………………………………..2434
5.4.6.4 Replace the stick cylinder hoses…………………………………………………………………2436
5.4.6.5 Replace the bucket cylinder hoses………………………………………………………………..2438
5.4.6.6 Replace the clam cylinder hoses………………………………………………………………….2440
5.5 Ground engaging tools (GET)………………………………………………………………………………..2445
5.5.1 Replacement of the GET……………………………………………………………………………….2445
5.6 Cylinder bypass test………………………………………………………………………………………2446
6 Service Information…………………………………………………………………………………………….2447
6.1 Fluids and lubricants……………………………………………………………………………………..2448
6.2 Lifting Gears…………………………………………………………………………………………….2448
6.3 Safety hints for sling accessory……………………………………………………………………………2450
6.4 Weight tables…………………………………………………………………………………………….2451
6.4.1 Superstructure………………………………………………………………………………………2451
6.4.2 Undercarriage……………………………………………………………………………………….2453
6.4.3 Backhoe attachment (BHA)……………………………………………………………………………..2454
6.4.4 Face shovel attachment (FSA)………………………………………………………………………….2455
6.5 Torque charts according to KOMATSU company standard…………………………………………………………..2456
6.5.1 Metric standard thread……………………………………………………………………………….2456
6.5.2 Metric fine thread…………………………………………………………………………………..2457
6.5.3 Cummins motor torques – metric………………………………………………………………………..2458
6.5.4 Cummins motor torques – U.S. customary…………………………………………………………………2458
6.5.5 SAE-flange connections……………………………………………………………………………….2459
6.6 Blind plugs………………………………………………………………………………………………2460
6.6.1 Dummy plates for SAE–flanges………………………………………………………………………….2460
6.6.2 Classification of threads to the nominal width………………………………………………………….2462
6.6.3 Plugs and fittings according to DIN 2353……………………………………………………………….2463
6.7 Conversion table………………………………………………………………………………………….2464
6.7.1 Method of using the conversion table…………………………………………………………………..2464
6.7.2 Millimeter – inch & kilogram – pound…………………………………………………………………..2465
6.7.3 Liter – U.S. gallon & liter – U.K. gallon………………………………………………………………2466
6.7.4 Nm- ft.lb…………………………………………………………………………………………..2467
6.7.5 Bar – PSI – kPa – MPa………………………………………………………………………………..2468
6.7.6 Temperature…………………………………………………………………………………………2469
6.8 Tools……………………………………………………………………………………………………2470
6.8.1 Standard tool case…………………………………………………………………………………..2470
6.8.2 Used special tools (Overview)…………………………………………………………………………2472
6.9 Work instructions…………………………………………………………………………………………2475
6.9.1 Bleeding the track tensioning system…………………………………………………………………..2475
6.9.2 Hints for hydraulic hose installation………………………………………………………………….2477
6.9.3 Remove / install the crawler carrier…………………………………………………………………..2480
6.9.4 Repair procedure for the radiator assembly……………………………………………………………..2481
7 Parts & Service News……………………………………………………………………………………………2483
7.1 List of the PARTS AND SERVICE NEWS………………………………………………………………………….2484

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