Komatsu Hydraulic Mining Excavator PC5500-11 T2 Shop Manual PDF

Description

Komatsu Hydraulic Mining Excavator PC5500-11 T2 Shop Manual  – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Mining Excavator PC5500-11 T2 Shop Manual  – PDF DOWNLOAD

Language : English
Pages :1820
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Mining Excavator PC5500-11 T2 Shop Manual  – PDF DOWNLOAD

SERIAL NUMBER 15191 and up

SAFETY INFORMATION
To enable you to use this excavator safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the excavator must always be
followed.
The safety information in this manual does not replace any safety rules or laws in your area.
To identify important safety messages in the manual and on the excavator labels, the following signal words are
used.
The “Safety Alert Symbol” identifies important safety messages on excavators, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.

TABLE OF CONTENTS:

Komatsu Hydraulic Mining Excavator PC5500-11 T2 Shop Manual  – PDF DOWNLOAD

SERIAL NUMBER 15191 and up

SHOP MANUAL PC5500-11 T2 1
CHANGE HISTORY 2
00 FOREWORD & SAFETY 3
1 FOREWORD 5
11 BEFORE READING THIS MANUAL 6
111 CSA (Canadian Standards Association) 6
12 CONTENTS OF THIS BINDER 7
121 Contacting the Service 7
122 Guarantee 7
13 DIVISION OF THE BINDER 8
2 SAFETY 9
21 SAFETY INFORMATION 10
22 OVERVIEW 11
221 NORMAL OPERATIONS 11
222 REGULAR MAINTENANCE 11
223 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 11
224 ADDITIONAL SAFETY PRECAUTIONS 11
23 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 12
231 SOUND 12
232 VIBRATION 13
24 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 14
241 UNDERSTANDING THE excavator 14
242 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 14
2421 ENSURING SAFE OPERATION 14
243 PREPARATIONS FOR SAFE OPERATION 14
2431 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 14
2432 INSPECTING THE excavator 14
2433 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 15
2434 KEEP excavator CLEAN 15
2435 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 15
2436 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 16
2437 IF A PROBLEM IS FOUND 16
244 FIRE PREVENTION 16
2441 PRECAUTIONS TO PREVENT FIRE 16
2442 ACTION IF FIRE OCCURS ON PC3000 Tier 2 and Electro 17
2443 ACTION IF FIRE OCCURS ON PC3000 Tier 4, PC4000, PC5500, PC7000, PC8000 18
2444 EMERGENCY EXIT FROM OPERATOR’S CAB FOR PC3000 18
2445 EMERGENCY EXIT FROM OPERATOR’S CAB FOR PC4000, PC5500, PC7000, PC8000 19
245 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR 19
2451 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE excavator 19
2452 NO JUMPING ON OR OFF THE excavator 19
2453 NO PEOPLE ON THE ATTACHMENT 19
2454 WORKING IN HIGH PLACES 20
2455 LEAVING OPERATOR’S SEAT WITH LOCK 21
2456 LEAVING THE excavator 21
246 BURN PREVENTION 21
2461 Hot coolant 21
2462 Hot oil 22
247 PRECAUTIONS WHEN CLEANING CAB GLASS 22
248 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 22
249 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 23
2491 UNAUTHORIZED MODIFICATION 23
2492 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 23
2410 ELECTROMAGNETIC COMPATIBILITY (EMC) 23
2411 PRECAUTIONS AT JOBSITE 24
24111 VISIBILITY FROM OPERATOR’S SEAT 25
24112 CAMERA SYSTEM WITH MONITORS 25
24113 ENSURE GOOD VISIBILITY 25
24114 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 25
24115 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 26
24116 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 26
24117 Lightning Strikes 27
24118 WORKING ON LOOSE GROUND 27
24119 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 28
241110 VENTILATION OF ENCLOSED AREAS 29
2412 STARTING motor 30
24121 WARNING TAG 30
24122 CHECKS BEFORE STARTING motor 30
24123 PRECAUTION WHEN STARTING motor 30
24124 PRECAUTION IN COLD AREAS 31
2413 OPERATION 31
24131 CHECKS BEFORE OPERATION 31
24132 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 32
24133 PRECAUTIONS WHEN traveling 33
24134 TRAVELING ON SLOPES 34
24135 OPERATIONS ON SLOPES 35
24136 PROHIBITED OPERATIONS 35
24137 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 36
24138 PARKING THE excavator 36
24139 TRANSPORTATION 36
25 PRECAUTION FOR MAINTENANCE 37
251 GENERAL PRECAUTIONS 37
2511 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 38
2512 STOP motor FOR MAINTENANCE 39
2513 WARNING TAG 39
2514 Maintenance safety Switch 39
2515 KEEP WORKPLACE CLEAN AND TIDY 40
2516 APPOINT LEADER WHEN WORKING WITH OTHERS 41
2517 TWO WORKERS FOR MAINTENANCE WHEN THE excavator IS RUNNING 41
2518 INSTALLING, REMOVING OR STORING ATTACHMENTS 41
2519 PRECAUTIONS WHEN WORKING UNDER THE excavator OR EQUIPMENT 42
25110 NOISE 42
25111 WHEN USING A HAMMER 42
25112 PROPER TOOLS 43
25113 ACCUMULATOR 43
25114 PERSONNEL 43
252 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 44
2521 PRECAUTION WHEN WELDING 44
2522 BATTERY HANDLING 44
253 PRECAUTIONS WITH HIGH PRESSURE FLUID 45
2531 PRECAUTIONS WITH HIGH FUEL PRESSURE 46
2532 HANDLING HIGH PRESSURES HOSES OR PIPES 47
2533 REPLACEMENT OF HOSE LINES 47
2534 INSPECTION OF HOSE LINES 47
2535 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 48
2536 PRECAUTIONS FOR HIGH VOLTAGE 48
2537 AIR CONDITIONING MAINTENANCE 48
2538 COMPRESSED AIR 49
2539 WASTE MATERIALS 49
26 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 50
261 INSPECTION OF THE HYDRAULIC SYSTEM 50
262 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS 50
263 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 50
27 SPECIAL SAFETY EQUIPMENT 51
271 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’S CAB 52
272 OBJECT HANDLING 52
273 LIGHTING 52
274 WARNING BEACON 52
275 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 52
2751 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 52
2752 INSTRUCTIONS FOR USE 53
2753 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 54
2754 INSTRUCTIONS FOR USE 54
01 SPECIFICATION 57
PC5500-11 T2 59
10 STRUCTURE & FUNCTION 63
TOC 65
1 Introduction 77
11 Foreword 78
12 Recommendations for environmentally friendly operation and maintenance of hydraulic mining excavators 79
13 Explanation of abbreviations 80
14 Diagrams & illustrations in this manual 81
2 Specifications 83
21 Lifting Gears 84
22 Safety hints for sling accessory 86
23 Standard Tightening Torque Chart 87
24 Conversion Table 88
25 Blind plugs 94
26 Classification of threads to the nominal width 96
27 Plugs & fittings according to ISO 8434-1 / DIN 2353 97
3 Main assembly groups 99
31 General layout 100
32 Superstructure 102
321 Side view 102
322 Superstructure top view 104
33 Machinery house 106
34 Hydraulic oil tank 108
35 Hydraulic oil cooler 110
36 Fuel tank with Wiggins service system VR300 112
37 Cab support 114
38 Operator’s cab 116
39 Air conditioner 118
310 Main control blocks (FSA) 120
311 Slew machinery 122
3111 Slew gear type 632770 122
312 Undercarriage 124
313 Slew ring 126
314 Attachment 128
3141 Front Shovel Attachment (FSA) 128
3142 Backhoe Attachment (BHA) 130
315 Counterweight 132
316 KomVision camera system 134
317 PLM (Payload monitoring) 135
4 Drive 137
41 Prime drive assembly 138
42 Engine and PTO mounts 140
421 Checks and adjustments 141
43 Flexible coupling 142
431 Information for maintenance 144
432 Coupling elements 145
433 Separation and assembly of coupling inner and outer part 146
434 Operation troubles, causes, and rectification 147
44 Radiator assembly and fan drive 148
441 Radiator assembly 148
442 Radiator fan drive 150
4421 Hydraulic schematic of radiator fan drive 152
443 Fan pump type HPV112 154
444 Radiator fan speed testing & adjustment 156
4441 Testing & readjustment procedure 158
4442 Basic adjustment procedure 159
45 Pump distributor gearbox (PTO) 160
451 Pump drive chamber ventilation, oil level & oil drain 162
452 PTO gear oil standard 163
453 Pump drive spline lubrication 164
4531 Oil level in main pump & gear oil pump drive shaft housing 165
454 PTO lubrication and cooling 166
4541 Hydraulic components and schematic of cooling circuit-1 166
4542 Schematic overview – PTO gear oil cooling circuit-1 168
4543 Checks and adjustments 170
46 Hydraulic pumps – location, drive speed and flow rates 172
47 Air cleaner 176
5 Hydraulic oil tank 179
51 General layout 180
52 Hydraulic oil level definition 182
521 Oil level sight gauge for return oil chamber 183
522 View onto a return oil filter 185
53 Hydraulic oil tank, location of the electric equipment 186
54 Suction oil tank with strainers 188
55 Return oil collector pipe with strainer 190
56 Back pressure valve 192
57 Transfer pump 194
58 Return and leak oil filter 196
59 Breather filter 198
6 Hydraulic oil cooling 201
61 Overall view on the hydraulic oil cooling 202
611 Hydraulic oil cooling overview part 2 204
62 Function of the hydraulic oil cooling circuit 206
63 Adjustment of the back pressure valve 208
64 Stepless cooler fan RPM control 210
641 SRV 212
642 Components of the fan drive circuits 214
643 Fan pump type HPV112 216
65 Oil cooler fan speed 218
66 Oil cooler fan speed testing/adjustment 220
661 Testing & readjustment procedure via K+ 222
662 SRV adjustment procedure 223
67 Hydraulic oil temperature charts 224
7 Controlling 225
71 PPC safety circuit 226
72 General layout 230
73 Control and filter panels – location of components 232
731 Control and filter panel engine 1 (rear) 232
732 Valve cartridge block engine 1 (rear) 234
733 Control and filter panel engine 2 (front) 236
734 Static air bleeding from hydraulic pumps via transfer pump 238
74 Pilot pressure supply and adjustments 240
741 Pilot pressure control (PPC) circuit 240
742 Pilot pressure operating the main block spools 242
743 Checks and adjustment of pilot pressure 244
744 Remote control valves arrangement 246
75 Function of the electro hydraulic control system 248
751 Illustration of the joystick signal flow (example) 250
76 Hand lever (joystick) control 252
761 Voltage supply of LH hand lever 20S020 253
762 Direction signal course from hand lever to controllers 254
763 Double ratiometric* output diagram 255
77 Foot pedal control 256
771 Voltage supply of foot pedal 20S021a 258
772 Direction signal course from foot pedal to controllers 259
773 Double ratiometric* output diagram for 2 direction pedal 260
774 Single ratiometric* output diagram for 1 direction pedal 260
78 Hand lever & foot pedal monitoring 262
781 Lever monitoring screens (example) 264
782 Valve monitoring screen (example) 266
79 Valve solenoid adjustment 268
791 Overview sol min/max current & adjustment range 269
710 ACCEL & DECEL time adjustment 270
7101 Accel & Decel times 270
8 Components 273
81 Main control blocks and high pressure screens (FSA) 274
82 Main control blocks with valves and HP screens (FSA) 276
83 Main control blocks with valves and HP screens (BHA) 278
84 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) 280
85 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) 282
86 Restrictor block with secondary relief valve 284
87 Anti-cavitation valve (ACV) block 286
871 Single ACV block on the manifold 286
872 Double ACV block on the manifold 288
88 Remote control valves 290
89 4/3 Directional solenoid valves 292
810 Proportional solenoid valves 294
811 High-pressure screen 296
812 Control blocks and valves 298
8121 Main control blocks I, II, III (4 spool blocks) 298
81211 Spin lock for valve blocks (ND52) 299
8122 Hydraulic diagram of a 4-spool valve block 300
8123 Spool types 301
8124 Spool positions (control block) 304
8125 MRV, SRV, and ACV 306
8126 Load holding valve 308
8127 Main control block IV (slew) 310
813 Travel brake valve 312
814 4/2 Directional valves 314
815 Pressure double stage valve 316
816 Hydraulic cylinder 318
8161 Hydraulic cylinder 318
8162 Cylinder data markings 320
9 Main hydraulic pumps & pump regulation system 321
91 General 322
911 Pump data 324
92 Main pumps 328
921 Hydraulic pump type HPV375 328
9211 Main pump sectional drawings 330
922 Servo valve 332
9221 VC valve  servo piston 333
923 EPC valve 338
93 Electronic pump regulation system 340
931 Cut-off function 342
932 Slew control 342
933 Temperature control 342
934 Hydraulic oil temperature charts 343
94 Pump & valve controllers 344
941 Service menu screen 346
942 Service ID 346
943 Service menu – 01 Monitoring 346
95 Monitoring PUMP 1 controller 347
951 Monitoring PUMP 2 controller 348
96 Using machine monitor functions for monitoring 349
97 Error indication of pump controllers 349
98 Adjustments for pump controllers 350
981 Adjustments for PUMP 1 controller 350
982 Adjustments for PUMP 2 controller 351
99 Details on adjustable parameters 352
991 PUMP1 controller 352
992 PUMP2 controller 354
993 Description of primary p-factor 356
994 Pump sol min current values according to pump type plate 357
995 Pump sol max current values according to pump type plate 358
910 Checks and adjustments 360
9101 Engine power check 360
911 Engine speed sensors (pick-up) 362
9111 General 363
9112 Engine speed sensor (pick-up) adjustment 363
9113 In case of problems – when correct speed sensor adjustment is guaranteed 364
10 Operating hydraulics 367
101 General 368
1011 Allocation of pumps and main valve blocks 370
102 Spool functions (FSA) 372
1021 Floating function for boom and stick cylinders 372
1022 Spool functions (BHA) 374
103 Hydraulics for the attachment cylinders 376
1031 Electric / hydraulic flowchart “Boom UP” (FSA) 376
1032 Electric / hydraulic flowchart “boom up” (BHA) 378
1033 Electric / hydraulic flowchart “boom down” (FSA), single movement and Auto-float ON 380
1034 Electric / hydraulic flowchart “boom down” (FSA), Auto-float OFF – button 20S095 pressed and single movement 382
1035 Electric / hydraulic flowchart “Boom down” (BHA) 384
1036 Electric / hydraulic flowchart “Stick out” (FSA) 386
1037 Electric / hydraulic flowchart “Stick out” (BHA) 388
1038 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float ON and single movement 390
1039 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float OFF – 20S098 pressed & single movement 392
10310 Electric / hydraulic flowchart “Stick in” (BHA) 394
10311 Electric / hydraulic flowchart “Bucket fill” (FSA) 396
10312 Electric / hydraulic flowchart “Bucket fill” (BHA) 398
10313 Electric / hydraulic flowchart “Bucket dump” (FSA) 400
10314 Electric / hydraulic flowchart “Bucket dump” (BHA) 402
10315 Electric / hydraulic flowchart “Clam open” (FSA) 404
10316 Electric / hydraulic flowchart “Clam close” (FSA) 406
10317 Checks & adjustments of main relief valve (MRV) 408
10318 Checks and adjustments of secondary relief valves (SRV) 410
103181 Boom cylinders, piston side (BHA & FSA), boom up 410
103182 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down 414
103183 Stick cylinders, piston side (FSA), stick out 418
103184 Stick cylinders, piston side (BHA), stick in 422
103185 Stick cylinders, piston rod side (FSA), stick in 426
103186 Stick cylinders, piston rod side (BHA), stick out 430
103187 Bucket cylinders, piston side (FSA), bucket fill 434
103188 Bucket cylinders, piston side (BHA), bucket fill 438
103189 Bucket cylinders, piston rod side (FSA), bucket dump 442
1031810 Bucket cylinders, piston rod side (BHA), bucket dump 446
1031811 Clam cylinders, piston rod side (FSA), clam open 450
1031812 Clam cylinders, piston side (FSA), clam close 454
10319 Checks and adjustments of cycle times 458
103191 Checks and adjustments of boom lowering speed (FSA) 458
103192 Checks and adjustments of boom lowering speed (BHA) 462
103193 Checks and adjustments of stick retract speed (FSA) 466
103194 Checks and adjustments of stick retract speed (BHA) 470
103195 Checks and adjustments of bucket dump speed (FSA) 474
103196 Checks and adjustments of bucket dump speed (BHA) 478
103197 Checks and Adjustment of bucket Curl Speed (BHA) 482
103198 Checks and adjustments of clam close speed (FSA) 486
104 Hydraulics for slew circuit 488
1041 Slew circuit with variable slew motors 488
1042 Slew motor (variable displacement) 492
10421 Hydraulic slew motor – displacement control 494
1043 Slew gearbox type 2063 496
1044 Slew gearbox type 632770 498
1045 Slew parking brake (on slew gear type 2063) 500
1046 Slew parking brake (on slew gear type 632770) 502
1047 Slew brake valve 504
1048 Flushing circuit 508
1049 Electric / hydraulic flowchart “Slew left” FSA 510
10410 Electric / hydraulic flowchart “Slew left” BHA 512
10411 Electric / hydraulic flowchart “Slew right” FSA 514
10412 Electric / hydraulic flowchart “Slew right” BHA 516
10413 Checks and adjustments for the slew circuit 518
104131 Pressure checks & adjustment – double stage valve (DSV) 519
104132 Checks & adjustments – brake pilot pressure 521
104133 Checks & adjustments – slew speed 522
10414 Function check for hydraulic slew brake 524
10415 Function check for slew parking brake 526
104151 Slew parking brake release pressure check 526
105 Hydraulics for the travel circuit 528
1051 Travel circuit 528
1052 Travel motor 532
1053 Rotary joint 534
1054 Travel gearbox 536
10541 Travel gearbox type 2063 536
10542 Travel gearbox type 631053 538
1055 Travel parking brake 540
10551 Travel parking brake on travel gear type 2063 540
10552 Travel parking brake on travel gear type 631053 541
10553 Travel brake valve 542
1056 Electric / hydraulic flowchart “travel forward” 544
1057 Electric / hydraulic flowchart “travel backwards” 546
1058 Checks and adjustments 548
10581 Checks and adjustments for travel circuit 548
10582 Function check for travel parking brake 552
11 Hydraulic track tensioning system 555
111 General 556
112 Functional description 560
113 Double stage valve 562
114 Tensioning cylinder 564
115 Adjustments / checks 566
12 Access stairway, hydraulically operated 569
121 Overview 570
122 Function of hydraulically operated access stairway 572
123 Adjustments / checks 576
13 Central refilling system (Service arm) 579
131 General 580
132 Function 582
14 Hints for reading Hydraulic Diagram 585
141 General 586
142 Hydraulic symbols 588
1421 Lines, unions 589
1422 Components, valves 591
1423 Sensors 591
1424 Valves, valve components 592
1425 Pump, motor, cylinder 596
15 Hints for reading electric Wiring Diagram 599
151 General 600
152 Reference code of the electrical components 601
1521 Area code 601
1522 Component identifying letter 602
153 Graphical symbols 603
154 Concept of Wiring Diagram 608
1541 Cover page of Komatsu W/D 608
1542 Example 1 – schematics in W/D 610
1543 Example 2 – schematics in W/D 612
1544 Table of contents in W/D 614
1545 Location list 616
1546 Cross reference list for electr components in W/D 618
1547 Cross reference list for terminals in W/D 620
1548 Cross reference list for connectors in W/D 622
1549 Cross reference list for terminal boards in W/D 624
15410 Connection table 626
155 Cable and connector marking 628
156 Cable color identification 630
16 Monitoring & Control System 631
161 Controller system overview 632
162 System layout 634
1621 CAN #1 overview 634
1622 CAN #2 overview 635
1623 CAN #0 at 52K014-1/-2 636
1624 CAN #0 overview 636
163 Interface connection 637
1631 General description 638
164 Machine monitor – Operator level 639
165 Main gauge screens 640
166 Operator menu 644
1661 Operator menu → Shovel payload 646
1662 Operator menu → ECO Guidance – Operation Records 648
1663 Operator menu → ECO Guidance – Average Fuel Consumption Logs 650
1664 Operator menu → Machine Setting 652
1665 Operator menu → Maintenance 654
16651 Reset of ’remaining time’ till next maintenance interval 656
16652 Usage limitation 657
1666 Operator menu → Monitor Setting – Screen Adjustment 659
1667 Operator menu → Monitor Setting – Clock Adjustment – Calender 660
1668 Operator menu → Monitor Setting – Clock Adjustment – Time 661
1669 Operator menu → Monitor Setting – Clock Adjustment – 12h/24h Mode 662
16610 Operator menu → Monitor Setting – Clock Adjustment – Daylight Saving Time 663
16611 Operator menu → Monitor Setting – Language 664
16612 Operator menu → Monitor Setting – ID key information 665
167 Status indication & errors on operator level 666
1671 Prompts (status indication) 666
1672 Cautions 667
1673 Emergency shutdown screen 668
1674 Fault levels for error messages 670
1675 Action code level L01 671
1676 Action code level L02 672
1677 Action code level L03 673
1678 Action code level L04 674
1679 Error list 675
168 Table of failure codes 676
1681 Table of failure codes for Mechanical Systems PC5500-11 T2 676
1682 Table of failure codes for Electrical Systems PC5500-11 T2 678
1683 Failure codes without monitor indication 692
1684 Additional text information for action codes 692
169 Table of C-codes – Diesel engines 693
1610 Flow charts of machine monitor screens 701
16101 Flow chart Operator Level 701
16102 Flow chart Service Level 702
1611 Machine monitor – Service level 703
16111 Entering Service Level 703
16112 Key symbols (F1F6) on the Service Level 705
16113 Service Menu selection screens 706
1612 Service Menu – item 01 Monitoring / Custom 707
16121 Monitoring list for: ENG1 controller 707
16122 Monitoring list for: ENG2 controller 708
16123 Monitoring list for: PUMP1 controller 709
16124 Monitoring list for: PUMP2 controller 712
16125 Monitoring list for: VALVE0 controller 715
16126 Monitoring list for: VALVE1 controller 718
16127 Monitoring list for: VALVE2 controller 721
16128 Monitoring list for: MON (monitor) 723
16129 Monitoring list for: KOM PLS (K+ controller) 725
161210 How to perform the monitoring function 727
1613 Service Menu – item 02 PM Clinic 729
16131 PM Clinic (General) 729
16132 PM Clinic (Power Check) 730
16133 Functions of PM CLINIC POWER CHECK 731
1614 Service Menu – Item 03 Abnormality record 733
16141 Reset error messages 734
1615 Service Menu – item 04 Maintenance record 735
1616 Service Menu – item 05 Maintenance Mode Setting 736
1617 Service Menu – item 06 Snap Shot 737
1618 Service Menu – item 07 Phone Number Entry 738
1619 Service menu – item 08 Default 739
1620 Service Menu – item 09 Unit 741
1621 Service Menu – item 10 Adjustment 743
16211 Adjustments for: PUMP1 controller 743
16212 Adjustments for: PUMP2 controller 746
16213 Pump sol ’min’ & ’mAX’ current values according to pump data plate 748
16214 Adjustments for: VALVE0 controller 749
16215 Accel & Decel times 755
16216 Adjustments for: VALVE2 controller 756
16217 Adjustments for: MON (Monitor) 757
162171 Using Idling Stop Timer 758
1622 Service Menu – item 11 Machine Configuration 759
16221 Details of Machine Configuration 760
16222 Changing lever control from EURO to KMG 761
162221 Changing lever control from KMG to EURO 761
16223 Changing attachment type from FSA to BHA 763
162231 Changing attachment type from BHA to FSA 763
16224 In case of problems during changing procedure for lever control or attachment type 764
1623 Automatic engine speed control 765
16231 Auto-Deceleration mode 765
16232 Auto Low Idle mode 765
16233 Idling Stop Timer 765
1624 KOMTRAX Plus controller (UM600) 767
1625 CR720 controller 771
16251 Location of CR720 controllers 771
1626 Controller replacement procedure 773
16261 Sequence of controller replacement procedure 773
16262 After controller replacement 774
17 Lubrication system 775
171 General overview SLS & CLS1 / 2 776
1711 General description 777
172 Basic function of lubrication systems 778
173 Lubrication systems (SLS & CLS1/2) 780
1731 Lubrication pump station 782
1732 General Information on CLS1/2 784
1733 General information on SLS 784
1734 Manual lube activation 784
174 Lubrication cycle 785
1741 Operation and control 785
1742 Lubrication cycle – processing 786
1743 Time segments & switch points of a lubrication cycle 787
1744 Lubrication modes 788
17441 Automatic lubrication mode 788
17442 Manual lubrication mode 788
17443 Reduced pause time for service 788
175 Hydraulically driven lube pump 790
1751 Adjustment of lube pump speed 792
17511 Stroke speed adjustment 793
17512 Working pressure 793
176 Lubricant injectors 794
1761 Tightening torques for fittings at grease injectors 795
1762 Description 795
1763 Adjustment of lubricant output 795
1764 Operation principle of lubricant injectors 796
17641 Function description 797
1765 Connection of two or more injectors 798
177 Vent valve & grease outlet filter 800
1771 Vent valve description 801
178 End-line switch 802
1781 Description 803
1782 CLS1/2 end-line switch adjustment 804
1783 SLS end-line switch adjustment 806
179 Lubricant level sensors 808
1791 Description 809
1792 Checks 809
1710 Commissioning 810
17101 Commissioning of CLS 1/2 lubrication system 810
17102 Fine adjustment 811
17103 Commissioning of SLS lubrication system 812
18 Air conditioner 815
181 Large A/C Systems on Hydraulic Mining Excavators 816
182 Working on A/C systems 818
1821 Refrigerant Recovery 818
1822 Compressor oil procedures 818
183 Maintenance & preventive maintenance of A/C systems 819
184 Commissioning of A/C systems 820
185 Compressor oil – Lubrication chart 822
186 Standard Air Conditioning System Diesel Drive 824
1861 A/C compressor type TM-16 826
1862 A/C compressor type TM-21 827
1863 Principle diagram of an electromagnetic clutch 828
1864 Filter-drier 829
187 Air conditioner unit at operator’s cab 830
1871 Shut-Off valves at dryer cartridge 831
188 A/C control panel 832
1881 Button layout 833
1882 Display/LEDs 834
189 Additional air conditioner 836
1891 Top view 836
1892 Side view 838
1893 Air conditioner condenser unit 839
19 Deep temperature equipment (option) 841
191 General information 842
1911 Introduction 842
1912 Deep temperature components overview 842
1913 Power supply preconditions for preheating 843
1914 Power requirements for preheating systems 844
192 Preheating procedure 845
1921 Global flow chart of the preheating procedure 845
1922 Starting the preheating procedure 846
1923 Preheating of operator’s cab and Diesel engine [coolant system] 847
1924 Preheating of lubricants and superstructure (Diesel) [electric system] 848
193 Constant heating of travel motors (TTT equipment below-40°C only) 849
194 Component location 850
1941 Electric heating elements for hydraulic & batteries [electric excavator] 850
1942 Electric heating elements for hydraulics [Diesel excavator] 852
1943 Electric heating elements for engines & batteries [Diesel excavator] 854
195 Components of TT equipment 856
1951 Preheating components on a Diesel excavator 856
1952 Preheating components on an electric excavator 857
1953 Wiring Diagrams for preheating systems 858
19531 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 858
19532 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 859
19533 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 860
19534 Wiring diagram “Suction Oil Manifold Preheating” 861
19535 Wiring diagram “PTO Preheating” 862
19536 Wiring diagram “Battery heater pads” 863
40 TROUBLESHOOTING 865
TOC 867
1 Introduction 895
11 Overview 896
111 General advice when using troubleshooting charts 896
12 General precautions 897
2 General Information for Troubleshooting 899
21 Preparations For Work 900
22 Precautions During Work 900
23 Precautions When Carrying Out Any Operation 901
231 Precautions when carrying out removal work 901
232 Precautions when carrying out installation work 901
233 Precautions when completing the operation 902
24 Fundamental Requirements for Trouble shooting 903
241 Technical documentation 903
242 Tools 903
2421 Reference Guide for Deutsch Removal Tools 906
243 Personnel 907
25 Points To Remember When Trouble- shooting 907
26 Sequence Of Events In Troubleshooting 909
27 Checks Before Troubleshooting 910
28 Handling Of Electric Equipment And Hydraulic Components 911
281 Points to remember when handling electric equipment 911
282 Points To Remember When Handling Hydraulic Equipment 914
29 General working procedures 916
291 Air Bleeding of Various Hydraulic Parts 916
292 Air bleeding from hydraulic pumps 916
293 Air bleeding from hydraulic cylinders 916
210 Cylinder bypass test 917
211 Basics about “How to crimp” (with strain relief) 918
2111 Crimp tool & repair kit 918
2112 General 919
2113 Select the required connector components 919
2114 Stripping a wire 920
2115 Crimping 921
2116 Connector assembly after crimping 922
212 Cable Shielding 923
3 Mounting Locations and Connector Types 925
31 Superstructure 926
311 Superstructure side view 926
312 Superstructure top view 928
32 Machinery house 930
321 Location of engine remote oil tank sensors 932
33 Location of hydraulic components 934
331 Control and filter panel engine 1 (rear) 934
332 Valve cartridge block engine 1 (rear) 936
333 Control and filter panel engine 2 (front) 938
334 Remote control valves arrangement 940
34 View onto SLS or CLS1/2 grease container and lubrication cycle components 942
35 Hydraulic oil tank & suction oil tank – Location of electrical components 944
36 Hydraulically operated access stairway 946
37 Refilling arm 948
38 Connector Types Overview 950
4 Standard Value Table for Electrical Components 955
5 Tables for Testing and Troubleshooting 969
51 Test Value Tables for Transducers 970
511 Pump press transducers 970
512 PLM pressure sensors 971
513 Hydraulic oil pressure transducers 972
514 Miscellaneous Pressure Transducers 973
515 Temperature Transducers 974
52 Hydraulic oil temperature charts 975
53 PTO gear oil temperature charts 975
54 Table of failure codes 976
541 Table of failure codes for Electrical Systems PC5500-11 T2 978
55 Table of C-codes – Diesel engines QSK38 T2 992
56 Table of PLM fault codes 999
561 Note for troubleshooting of PLM fault codes1000
57 Tables of Symptom Codes1001
571 Symptoms of engines and Related electrical systems1001
572 Symptoms of Hydraulic System1001
573 Symptoms of Mechanical System1002
574 Symptoms of Additional Systems1002
58 Cable colour identification1003
6 Troubleshooting by Trouble Code1005
B@HANS – Hyd Oil Overheat1006
Monitoring hydraulic oil temperature1007
Hydraulic oil temperature charts1008
6A1BMA – Trouble Shut-Off (gate) valve not open error1009
View onto gap of proximity switch 40B0311010
Wiring Diagram (40B031) for message 6A1BMA1011
AA10NX – Air Cleaner1 Clogging1012
AA1FNX – Air Cleaner2 Clogging1012
View onto an engine air cleaner (AA10NX & AA1FNX)1013
AB00KE – Charge Voltage Low1014
AB0MKE – Charge Voltage2 Low1014
Wiring Diagram (alternator) for message AB00KE or AB0MKE1015
B@F0MA – CLS1 Lubrication System Error1016
B@CPMA – SLS Lubrication System Error1017
B@CNMA – CLS2 Lubrication System Error1018
B@F0N9 – CLS1 pressure increase time too long1020
B@CNN9 – CLS2 pressure increase time too long1020
B@CPN9 – SLS pressure increase time too long1020
Allocation of vent valves and end-of-line switches1021
Vent valve (62Q507a & 62Q509a & 62Q642a)1022
Wiring Diagram – lube pump solenoid & vent valve (CLS1/2 & SLS)1023
B@F0N0 – CLS1 pressure decrease time too long1024
B@CNN0 – CLS2 pressure decrease time too long1024
B@CPN0 – SLS pressure decrease time too long1024
Vent valve (62Q507a & 62Q509a & 62Q642a)1025
B@F0ZK – CLS1 grease level too low1026
B@CPZK – SLS grease level too low1026
Wiring Diagram – grease level sensors (CLS1/2 & SLS)1027
B@HAZK – Hydraulic oil level too low1028
Hydraulic oil level in defined excavator position1029
Wiring Diagram – hydraulic oil level sensor 40B0041030
B@CBNS – PTO1 Gear Oil Temp High1031
B@KCNS – PTO2 Gear Oil Temp High1031
B@CBNS – PTO1 Gear Oil Temp High1032
View onto pump distributor gearbox (PTO1/2)1033
B@CBZG – PTO1 Gear Lubrication Error1034
B@KCZG – PTO2 Gear Lubrication Error1034
Monitoring PTO1/2 lube oil pressure1035
Shutdown adjustment for PTO1/2 lube oil pressure1035
B@H2NX – Breather Filter Clogging1036
40B024 and indicator plate for definition of oil levels1037
B@M9NX – PTO1 Gear Oil Filter Clogging1038
B@N8NX – PTO2 Gear Oil Filter Clogging1038
View onto PTO1/2 gear oil filter with pressure sensor 57B027-1/-21039
B@HBNX – Return Oil Filter Clogging1040
B@L4NX – Leak Oil Filter Clogging1041
B@L5N9 – Pilot Press X2 Too Low1042
Valve cartridge block, location of components1043
B@L5N0 – Pilot Press X2 Too High1044
Valve cartridge block, location of components1045
B@BKPQ – Eng Remote Oil Tank1 Empty1046
B@BLPQ – Eng Remote Oil Tank2 Empty1046
B@HANX – Screen At Hyd Cooler Entry Clogging1048
Monitoring screens for 40B165 and 40B1661048
Hydraulic oil tank & return oil collector pipe with strainer – location of components1049
AB30MA – Starter Circuit Abnormality1050
Wiring Diagram for AB30MA1051
989HMA – Emergency stop line abnormality1052
Monitoring screens and Wiring Diagram for 989HMA1053
DGT3MA – PTO1 oil temperature sensor abnormality1054
Wiring Diagram, monitoring screen, and location of 57B049-11055
DGH2MA – Hydraulic oil temp sensor abnormality1056
Wiring Diagram, monitoring screen, and location of 59B0151057
DHQ7MA – PTO1 lube pressure sensor abnormality1058
Monitoring screen, Wiring Diagram, and location of 57B017-11059
D1E7KB – Starter cut relay short circuit1060
Wiring Diagram and monitoring screen – Starter cut relay for message D1E7KB1061
D1E7KY – Starter cut relay hot short circuit1062
Wiring Diagram – Starter cut relay for message D1E7KY1063
DHPEMA – Pump-1 pressure sensor abnormality1064
DHPGMA – Pump-2 pressure sensor abnormality1064
DHPJMA – Pump-3 pressure sensor abnormality1064
DHPLMA – Pump-4 pressure sensor abnormality1064
DHPNMA – Pump-5 pressure sensor abnormality1064
DHPQMA – Pump-6 pressure sensor abnormality1064
Main pumps 13 → Monitoring screen & Wiring Diagram – PWR & GND supply for pump pressure transducers1066
Main pumps 46 → Monitoring screen & Wiring Diagram – PWR & GND supply for pump pressure transducers1067
DLE2MA – Engine speed sensor abnormality1068
Monitoring screen and Wiring Diagram 52B064 -1 for message DLE2MA1069
DA27KP – 24V sensor power abnormality1070
Wiring Diagram – 24V sensor power supply for DA27KP1071
DA26KP – 5V sensor2 power abnormality1072
Wiring Diagram – 5V sensor power supply for DA26KP1073
DA2LKA – Operating Lamp Open Circuit(Pump Con)1074
Wiring Diagram – Operating Lamp Open Circuit(Pump Con)1075
DA2LKB – Operating Lamp Short Circuit(Pump Con)1076
Wiring Diagram – Operating Lamp Short Circuit(Pump Con)1077
DA22KK – Solenoid Power Low Error(Pump Con)1078
DA22MA – Solenoid Power Circuit Abnormality1079
Wiring Diagram 1 – monitoring safety power line for DA22MA1080
Wiring Diagram 2 – 11Q044d for DA22MA1081
DXAAKA – Pump1 Front Solenoid open circuit1082
DXACKA – Pump2 Front Solenoid open circuit1082
DXAEKA – Pump3 Front Solenoid open circuit1082
Wiring Diagram – EPC valve control (PUMP1)1083
DXAAKB – Pump1 Front Solenoid short circuit1084
DXACKB – Pump2 Front Solenoid short circuit1084
DXAEKB – Pump3 Front Solenoid short circuit1084
Wiring Diagram – EPC valve control (PUMP1)1085
DWA5KA – CLS pump solenoid open circuit1086
DWA8KA – SLS pump solenoid open circuit1086
Wiring Diagram – CLS1/SLS pump solenoid control1087
DWA5KB – CLS pump solenoid short circuit1088
DWA8KB – SLS pump solenoid short circuit1088
Wiring Diagram – CLS1/SLS pump solenoid control1089
DWA5KY – CLS pump solenoid hot short circuit1090
DWA8KY – SLS pump solenoid hot short circuit1090
Wiring Diagram – CLS/SLS pump solenoid / hot short circuit1091
DWA7KA – CLS line release solenoid open circuit1092
DWA9KA – SLS lube line release sol open circuit1092
Wiring Diagram – CLS1/SLS lube line release solenoid control1093
DWA7KB – CLS line release solenoid short circuit1094
DWA9KB – SLS lube line release solenoid short circuit1094
Wiring Diagram – CLS/SLS lube line release solenoid control1095
DWA7KY – CLS line release sol hot short circuit1096
DWA9KY – SLS lube line release sol hot short circuit1096
Wiring Diagram – CLS/SLS lube line release solenoid / hot short circuit1097
DWAAKA – PTO lube preload solenoid open circuit1098
Wiring Diagram and monitoring screen for message DWAAKA1099
DWAAKB – PTO lube preload solenoid short circuit1100
Wiring Diagram and monitoring screen for message DWAAKB1101
DWAAKY – PTO lube preload sol hot short circuit1102
Wiring Diagram for message DWAAKY1103
D168KB – Oil cooler preload sol relay short circuit1104
Wiring Diagram and monitoring screen – Relay 11K070 (D168KB)1105
D1E9KB – Wiper fast relay short circuit1106
D1ETKB – Wiper slow relay short circuit1106
D1EBKB – Wiper stop relay short circuit1106
Wiring Diagram – wiper motor control1107
D162KB – Horn relay short circuit1108
Wiring Diagram and monitoring screen – signal horn control1109
D1F0KB – Engine1/motor1 shutdown relay short circuit1110
D1F4KB – Engine2/motor2 shutdown relay short circuit1110
Wiring Diagram and monitoring screen – engine1/2 shutdown relay 11K064-1/21111
D1F0KY – Engine1/motor1 shutdown relay hot short1112
D1F4KY – Engine2/motor2 shutdown relay hot short1112
Wiring Diagram for D1F0KY / D1F4KY1113
DWNCKA – Hyd Oil Cooler fan pump1 Sol open circuit1114
DWNUKA – Hyd Oil Cooler fan pump2 Sol open circuit1114
Wiring Diagram – Hyd oil cooler fan pump1/2 solenoid1115
DWNCKB – Hyd Oil Cooler fan pump1 Sol short circuit1116
DWNUKB – Hyd Oil Cooler fan pump2 Sol short circuit1116
Wiring Diagram – Hyd oil cooler fan pump1/2 solenoid1117
DXQ0KA – X1 pilot pressure pump1 Sol open circuit1118
DXQ1KA – X1 pilot pressure pump2 Sol open circuit1118
Wiring Diagram – X1 pilot pressure pump1/2 solenoid1119
DXQ0KB – X1 pilot pressure pump1 Sol short circuit1120
DXQ1KB – X1 pilot pressure pump2 Sol short circuit1120
Wiring Diagram – X1 pilot pressure pump1/2 solenoid1121
DWN5KA – Radiator fan pump1 Sol open circuit1122
DWNTKA – Radiator fan pump2 Sol open circuit1122
Wiring Diagram – Radiator fan pump1/2 solenoid1123
DWN5KB – Radiator fan pump1 Sol short circuit1124
DWNTKB – Radiator fan pump2 Sol short circuit1124
Wiring Diagram – Radiator fan pump1/2 solenoid1125
D110KA – Battery relay open circuit1126
Wiring Diagram – battery relay 11Q044d1127
D110KB – Battery relay short circuit1128
Wiring Diagram – Battery relay 11Q044d1129
DA29KQ – Model Selection Abnormality1130
Wiring Diagram and monitoring screen – machine selection PUMP1 (DA29KQ)1131
DA2YKQ – Motor/Engine Selection Abnormality1132
Monitoring screen for motor/engine selection PUMP11132
DA20KQ – Pump Con Selection Abnormality1133
Monitoring screen for PUMP1 controller selection1133
DLM8MA – Oil cooler fan1 speed sensor abnormality1134
Wiring Diagram and monitoring screen – Oil cooler fan1 speed sensor (DLM8MA)1135
DXAGKA – Pump4 Front Solenoid open circuit1136
DXAJKA – Pump5 Front Solenoid open circuit1136
DXALKA – Pump6 Front Solenoid open circuit1136
Wiring Diagram – EPC valve control (PUMP2)1137
DXAGKB – Pump4 Front Solenoid short circuit1138
DXAJKB – Pump5 Front Solenoid short circuit1138
DXALKB – Pump6 Front Solenoid short circuit1138
Wiring Diagram – EPC valve control (PUMP2)1139
DWAEKA – CLS2 pump solenoid open circuit1140
Wiring Diagram and monitoring screen – CLS2 pump solenoid control1141
DWAEKB – CLS2 pump solenoid short circuit1142
Wiring Diagram and monitoring screen – CLS2 pump solenoid control1143
DWAEKY – CLS2 pump solenoid hot short circuit1144
Wiring Diagram and monitoring screen – CLS2 pump solenoid / hot short circuit1145
DWAFKA – CLS2 line release solenoid open circuit1146
Wiring Diagram and monitoring screen – CLS2 lube line release solenoid control1147
DWAFKB – CLS2 line release solenoid short circuit1148
Wiring Diagram and monitoring screen – CLS2 lube line release solenoid control1149
DWAFKY – CLS2 line release sol hot short circuit1150
Wiring Diagram & monitoring screen – CLS2 lube line release solenoid / hot short circuit1151
DWABKA – PTO2 lube preload solenoid open circuit1152
Wiring Diagram and monitoring screen for message DWABKA1153
DWABKB – PTO2 lube preload solenoid short circuit1154
Wiring Diagram and monitoring screen for message DWABKB1155
DWABKY – PTO lube preload sol hot short circuit1156
Wiring Diagram for message DWABKY1157
DGT8MA – PTO2 oil temperature sensor abnormality1158
Wiring Diagram, monitoring screen, and location of 57B049-21159
DGE5MA – Ambient air temp sensor abnormality1160
Wiring Diagram and monitoring screen for message DGE5MA1161
DHQ8MA – PTO2 lube pressure sensor abnormality1162
Monitoring screen, Wiring Diagram, and location of 57B017-21163
AB3EMA – Starter Circuit Abnormality1164
Wiring Diagram for AB3EMA1165
D1EEKB – Starter cut relay short circuit1166
Wiring Diagram and monitoring screen – Starter cut relay for message D1EEKB1167
D1EEKY – Starter cut relay hot short circuit1168
Wiring Diagram – Starter cut relay for message D1EEKY1169
FF11KB – Starter power cut relay1 short circuit1170
Wiring Diagram and monitoring screen – Starter power cut relay for message FF11KB1171
FF11KY – Starter power cut relay1 hot short circuit1172
Wiring Diagram – Starter power cut relay1 hot short circuit for message FF11KY1173
FF11LK – Starter power cut relay1 abnormality1174
FF12LK – Starter power cut relay2 abnormality1175
DBZ7KP – 24V sensor power abnormality1176
Wiring Diagram – 24V sensor power supply for DBZ7KP1177
DBZ6KP – 5V sensor2 power abnormality1178
Wiring Diagram – 5V sensor power supply for DBZ6KP1179
DBZLKA – Operating Lamp Open Circuit(Pump2 Con)1180
Wiring Diagram – Operating Lamp Open Circuit(Pump2 Con)1181
DBZLKB – Operating Lamp Short Circuit(Pump2 Con)1182
Wiring Diagram – Operating Lamp Short Circuit(Pump2 Con)1183
DBZ2KK – Solenoid Power Low Error(Pump2 Con)1184
DLE6MA – Engine2 speed sensor abnormality1186
Monitoring screen and Wiring Diagram – 52B064-2 for message DLE6MA1187
DBZ9KQ – Model Selection Abnormality1188
Wiring Diagram and monitoring screen – machine selection PUMP2 (DBZ9KQ)1189
DBZWKQ – Motor/Engine Selection Abnormality1190
Monitoring screen for motor/engine selection PUMP21190
DBZ0KQ – Pump2 Con Selection Abnormality1191
Monitoring screen for PUMP2 controller selection1191
DLMAMA – Oil cooler fan2 speed sensor abnormality1192
Wiring Diagram and monitoring screen – Oil cooler fan2 speed sensor (DLMAMA)1193
DDABL4 – Lock lever switch mismatch1194
DDXAL4 – Ladder up position proximity switch mismatch1195
DDXBL4 – Service arm upper position proximity switch mismatch1196
DKURMA – R lever right-left potentio abnormality1198
Wiring Diagram – right lever right-left potentiometer input (DKURMA)1199
DKUSMA – R lever right-left redu pot abnorm(VALVE/M)1200
Wiring Diagram – right lever redundant right-left potentiometer input (DKUSMA)1201
DKUQL8 – R lever right-left potentio error1202
Wiring Diagram – right lever main + redundant right-left signal voltage (DKUQL8)1203
DKUQL4 – R lever right-left sig mismatch(VALVE/M)1204
Wiring Diagram – R lever right-left redundant signal input at VALVE0 and VALVE11205
DKUNMA – R lever front-back potentio abnormality1206
Wiring Diagram – right lever front-back potentiometer input (DKUNMA)1207
DKUPMA – R lever front-back redu pot abnorm(VALVE/M)1208
Wiring Diagram – right lever redundant front-back potentiometer input (DKUPMA)1209
DKUML8 – R lever front-back potentio error1210
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8)1211
DKUML4 – R lever front-back sig mismatch(VALVE/M)1212
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE11213
DKUXMA – Left lever right-left potentio abnormality1214
Wiring Diagram – left lever right-left potentiometer input (DKUXMA)1215
DKUYMA – L lever right-left redu pot abnorm(VALVE/M)1216
Wiring Diagram – left lever redundant right-left potentiometer input (DKUYMA)1217
DKUWL8 – L lever right-left potentio error1218
Wiring Diagram – left lever main + redundant right-left signal voltage (DKUWL8)1219
DKUWL4 – L lever right-left sig mismatch(VALVE/M)1220
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE11221
DKUUMA – L lever front-back potentio abnormality1222
Wiring Diagram – left lever front-back potentiometer input (DKUUMA)1223
DKUVMA – L lever front-back redu pot abnorm(VALVE/M)1224
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/M) for DKUVMA1225
DKUTL8 – L lever front-back potentio error1226
Wiring Diagram – L lever front-back potentio error (DKUTL8)1227
DKUTL4 – L lever front-back sig mismatch(VALVE/M)1228
Wiring Diagram – L lever front-back sig mismatch(VALVE/M) for DKUTL41229
DKW1MA – R pedal potentio abnormality1230
Wiring Diagram – R pedal potentio abnormality (DKW1MA)1231
DKW2MA – R pedal redundant pot abnormality(VALVE/M)1232
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA1233
DKW0L8 – R pedal potentio error1234
Wiring Diagram – R pedal potentio error (DKW0L8)1235
DKW0L4 – R pedal signal mismatch(VALVE/M Con)1236
Wiring Diagram – R pedal signal mismatch(VALVE/M Con) for DKW0L41237
DKW4MA – L pedal potentio abnormality1238
Wiring Diagram – L pedal potentio abnormality (DKW4MA)1239
DKW5MA – L pedal redundant pot abnormality(VALVE/M)1240
Wiring Diagram – L pedal redundant pot abnormality(VALVE/M) for DKW5MA1241
DKW3L8 – L pedal potentio error1242
Wiring Diagram – L pedal potentio error (DKW3L8)1243
DKW3L4 – L pedal signal mismatch(VALVE/M Con)1244
Wiring Diagram – L pedal signal mismatch(VALVE/M Con) for DKW3L41245
DKW7MA – Clam open potentio abnormality1246
Wiring Diagram – Clam open potentio abnormality (DKW7MA)1247
DKW8MA – Clam open redu pot abnormality(VALVE/M)1248
Wiring Diagram – Clam open redu pot abnormality(VALVE/M) for DKW8MA1249
DKW6L8 – Clam open potentio error1250
Wiring Diagram – Clam open potentio error (DKW6L8)1251
DKW6L4 – Clam open signal mismatch(VALVE/M Con)1252
Wiring Diagram – Clam open signal mismatch(VALVE/M Con) for DKW6L41253
DKWAMA – Clam close potentio abnormality1254
Wiring Diagram – Clam close potentio abnormality (DKWAMA)1255
DKWBMA – Clam close redundant pot abnorm(VALVE/M)1256
Wiring Diagram – Clam close redundant pot abnorm(VALVE/M) for DKWBMA1257
DKW9L8 – Clam close potentio error1258
Wiring Diagram – Clam close potentio error (DKW9L8)1259
DKW9L4 – Clam close signal mismatch(VALVE/M Con)1260
Wiring Diagram – Clam close signal mismatch(VALVE/M Con) for DKW9L41261
DKWDMA – Hydraulic slew brake potentio abnormality1262
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA)1263
DKWEMA – Hyd slew brake redu pot abnorm(VALVE/M)1264
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/M) for DKWEMA1265
DKWCL8 – Hydraulic slew brake potentio error1266
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8)1267
DKWCL4 – Hyd slew brake sig mismatch(VALVE/M)1268
Wiring Diagram – Hyd slew brake sig mismatch(VALVE/M) for DKWCL41269
DBWLKA – Operating Lamp Open Circuit(VALVE/M Con)1270
Wiring Diagram – Operating Lamp Open Circuit(VALVE/M Con)1271
DBWLKB – Operating Lamp Short Circuit(VALVE/M Con)1272
Wiring Diagram – Operating Lamp Short Circuit(VALVE/M Con)1273
DWNPKA – Service arm up solenoid open circuit1274
Wiring Diagram and monitoring screen for message DWNPKA1275
DWNPKB – Service arm up solenoid short circuit1276
Wiring Diagram and monitoring screen for message DWNPKB1277
DWNPKY – Service arm up solenoid hot short circuit1278
Wiring Diagram and monitoring screen for message DWNPKY1279
DWNQKA – Service arm down solenoid open circuit1280
Wiring Diagram and monitoring screen for message DWNQKA1281
DWNQKB – Service arm down solenoid short circuit1282
Wiring Diagram and monitoring screen for message DWNQKB1283
DWNQKY – Service arm down solenoid hot short circuit1284
Wiring Diagram and monitoring screen for message DWNQKY1285
DW4BKA – Travel parking brake solenoid open circuit1286
Wiring Diagram and monitoring screen for message DW4BKA1287
DW4BKB – Travel parking brake sol short circuit1288
Wiring Diagram and monitoring screen for message DW4BKB1289
DW4BKY – Travel parking brake sol hot short circuit1290
Wiring Diagram and monitoring screen for message DW4BKY1291
DW4BMA – Travel parking brake solenoid circuit abnormality1292
Wiring Diagram and monitoring screen for DW4BMA1293
DW45KA – Slew parking brake solenoid open circuit1294
Wiring Diagram and monitoring screen for message DW45KA1295
DW45KB – Slew parking brake solenoid short circuit1296
Wiring Diagram and monitoring screen for message DW45KB1297
DW45KY – Slew parking brake sol hot short circuit1298
Wiring Diagram and monitoring screen for message DW45KY1299
DW45MA – Slew parking brake solenoid circuit abnormality1300
Wiring Diagram and monitoring screen for DW45MA1301
DXN2KA – Boom1 epc solenoid open circuit1302
DXN3KA – Stick1 epc solenoid open circuit1302
DXNJKA – Bucket1 epc solenoid open circuit1302
DXNHKA – Travel1 left epc solenoid open circuit1302
DXN4KA – Boom2 epc solenoid open circuit1302
DXN5KA – Clam2 epc solenoid open circuit1302
DXN6KA – Stick2 epc solenoid open circuit1302
DXN8KA – Bucket2 epc solenoid open circuit1302
DXNBKA – Bucket3 epc solenoid open circuit1302
DXNCKA – Boom3 epc solenoid open circuit1302
DXNLKA – Stick3 epc solenoid open circuit1302
DXNKKA – Travel3 right epc solenoid open circuit1302
DXNMKA – Slew4 epc solenoid open circuit1302
Details of above 6-digit failure codes (FSA & BHA)1303
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K6231304
Wiring Diagram for EPC 61K624 – 61K6251305
Wiring Diagram for EPC 61K626 – 61K627 – 61K628 – 61K6291306
Wiring Diagram for EPC 61K630 – 61K631 – 61K6321307
Monitoring screens as an example1308
DXN2KB – Boom1 epc solenoid short circuit (BHA)1310
DXN3KB – Stick1 epc solenoid short circuit1310
DXNJKB – Bucket1 epc solenoid short circuit1310
DXNHKB – Travel1 left epc solenoid short circuit1310
DXN4KB – Boom2 epc solenoid short circuit1310
DXN5KB – Clam2 epc solenoid short circuit (FSA)1310
DXN6KB – Stick2 epc solenoid short circuit (BHA)1310
DXN8KB – Bucket2 epc solenoid short circuit1310
DXNBKB – Bucket3 epc solenoid short circuit1310
DXNCKB – Boom3 epc solenoid short circuit1310
DXNLKB – Stick3 epc solenoid short circuit1310
DXNKKB – Travel3 right epc solenoid short circuit1310
DXNMKB – Slew4 epc solenoid short circuit1310
Details of above 6-digit failure codes (FSA & BHA)1311
DXN2KY – Boom1 epc solenoid hot short circuit (BHA)1312
DXN3KY – Stick1 epc solenoid hot short circuit1312
DXNJKY – Bucket1 epc solenoid hot short circuit1312
DXNHKY – Travel1 left epc solenoid hot short circuit1312
DXN4KY – Boom2 epc solenoid hot short circuit1312
DXN5KY – Clam2 epc solenoid hot short circuit (FSA)1312
DXN6KY – Stick2 epc solenoid hot short circuit (BHA)1312
DXN8KY – Bucket2 epc solenoid hot short circuit1312
DXNBKY – Bucket3 epc solenoid hot short circuit1312
DXNCKY – Boom3 epc solenoid hot short circuit1312
DXNLKY – Stick3 epc solenoid hot short circuit1312
DXNKKY – Travel3 right epc solenoid hot short circuit1312
DXNMKY – Slew4 epc solenoid hot short circuit1312
Details of above 6-digit failure codes (FSA & BHA)1313
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K6231314
Wiring Diagram for EPC 61K624 – 61K6251315
Wiring Diagram for EPC 61K626 – 61K627 – 61K628 – 61K6291316
Wiring Diagram for EPC 61K630 – 61K631 – 61K6321317
DWACKA – Service arm check valve sol open circuit1318
Wiring Diagram and monitoring screen for message DWACKA1319
DWACKB – Service arm check valve sol short circuit1320
Wiring Diagram and monitoring screen for message DWACKB1321
DWACKY – Service arm check valveSol hotShortCircuit1322
Wiring Diagram and monitoring screen for message DWACKY1323
DWADKA – Ladder speed control solenoid open circuit1324
Wiring Diagram and monitoring screen for message DWADKA1325
DWADKB – Ladder speed control sol short circuit1326
Wiring Diagram and monitoring screen for message DWADKB1327
DWADKY – Ladder speed control sol hot short circuit1328
Wiring Diagram – Ladder speed control sol hot short circuit (DWADKY)1329
DBW5MA – 5V sensor1 power abnormality1330
DBW6MA – 5V sensor2 power abnormality1330
Wiring Diagram – 5V power supply and GND output at VALVE01334
DBW9KQ – Model Selection Abnormality1336
Monitoring screen and Wiring Diagram – model selection abnormality (DBW9KQ)1337
DBWZKQ – Lever control selection abnormality1338
Monitoring screen & Wiring Diagram – Lever control selection abnormality (DBWZKQ)1339
DBWYKQ – Attachment selection abnormality1340
Monitoring screen & Wiring Diagram – Attachment selection abnormality (DBWYKQ)1341
DBW2KK – Solenoid Power Low Error(VALVE/M Con)1342
Wiring Diagram 1 for message DBW2KK1344
Wiring Diagram 2 for message DBW2KK1345
DBW0KQ – VALVE/M Con Selection Abnormality1346
Monitoring screen and Wiring Diagram for message DBW0KQ1347
DDDWMC – Ladder operation switch abnormality1348
Wiring Diagram and monitoring screen for message DDDWMC1349
DKWHMA – R lever right-left redu pot abnorm(VLV/S1)1350
Wiring Diagram – right lever redundant right-left potentiometer input (DKWHMA)1351
DKWFL4 – R lever right-left sig mismatch(VALVE/S1)1352
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE11353
DKWLMA – R lever front-back redu pot abnorm(VLV/S1)1354
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA)1355
DKWJL4 – R lever front-back sig mismatch(VALVE/S1)1356
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE11357
DKWPMA – L lever right-left redu pot abnorm(VLV/S1)1358
Wiring Diagram – left lever redundant right-left potentiometer input (DKWPMA)1359
DKWML4 – L lever right-left sig mismatch(VALVE/S1)1360
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE11361
DKWSMA – L lever front-back redu pot abnorm(VLV/S1)1362
Wiring Diagram – L lever front-back redu pot abnorm(VLV/S1) for DKWSMA1363
DKWQL4 – L lever front-back sig mismatch(VALVE/S1)1364
Wiring Diagram – L lever front-back sig mismatch(VALVE/S1) for DKWQL41365
DKWVMA – R pedal red pot abnormality(VALVE/S1)1366
Wiring Diagram – R pedal red pot abnormality(VALVE/S1) for DKWVMA1367
DKWTL4 – R pedal signal mismatch(VALVE/S1 Con)1368
Wiring Diagram – R pedal signal mismatch(VALVE/S1 Con) for DKWTL41369
DKWYMA – L pedal red pot abnormality(VALVE/S1)1370
Wiring Diagram – L pedal red pot abnormality(VALVE/S1) for DKWYMA1371
DKWWL4 – L pedal signal mismatch(VALVE/S1 Con)1372
Wiring Diagram – L pedal signal mismatch(VALVE/S1 Con) for DKWWL41373
DKX2MA – Clam open redu pot abnormality(VALVE/S1)1374
Wiring Diagram – Clam open redu pot abnormality(VALVE/S1) for DKX2MA1375
DKX0L4 – Clam open signal mismatch(VALVE/S1 Con)1376
Wiring Diagram – Clam open signal mismatch(VALVE/S1 Con) for DKX0L41377
DKX5MA – Clam close redu pot abnormality(VALVE/S1)1378
Wiring Diagram – Clam close redu pot abnormality(VALVE/S1) for DKX5MA1379
DKX3L4 – Clam close signal mismatch(VALVE/S1 Con)1380
Wiring Diagram – Clam close signal mismatch(VALVE/S1 Con) for DKX3L41381
DKX8MA – Hyd slew brake redu pot abnorm(VALVE/S1)1382
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/S1) for DKX8MA1383
DKX6L4 – Hyd slew brake signal mismatch(VALVE/S1)1384
Wiring Diagram – Hyd slew brake signal mismatch(VALVE/S1) for DKX6L41385
DBXLKA – Operating Lamp Open Circuit(VALVE/S1 Con)1386
Wiring Diagram – Operating Lamp Open Circuit(VALVE/S1 Con)1387
DBXLKB – Operating Lamp Short Circuit(VALVE/S1 Con)1388
Wiring Diagram – Operating Lamp Short Circuit(VALVE/S1 Con)1389
DWNRKB – Ladder up solenoid short circuit1390
Wiring Diagram and monitoring screen for message DWNRKB1391
DWNRKY – Ladder up solenoid hot short circuit1392
Wiring Diagram – Ladder up solenoid hot short circuit (DWNRKY)1393
DWNRMA – Ladder up solenoid circuit abnormality1394
Wiring Diagram and monitoring screen for DWNRMA1395
DW7RKA – Hydraulic slew brake solenoid open circuit1396
Wiring Diagram and monitoring screen for message DW7RKA1397
DW7RKB – Hydraulic slew brake sol short circuit1398
Wiring Diagram and monitoring screen for message DW7RKB1399
DW7RKY – Hyd slew brake sol hot short circuit1400
Wiring Diagram – Hyd slew brake sol hot short circuit (DW7RKY)1401
DWASKA – Bucket1 fill solenoid open circuit1402
Wiring Diagram and monitoring screen for message DWASKA1403
DWASKB – Bucket1 fill solenoid short circuit1404
Wiring Diagram and monitoring screen for message DWASKB1405
DWASKY – Bucket1 fill solenoid hot short circuit1406
Wiring Diagram and monitoring screen for message DWASKY1407
DWAWKA – Bucket1 dump solenoid open circuit1408
Wiring Diagram and monitoring screen for message DWAWKA1409
DWAWKB – Bucket1 dump solenoid short circuit1410
Wiring Diagram and monitoring screen for message DWAWKB1411
DWAWKY – Bucket1 dump solenoid hot short circuit1412
Wiring Diagram and monitoring screen for message DWAWKY1413
DWKAKA – Travel1 left forward sol open circuit1414
Wiring Diagram and monitoring screen for message DWKAKA1415
DWKAKB – Travel1 left forward sol short circuit1416
Wiring Diagram and monitoring screen for message DWKAKB1417
DWKAKY – Travel1 left forward sol hot short circuit1418
Wiring Diagram and monitoring screen for message DWKAKY1419
DWKEKA – Travel1 left backward sol open circuit1420
Wiring Diagram and monitoring screen for message DWKEKA1421
DWKEKB – Travel1 left backward sol short circuit1422
Wiring Diagram and monitoring screen for message DWKEKB1423
DWKEKY – Travel1 left backward sol hot short circuit1424
Wiring Diagram and monitoring screen for message DWKEKY1425
DWBEKA – Boom1 down solenoid open circuit1426
Wiring Diagram and monitoring screen for message DWBEKA1427
DWBEKB – Boom1 down solenoid short circuit1428
Wiring Diagram and monitoring screen for message DWBEKB1429
DWBEKY – Boom1 down solenoid hot short circuit1430
Wiring Diagram and monitoring screen for message DWBEKY1431
DWBAKA – Boom1 up solenoid open circuit1432
Wiring Diagram and monitoring screen for message DWBAKA1433
DWBAKB – Boom1 up solenoid short circuit1434
Wiring Diagram and monitoring screen for message DWBAKB1435
DWBAKY – Boom1 up solenoid hot short circuit1436
Wiring Diagram and monitoring screen for message DWBAKY1437
DWBJKA – Stick1 out solenoid open circuit1438
Wiring Diagram and monitoring screen for message DWBJKA1439
DWBJKB – Stick1 out solenoid short circuit1440
Wiring Diagram and monitoring screen for message DWBJKB1441
DWBJKY – Stick1 out solenoid hot short circuit1442
Wiring Diagram and monitoring screen for message DWBJKY1443
DWBNKA – Stick1 in solenoid open circuit1444
Wiring Diagram and monitoring screen for message DWBNKA1445
DWBNKB – Stick1 in solenoid short circuit1446
Wiring Diagram and monitoring screen for message DWBNKB1447
DWBNKY – Stick1 in solenoid hot short circuit1448
Wiring Diagram and monitoring screen for message DWBNKY1449
DWBBKA – Boom2 up solenoid open circuit1450
Wiring Diagram (BHA) and monitoring screen for message DWBBKA1451
Wiring Diagram (FSA) and monitoring screen for message DWBBKA1452
DWBBKB – Boom2 up solenoid short circuit1453
Wiring Diagram (BHA) and monitoring screen for message DWBBKB1454
Wiring Diagram (FSA) and monitoring screen for message DWBBKB1455
DWBBKY – Boom2 up solenoid hot short circuit1456
Wiring Diagram for message DWBBKY1457
DWBFKA – Boom2 down solenoid open circuit1458
Wiring Diagram (BHA) and monitoring screen for message DWBFKA1459
Wiring Diagram (FSA) and monitoring screen for message DWBFKA1460
DWBFKB – Boom2 down solenoid short circuit1461
Wiring Diagram (BHA) and monitoring screen for message DWBFKB1462
Wiring Diagram (FSA) and monitoring screen for message DWBFKB1463
DWBFKY – Boom2 down solenoid hot short circuit1464
Wiring Diagram for message DWBFKY1465
DWBXKA – Clam2 close solenoid open circuit1466
Wiring Diagram and monitoring screen for message DWBXKA1467
DWBXKB – Clam2 close solenoid short circuit1468
Wiring Diagram and monitoring screen for message DWBXKB1469
DWBXKY – Clam2 close solenoid hot short circuit1470
Wiring Diagram and monitoring screen for message DWBXKY1471
DWBKKA – Stick2 out solenoid open circuit1472
Wiring Diagram and monitoring screen for message DWBKKA1473
DWBKKB – Stick2 out solenoid short circuit1474
Wiring Diagram and monitoring screen for message DWBKKB1475
DWBKKY – Stick2 out solenoid hot short circuit1476
Wiring Diagram and monitoring screen for message DWBKKY1477
DWBTKA – Clam2 open solenoid open circuit1478
Wiring Diagram and monitoring screen for message DWBTKA1479
DWBTKB – Clam2 open solenoid short circuit1480
Wiring Diagram and monitoring screen for message DWBTKB1481
DWBTKY – Clam2 open solenoid hot short circuit1482
Wiring Diagram and monitoring screen for message DWBTKY1483
DWBPKA – Stick2 in solenoid open circuit1484
Wiring Diagram and monitoring screen for message DWBPKA1485
DWBPKB – Stick2 in solenoid short circuit1486
Wiring Diagram and monitoring screen for message DWBPKB1487
DWBPKY – Stick2 in solenoid hot short circuit1488
Wiring Diagram and monitoring screen for message DWBPKY1489
DWATKA – Bucket2 fill solenoid open circuit1490
Wiring Diagram (BHA) and monitoring screen for message DWATKA1491
Wiring Diagram (FSA) and monitoring screen for message DWATKA1492
DWATKB – Bucket2 fill solenoid short circuit1493
Wiring Diagram (BHA) and monitoring screen for message DWATKB1494
Wiring Diagram (FSA) and monitoring screen for message DWATKB1495
DWATKY – Bucket2 fill solenoid hot short circuit1496
Wiring Diagram for message DWATKY1497
DWAXKA – Bucket2 dump solenoid open circuit1498
Wiring Diagram (BHA) and monitoring screen for message DWAXKA1499
Wiring Diagram (FSA) and monitoring screen for message DWAXKA1500
DWAXKB – Bucket2 dump solenoid short circuit1501
Wiring Diagram (BHA) and monitoring screen for message DWAXKB1502
Wiring Diagram (FSA) and monitoring screen for message DWAXKB1503
DWAXKY – Bucket2 dump solenoid hot short circuit1504
Wiring Diagram and monitoring screen for message DWAXKY1505
D5ZWKB – Travel hour meter short circuit1506
Wiring Diagram and monitoring screen for message D5ZWKB1507
D1EUKB – Travel alarm relay short circuit1508
Wiring Diagram and monitoring screen for message D1EUKB1509
DBX9KQ – Model Selection Abnormality1510
Wiring Diagram and monitoring screen for message DBX9KQ1511
DBXZKQ – Lever Control Selection Abnormality1512
Wiring Diagram and monitoring screen for message DBXZKQ1513
DBXYKQ – Attachment selection abnormality1514
Wiring Diagram – Attachment selection abnormality (DBXYKQ)1515
D561MA – Lock lever sol power cut abnorm(VALVE/S1)1516
Wiring Diagram 1 for message D561MA1518
Monitoring screens and Wiring Diagram 2 for message D561MA1519
D563MA – Ladder up sensor sol cut abnorm(VLV/S1)1520
Wiring Diagram 1 for message D563MA1522
Monitoring screens and Wiring Diagram 2 for message D563MA1523
D565MA – Service arm (up) sensor sol cut abnorm(VLV/S1)1524
Wiring Diagram 1 for message D565MA1526
Wiring Diagram 2 and monitoring screens for message D565MA1527
DBX2KK – Solenoid Power Low Error(VALVE/S1 Con)1528
Monitoring screen and Wiring Diagram 1 for message DBX2KK1529
Wiring Diagram 2 for message DBX2KK – PPC safety circuit1530
DBX0KQ – VALVE/S1 Con Selection Abnormality1532
Wiring Diagram and monitoring screen for message DBX0KQ1533
DBYLKA – Operating Lamp Open Circuit(VALVE/S2 Con)1534
Wiring Diagram – Operating Lamp Open Circuit(VALVE/S2 Con)1535
DBYLKB – Operating Lamp Short Circuit(VALVE/S2 Con)1536
Wiring Diagram – Operating Lamp Short Circuit(VALVE/S2 Con)1537
DWAUKA – Bucket3 fill solenoid open circuit1538
Wiring Diagram and monitoring screen for message DWAUKA1539
DWAUKB – Bucket3 fill solenoid short circuit1540
Wiring Diagram and monitoring screen for message DWAUKB1541
DWAUKY – Bucket3 fill solenoid hot short circuit1542
Wiring Diagram and monitoring screen for message DWAUKY1543
DWAYKA – Bucket3 dump solenoid open circuit1544
Wiring Diagram and monitoring screen for message DWAYKA1545
DWAYKB – Bucket3 dump solenoid short circuit1546
Wiring Diagram and monitoring screen for message DWAYKB1547
DWAYKY – Bucket3 dump solenoid hot short circuit1548
Wiring Diagram and monitoring screen for message DWAYKY1549
DWBCKA – Boom3 up solenoid open circuit1550
Wiring Diagram and monitoring screen for message DWBCKA1551
DWBCKB – Boom3 up solenoid short circuit1552
Wiring Diagram and monitoring screen for message DWBCKB1553
DWBCKY – Boom3 up solenoid hot short circuit1554
Wiring Diagram and monitoring screen for message DWBCKY1555
DWBGKA – Boom3 down solenoid open circuit1556
Wiring Diagram and monitoring screen for message DWBGKA1557
DWBGKB – Boom3 down solenoid short circuit1558
Wiring Diagram and monitoring screen for message DWBGKB1559
DWBGKY – Boom3 down solenoid hot short circuit1560
Wiring Diagram and monitoring screen for message DWBGKY1561
DWBLKA – Stick3 out solenoid open circuit1562
Wiring Diagram (BHA) and monitoring screen for message DWBLKA1563
Wiring Diagram (FSA) and monitoring screen for message DWBLKA1564
DWBLKB – Stick3 out solenoid short circuit1565
Wiring Diagram (BHA) and monitoring screen for message DWBLKB1566
Wiring Diagram (FSA) and monitoring screen for message DWBLKB1567
DWBLKY – Stick3 out solenoid hot short circuit1568
Wiring Diagram and monitoring screen for message DWBLKY1569
DWBQKA – Stick3 in solenoid open circuit1570
Wiring Diagram (BHA) and monitoring screen for message DWBQKA1571
Wiring Diagram (FSA) and monitoring screen for message DWBQKA1572
DWBQKB – Stick3 in solenoid short circuit1573
Wiring Diagram (BHA) and monitoring screen for message DWBQKB1574
Wiring Diagram (FSA) and monitoring screen for message DWBQKB1575
DWBQKY – Stick3 in solenoid hot short circuit1576
Wiring Diagram and monitoring screen for message DWBQKY1577
DWKQKA – Travel3 right backward sol open circuit1578
Wiring Diagram and monitoring screen for message DWKQKA1579
DWKQKB – Travel3 right backward sol short circuit1580
Wiring Diagram and monitoring screen for message DWKQKB1581
DWKQKY – Travel3 right backward sol hot short1582
Wiring Diagram and monitoring screen for message DWKQKY1583
DWKLKA – Travel3 right forward sol open circuit1584
Wiring Diagram and monitoring screen for message DWKLKA1585
DWKLKB – Travel3 right forward sol short circuit1586
Wiring Diagram and monitoring screen for message DWKLKB1587
DWKLKY – Travel3 right forward sol hot short1588
Wiring Diagram and monitoring screen for message DWKLKY1589
DWARKA – Slew4 right solenoid open circuit1590
Wiring Diagram and monitoring screen for message DWARKA1591
DWARKB – Slew4 right solenoid short circuit1592
Wiring Diagram and monitoring screen for message DWARKB1593
DWARKY – Slew4 right solenoid hot short circuit1594
Wiring Diagram and monitoring screen for message DWARKY1595
DWAMKA – Slew4 left solenoid open circuit1596
Wiring Diagram and monitoring screen for message DWAMKA1597
DWAMKB – Slew4 left solenoid short circuit1598
Wiring Diagram and monitoring screen for message DWAMKB1599
DWAMKY – Slew4 left solenoid hot short circuit1600
Wiring Diagram and monitoring screen for message DWAMKY1601
DXEDKA – Hydraulic slew brake epc sol open circuit1602
Wiring Diagram and monitoring screen for message DXEDKA1603
DXEDKB – Hyd slew brake epc sol short circuit1604
Wiring Diagram and monitoring screen for message DXEDKB1605
DXEDKY – Hyd slew brake epc sol hot short circuit1606
Wiring Diagram and monitoring screen for message DXEDKY1607
DBY9KQ – Model Selection Abnormality1608
Wiring Diagram and monitoring screen for message DBY9KQ1609
DBYZKQ – Lever Control Selection Abnormality1610
Wiring Diagram and monitoring screen for message DBYZKQ1611
DBYYKQ – Attachment selection abnormality1612
Wiring Diagram – Attachment selection abnormality (DBYYKQ)1613
D562MA – Lock lever sol power cut abnorm(VALVE/S2)1614
Wiring Diagram 1 for message D562MA1616
Monitoring screens and Wiring Diagram 2 for message D562MA1617
D564MA – Ladder up sensor sol cut abnorm(VLV/S2)1618
Wiring Diagram 1 for message D564MA1620
Monitoring screens and Wiring Diagram 2 for message D564MA1621
D566MA – Service arm sensor sol cut abnorm(VALV/S2)1622
Wiring Diagram 1 for message D566MA1624
Monitoring screens and Wiring Diagram 2 for message D566MA1625
DBY2KK – Solenoid Power Low Error(VALVE/S2 Con)1626
Monitoring screen and Wiring Diagram 1 for message DBY2KK1627
Wiring Diagram 2 for message DBY2KK – PPC safety circuit1628
DBY0KQ – VALVE/S2 Con Selection Abnormality1630
Wiring Diagram and monitoring screen for message DBY0KQ1631
DJH2KX – Hydraulic oil level sensor abnormality1632
Wiring Diagram and monitoring screen for message DJH2KX1633
DJE3KX – Remote engine oil level1 sens abnormality1634
DJE4KX – Remote engine oil level2 sens abnormality1634
Wiring Diagram and monitoring screen for message DJE3KX & DJE4KX1635
B@NHKX – Hydraulic oil tank air filter sensor abnormality1636
Wiring Diagram and monitoring screen for message B@NHKX1637
DH2GKX – Suction tank pressure sensor abnormality1638
Wiring Diagram and monitoring screen for message DH2GKX1639
DH2HKX – Oil cooler pressure sensor abnormality1640
Wiring Diagram and monitoring screen for message DH2HKX1641
DH2JKX – Preload valve return oil press abnormality1642
Wiring Diagram and monitoring screen for message DH2JKX1643
DHSUKX – X2 pressure sensor abnormality1644
Wiring Diagram and monitoring screen for message DHSUKX1645
DJF1KX – Fuel level sensor abnormality1646
Wiring Diagram and monitoring screen for message DJF1KX1647
DH2KKX – Return oil chamber press sensor abnormal1648
Wiring Diagram and monitoring screen for message DH2KKX1649
DH2LKX – Leak oil chamber press sensor abnormality1650
Wiring Diagram and monitoring screen for message DH2LKX1651
DJE5L4 – SLS sensor system abnormality1652
Wiring Diagram and monitoring screen for message DJE5L41653
DJE6L4 – CLS sensor system abnormality1654
Wiring Diagram and monitoring screen for message DJE6L41655
DBVLKA – Operating Lamp Open Circuit(KOMTRAX)1656
Wiring Diagram for message DBVLKA1657
DBVLKB – Operating Lamp Short Circuit(KOMTRAX)1658
Wiring Diagram for message DBVLKB1659
DBV1KK – KOMTRAX Plus source voltage Error1660
Wiring Diagram for message DBV1KK1661
DBV5KB – 5V sensor1 power abnormality1662
Wiring Diagram 1 and monitoring screen for message DBV5KB1663
DBV6KB – 24V Sensor Power Abnormality1664
Wiring Diagram 1 and monitoring screen for message DBV6KB1665
DAFGMC – GPS Module Error1666
Wiring Diagram for message DAFGMC1667
D862KA – GPS Antenna Open Circuit1668
DBVVKR – Ethernet 1 Disconnection1669
DBVWKR – Ethernet 2 Disconnection1670
DA2RKR – CAN1 Discon (Pump Con)1672
CAN1 overview for message DA2RKR1673
DBZRKR – CAN1 Discon (Pump2 Con)1674
CAN1 overview for message DBZRKR1675
DBWRKR – CAN1 Discon (Valve/M Con)1676
CAN1 overview for message DBWRKR1677
DBXRKR – CAN1 Discon (Valve/S1 Con)1678
CAN1 overview for message DBXRKR1679
DBYRKR – CAN1 Discon (Valve/S2 Con)1680
CAN1 overview for message DBYRKR1681
DB2QKR – CAN2 Discon (Engine Con)1682
CAN2 overview for message DB2QKR1683
Wiring Diagram for PWR supply at 52K014-1 (DB2QKR)1684
F72QKR – CAN2 Discon (Engine2 Con)1685
CAN2 overview for message F72QKR1686
Wiring Diagram for PWR supply at 52K014-2 (F72QKR)1687
DA2QKR – CAN2 Discon (Pump Con)1688
CAN2 overview for message DA2QKR1689
DBZQKR – CAN2 Discon (Pump2 Con)1690
CAN2 overview for message DBZQKR1691
DBWQKR – CAN2 Discon (Valve/M Con)1692
CAN2 overview for message DBWQKR1693
DBXQKR – CAN2 Discon (Valve/S1 Con)1694
CAN2 overview for message DBXQKR1695
DBYQKR – CAN2 Discon (Valve/S2 Con)1696
CAN2 overview for message DBYQKR1697
DBVRKR – CAN1 Discon (KOMTRAX Plus)1698
CAN1 overview for message DBVRKR1699
DBVQKR – CAN2 Discon (KOMTRAX Plus)1700
CAN2 overview for message DBVQKR1701
DBPRKR – CAN1 Discon (KomVision)1702
Wiring Diagram for DBPRKR1703
DBPQKR – CAN2 Discon (KomVision)1704
Wiring Diagram for DBPQKR1705
DAFLKA – Operating Lamp Open Circuit(Monitor)1706
Wiring Diagram for message DAFLKA1707
DAFLKB – Operating Lamp Short Circuit(Monitor)1708
Wiring Diagram for message DAFLKB1709
DBSSKR – PLM Discon (Shovel PLM)1710
Wiring Diagram for message DBSSKR1711
DBSSKT – Shovel PLM Internal Error1712
Wiring Diagram – PLM components for message DBSSKT1713
D19YKB – Emergency Lighting Ladder Relay Short Circuit1714
Wiring Diagram and monitoring screen for message D19YKB1715
DV00KB – Shutdown Buzzer Short Circuit1716
Wiring Diagram and monitoring screen for message DV00KB1717
DAF0KM – Inconsistency of KomVision Setting1718
DBP5KP – Camera Power Output Voltage Low1720
Wiring Diagram for message DBP5KP1721
DBP0NR – KomVision Controller High Temperature Error1722
DPQ4KB – Short Circuit of KomVision Monitor ON/OFF Signal1724
Wiring Diagram for message DPQ4KB1725
DBP0KT – KomVision Controller Internal Error1726
DBP0KM – KomVision Controller Setting Error1727
DR10KA – Disconnection of Camera 1 NTSC Input1728
DR20KA – Disconnection of Camera 2 NTSC Input1728
DR30KA – Disconnection of Camera 3 NTSC Input1728
DR40KA – Disconnection of Camera 4 NTSC Input1728
DR50KA – Disconnection of Camera 5 NTSC Input1728
DR60KA – Disconnection of Camera 6 NTSC Input1728
DR90KA – Disconnection of Camera 7 NTSC Input1728
Wiring Diagram for message DR10KADR90KA1729
DPQ4KT – KomVision Monitor Internal Error1730
DBPLKA – Operating Lamp Open Circuit (KomVision)1732
Wiring Diagram for message DBPLKA1733
DBPLKB – Operating Lamp Short Circuit (KomVision)1734
Wiring Diagram for message DBPLKB1735
DBPWKR – Ethernet 1 Discon (KomVision)1736
DBPXKR – Ethernet 2 Discon (KomVision)1736
7 Troubleshooting by Symptoms1737
71 Symptoms of engines and related electrical systems1738
SEL001 – Engine does not start (engine does not rotate)1738
Wiring Diagram 1 (batteries) for symptom code SEL0011740
Wiring Diagram 2 (20S030 & 20S105a/b) for symptom code SEL0011741
Wiring Diagram 3 (engine enable) for symptom code SEL0011742
Wiring Diagram 4 (starter motors) for symptom code SEL001 (engine 1 as example)1743
SEL002 – Engine stops while in operation1744
Engine 2 stage Fuel System1745
SEL003 – Engine speed is hunting during boom-up movement1746
SEL004 – Engine does not stop1748
SEL005 – Engine lacks output (no power)1749
Judgment Table for SEL0051750
SEL006 – Engine does not start (Pre-lube does not stop)1751
SEL007 – Oil consumption is excessive1752
Judgment Table for SEL0071753
SEL008 – Oil becomes contaminated quickly1754
Judgment Table for SEL0081755
SEL009 – Fuel consumption is excessive1756
Judgment Table for SEL0091757
SEL010 – Oil is in engine coolant1758
Judgment Table for SEL0101759
SEL011 – Oil level rises1760
Judgment Table for SEL0111761
SEL012 – Coolant temperature becomes too high (overheating)1762
Judgment Table for SEL0121763
72 Symptoms of Hydraulic System1764
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function)1764
SHY002 – Engine speed sharply drops or engine stalls too much1766
SHY003 – No work equipment, travel, or slew movement1767
SHY004 – Work equipment has too much hydraulic drift1768
SHY005 – Work equipment has big time lag1769
SHY006 – Excavator deviates during travel movement1770
SHY007 – Hydraulic system has lack of power1772
Servo valve (SHY007)1773
SHY008 – Excavator does not slew1774
Slew brake block (SHY008)1775
SHY009 – Slew acceleration is poor1776
SHY010 – Excessive overrun when stopping slew movement1778
SHY011 – Floating system without function (FSA only)1780
SHY012 – Abnormal noise coming from SRV or MRV1781
SHY013 – Track tensioning system without function1782
Track tensioning – overview (SHY013)1783
SHY014 – Stairway does not move, or slow movement1784
SHY015 – Refilling arm does not move, or slow movement1786
SHY016 – Hydraulic driven grease pump does not move1788
SHY017 – Abnormal track chain movement during digging1790
SHY018 – Slew parking brake without function1791
SHY019 – Travel parking brake without function1792
73 Symptoms of Mechanical System1794
SME001 – Abnormal noise is made1794
Judgment Table for SME0011795
SME002 – Abnormal noise around PTOs / hydraulic pumps1796
SME003 – Vibration is excessive (engine mountings)1798
Judgment Table for SME0031799
SME004 – Vibration is excessive (engine torsion)1800
SME005 – There is a big shock when stopping slew movement1801
SME006 – There is a big abnormal noise when moving/stopping slew movement1802
SME007 – Fan blades make abnormal noise1804
SME008 – Abnormal noise coming from a travel gearbox1806
SME009 – Abnormal noise coming from work equipment (lack of grease)1808
SME010 – Abnormal idler movement1810
SME011 – Leak at PTO drive shaft seal1812
74 Symptoms of Additional Systems1814
SAD001 – Air conditioner for cabin does not work1814
View onto A/C unit (SAD001)1815
SAD002 – Air conditioner compressor clutch is burnt1816
View onto A/C compressor and its mounting (SAD002)1817
SAD003 – Air conditioning system defective (pipes & hoses full of moisture)1818
View onto A/C filling and service station1819

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24