Komatsu Hydraulic Mining Shovel PC4000-6 T2 Shop Manual 08205 PDF

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Komatsu Hydraulic Mining Shovel PC4000-6 T2 Shop Manual 08205 –  PDF DOWNLOAD

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Komatsu Hydraulic Mining Shovel PC4000-6 T2 Shop Manual 08205 –  PDF DOWNLOAD

Language : English
Pages : 1830
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Hydraulic Mining Shovel PC4000-6 T2 Shop Manual 08205 –  PDF DOWNLOAD

• SERIAL NUMBER 08205 and up

SHOP MANUAL Cover . 1
00 FOREWORD & SAFETY 3
1 Foreword 5
1.1 BEFORE READING THIS MANUAL 6
1.2 CONTENTS OF THIS BINDER . 7
1.2.1 Contacting the Service 7
1.2.2 Guarantee . 7
1.3 DIVISION OF THE BINDER 8
2 SAFETY 9
2.1 SAFETY INFORMATION 10
2.2 OVERVIEW 11
2.2.1 NORMAL OPERATIONS . 11
2.2.2 REGULAR MAINTENANCE . 11
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR . 11
2.2.4 ADDITIONAL SAFETY PRECAUTIONS . 11
2.3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB . 12
2.3.1 SOUND . 12
2.3.2 VIBRATION . 12
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 13
2.4.1 UNDERSTANDING THE MACHINE . 13
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 13
2.4.2.1 ENSURING SAFE OPERATION . 13
2.4.3 PREPARATIONS FOR SAFE OPERATION . 13
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 13
2.4.3.2 INSPECTING THE MACHINE 13
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 14
2.4.3.4 KEEP MACHINE CLEAN 14
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT . 14
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT . 15
2.4.3.7 IF A PROBLEM IS FOUND . 15
2.4.4 FIRE PREVENTION . 15
2.4.4.1 PRECAUTIONS TO PREVENT FIRE . 15
2.4.4.2 ACTION IF FIRE OCCURS . 17
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB 17
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 18
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 18
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE 18
2.4.5.3 NO PEOPLE ON THE ATTACHMENT . 18
2.4.5.4 WORKING IN HIGH PLACES 18
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK . 19
2.4.5.6 LEAVING THE MACHINE . 19
2.4.6 BURN PREVENTION . 19
2.4.6.1 Hot coolant . 19
2.4.6.2 Hot oil . 20
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS . 20
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 20
2.4.8.1 UNAUTHORIZED MODIFICATION . 21
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 21
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC) . 21
2.4.10 PRECAUTIONS AT JOBSITE . 22
2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT 23
2.4.10.2 CAMERA SYSTEM WITH MONITORS 23
2.4.10.3 ENSURE GOOD VISIBILITY . 23
2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS . 23
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS . 24
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES . 24
2.4.10.7 WORKING ON LOOSE GROUND 25
2.4.10.8 GAS, DUST, STEAM AND SMOKE . 25
2.4.10.9 VENTILATION OF ENCLOSED AREAS 26
2.4.11 STARTING motor . 27
2.4.11.1 WARNING TAG 27
2.4.11.2 CHECKS BEFORE STARTING motor . 27
2.4.11.3 PRECAUTION WHEN STARTING motor . 27
2.4.11.4 PRECAUTION IN COLD AREAS . 28
2.4.12 OPERATION 28
2.4.12.1 CHECKS BEFORE OPERATION 28
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 29
2.4.12.3 PRECAUTIONS WHEN travelling 30
2.4.12.4 TRAVELLING ON SLOPES . 31
2.4.12.5 OPERATIONS ON SLOPES . 32
2.4.12.6 PROHIBITED OPERATIONS 32
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 33
2.4.12.8 PARKING THE MACHINE 33
2.4.12.9 TRANSPORTATION . 33
2.5 PRECAUTION FOR MAINTENANCE 34
2.5.1 GENERAL PRECAUTIONS . 34
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES . 35
2.5.1.2 STOP motor FOR MAINTENANCE 36
2.5.1.3 WARNING TAG . 37
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY . 38
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS . 38
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING . 39
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS . 39
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT . 40
2.5.1.9 NOISE . 40
2.5.1.10 WHEN USING A HAMMER 40
2.5.1.11 PROPER TOOLS . 41
2.5.1.12 ACCUMULATOR 41
2.5.1.13 PERSONNEL 41
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 42
2.5.2.1 PRECAUTION WHEN WELDING . 42
2.5.2.2 BATTERY HANDLING 42
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID 43
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE . 43
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES 44
2.5.3.3 REPLACEMENT OF HOSE LINES . 44
2.5.3.4 INSPECTION OF HOSE LINES 44
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS . 45
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE 45
2.5.3.7 AIR CONDITIONING MAINTENANCE 45
2.5.3.8 COMPRESSED AIR 46
2.5.3.9 WASTE MATERIALS . 46
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS . 47
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM 47
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS . 47
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 47
2.7 SPECIAL SAFETY EQUIPMENT 48
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB . 49
2.7.2 OBJECT HANDLING . 49
2.7.3 LIGHTING 49
2.7.4 WARNING BEACON 49
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2.7.5.2 INSTRUCTIONS FOR USE 51
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 53
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS . 53
2.7.5.5 INSTRUCTIONS FOR USE 55
01 SPECIFICATION 57
Specification PC4000 59
10 STRUCTURE & FUNCTION . 67
TOC . 69
1 Introduction 79
1.1 Foreword 80
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 81
1.3 Explanation of abbreviations 82
1.4 Diagrams and illustrations in this manual . 83
2 Specifications 85
2.1 Lifting Gears . 86
2.2 Safety hints for sling accessory 88
2.3 Standard Tightening Torque Chart 89
2.4 Conversion Table 90
2.5 Blind plugs . 96
2.6 Classification of threads to the nominal width 98
2.7 Plugs and fittings according to ISO 8434-1 / DIN 2353 . 99
3 Main assembly groups 101
3.1 General layout 102
3.2 Superstructure 104
3.3 Machine house . 106
3.4 Hydraulic oil tank 108
3.5 Hydraulic oil cooler 110
3.6 Fuel tank . 112
3.7 Cab support . 114
3.8 Operator’s cab 116
3.9 Control blocks 118
3.10 Slew gear 120
3.10.1 Slew gear L&S 120
3.10.2 Slew gear SIEBENHAAR . 122
3.11 Undercarriage 124
3.12 Slew ring 126
3.13 Attachment . 128
3.13.1 Front Shovel Attachment (FSA) 128
3.13.2 Backhoe Attachment (BHA) . 130
3.14 Counterweight 132
4 Drive . 135
4.1 Prime drive assembly 136
4.2 Engine and PTO mounts . 138
4.2.1 Engine Mounts . 138
4.2.2 Torque Support 139
4.3 Flexible coupling . 140
4.4 Fan drive and radiator assembly . 142
4.4.1 Radiator fan drive 144
4.4.2 Fan pump 146
4.4.3 Radiator fan drive speed adjustment . 148
4.5 Pump distributor gearbox (PTO) 150
4.5.1 Pump spline lubrication . 152
4.5.1.1 Oil level in the main pump drive shaft housing 153
4.5.2 PTO lubrication and cooling . 154
4.5.2.1 Checks and adjustments 156
4.6 Hydraulic pumps – location, drive speed and flow rates 158
4.6.1 Pump data . 160
4.7 Air filter 162
5 Hydraulic oil tank 165
5.1 General layout 166
5.2 Hydraulic oil tank, location of the electric equipment 168
5.3 Suction oil tank with strainers . 170
5.4 Return oil collector pipe with strainer . 172
5.5 Back pressure valve . 174
5.6 Transfer pump . 176
5.7 Return and leak oil filter 178
5.8 Breather filter . 180
6 Hydraulic oil cooling . 183
6.1 Overall view of the hydraulic oil cooling . 184
6.2 Function of the hydraulic oil cooling circuit . 186
6.3 Adjustment of the back pressure valve . 188
6.4 Two stage cooler fan RPM control 190
6.4.1 Pressure reducing valve . 192
6.4.2 Solenoid valves . 194
6.4.3 Fan pump 196
6.5 Checks and Adjustments of the cooler fan drive speeds . 198
6.5.1 Function Check of Fan Speed Control . 202
7 Controlling . 203
7.1 General layout 204
7.2 Control and filter panel 206
7.3 Valve cartridge block . 208
7.4 Pilot pressure supply and adjustments . 210
7.4.1 Pilot pressure control (PPC) circuit 210
7.4.2 Checks and adjustment of pilot pressure . 214
7.4.3 Remote control valves arrangement . 216
7.5 Function of the electro hydraulic control system 218
7.6 Hand lever (joystick) control . 222
7.7 Foot pedal control 224
7.8 Proportional amplifier module, type A . 226
7.9 Proportional amplifier module, type B . 228
7.10 Ramp time module . 230
7.11 Adjustments of amplifier modules . 232
7.11.1 General 233
7.11.2 Adjusting the amplifiers type A 234
7.11.3 Adjusting the amplifiers type B 236
7.12 Adjusting the ramp time module . 238
8 Components 243
8.1 Main control blocks and high pressure filters (FSA) . 244
8.2 Main control blocks and high pressure filters (BHA) . 246
8.3 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) . 248
8.4 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) . 250
8.5 Single control blocks (floating) for stick and boom (FSA) . 252
8.6 Restrictor block with secondary relief valve 254
8.7 Anti-cavitation valve (ACV) block . 256
8.8 Remote control valves . 258
8.9 4/3 Directional solenoid valves . 260
8.10 Proportional solenoid valves . 262
8.11 High-pressure screen . 264
8.12 Control blocks and valves 266
8.12.1 Spool types 272
8.12.2 MRV, SRV and ACV . 274
8.12.3 Load holding valve . 276
8.13 Travel brake valve . 280
8.14 Pressure reducing valve 282
8.15 4/2 Directional valves . 284
8.16 Pressure double stage valve 286
8.17 Hydraulic cylinder with NOK-3 sealing 288
8.17.1 Cylinder data markings . 291
9 Main hydraulic pumps and pump regulation 293
9.1 General . 294
9.1.1 Pump locations and pump data 296
9.2 Main pumps 298
9.2.1 Hydraulic pump type HPV375+375 298
9.2.1.1 Main pump sectional drawings 300
9.2.2 Servo valve . 302
9.2.2.1 VC valve  servo piston . 303
9.2.2.2 EPC valve . 308
9.3 Electronic pump regulation system . 310
9.3.1 Cut-off function 312
9.3.2 Slew control 313
9.3.3 Altitude pump displacement 313
9.3.4 Temperature control . 314
9.3.4.1 Hydraulic oil temperature charts 314
9.3.5 Energy efficiency . 315
9.3.6 Diagnostics and monitoring 315
9.4 Pump controller (10K032), type CR710 316
9.5 Multimonitor 318
9.5.1 Service menu screen . 321
9.5.2 Service menu, option: 01 Monitoring . 322
9.5.2.1 Hold function . 325
9.5.3 Service menu, option: 02 Abnormality Record . 326
9.5.3.1 Troubleshooting procedures 326
9.5.3.2 Failure codes of the pump controller 327
9.5.4 Service menu, option: 03 Default 328
9.5.5 Service menu, option: 04 Adjustment . 329
9.5.6 Adjustable parameters . 330
9.5.7 Emergency mode 330
9.5.8 Description of the Primary P-Factor . 331
9.5.9 Adjustment, item 1: Primary P-factor 331
9.5.10 Adjustment, items 23 .30: Sol_adj_min_P1 .Sol_adj_min_P8 . 332
9.5.11 Adjustment, items 39 .46: Sol_adj_mAX_P1 .Sol_adj_mAX_P8 . 333
9.5.12 Adjustment, item 74: Altitude 334
9.5.13 Available parameters list 335
9.5.14 Service menu, option: 05 Display Setup . 337
9.6 Checks and adjustments 338
9.6.1 Engine power check 338
9.6.2 Cut-off function check 340
9.6.2.1 Cut-off for clam close (FSA only) . 341
9.7 Engine speed sensor (pick-up) . 342
9.7.1 General . 343
9.7.2 Engine speed sensor (pick-up) adjustment 343
10 Operating hydraulics . 345
10.1 General 346
10.1.1 Floating system (FSA) 348
10.2 Hydraulics for the attachment cylinders 350
10.2.1 Electric / hydraulic flowchart “Boom UP” (FSA) . 350
10.2.2 Electric / hydraulic flowchart “boom up” (BHA) . 352
10.2.3 Electric / hydraulic flowchart “boom down” (FSA) . 354
10.2.4 Electric / hydraulic flowchart “Boom down” (BHA) . 356
10.2.5 Electric / hydraulic flowchart “Stick out” (FSA) . 358
10.2.6 Electric / hydraulic flowchart “Stick out” (BHA) . 360
10.2.7 Electric / hydraulic flowchart “Stick in” (FSA) 362
10.2.8 Electric / hydraulic flowchart “Stick in” (BHA) 364
10.2.9 Electric / hydraulic flowchart “Bucket fill” (FSA) . 366
10.2.10 Electric / hydraulic flowchart “Bucket fill” (BHA) 368
10.2.11 Electric / hydraulic flowchart “Bucket dump” (FSA) 370
10.2.12 Electric / hydraulic flowchart “Bucket dump” (BHA) 372
10.2.13 Electric / hydraulic flowchart “Clam open” (FSA) 374
10.2.14 Electric / hydraulic flowchart “Clam close” (FSA) . 376
10.2.15 Checks and adjustments of the main relief valve (MRV) . 378
10.2.16 Checks and adjustments of the secondary relief valves (SRV) . 380
10.2.16.1 Boom cylinders, piston side (BHA & FSA), boom up 380
10.2.16.2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down . 384
10.2.16.3 Stick cylinders, piston side (FSA), stick out . 388
10.2.16.4 Stick cylinders, piston side (BHA), stick in 392
10.2.16.5 Stick cylinders, piston rod side (FSA), stick in 396
10.2.16.6 Stick cylinders, piston rod side (BHA), stick out . 400
10.2.16.7 Bucket cylinders, piston side (FSA), bucket fill 404
10.2.16.8 Bucket cylinders, piston side (BHA), bucket fill 408
10.2.16.9 Bucket cylinders, piston rod side (FSA), bucket dump 412
10.2.16.10 Bucket cylinders, piston rod side (BHA), bucket dump . 416
10.2.16.11 Clam cylinders, piston rod side (FSA), clam open . 420
10.2.16.12 Clam cylinders, piston side (FSA), clam close 424
10.2.17 Checks and adjustments of the lowering speed 428
10.2.17.1 Checks and adjustments of the lowering speed – boom (FSA) . 428
10.2.17.2 Checks and adjustments of the lowering speed – boom (BHA) . 434
10.2.17.3 Checks and adjustments of the lowering speed – stick (FSA) 436
10.2.17.4 Checks and adjustments of the lowering speed – stick (BHA) 442
10.2.17.5 Checks and adjustments of the lowering speed – bucket (FSA) . 444
10.2.17.6 Checks and adjustments of the lowering speed – bucket (BHA) . 446
10.2.17.7 Checks and adjustments of the lowering speed – clam (FSA) . 448
10.3 Hydraulics for the slew circuit 450
10.3.1 Slew circuit . 450
10.3.2 Slew motor . 454
10.3.3 Slew gearbox (L&S) . 456
10.3.4 Slew gearbox (SIEBENHAAR) 458
10.3.5 Slew parking brake (L&S) . 460
10.3.6 Slew parking brake (SIEBENHAAR) 462
10.3.7 Slew brake valve . 464
10.3.8 Electric / hydraulic flowchart “Slew left” . 468
10.3.9 Electric / hydraulic flowchart “Slew right” 470
10.3.10 Checks and adjustments for the slew circuit . 472
10.3.10.1 checks & adjustments, slew speed 472
10.3.10.2 Checks & adjustments, double stage valve 474
10.3.10.3 Checks of the brake pilot pressure 477
10.3.11 Function check for the hydraulic slew brake . 478
10.3.12 Slew parking brake release function check . 480
10.4 Hydraulics for the travel circuit 482
10.4.1 Travel circuit . 482
10.4.2 Travel motor . 484
10.4.3 Rotary joint . 486
10.4.4 Travel gearbox . 488
10.4.4.1 Travel gearbox (L & S) . 488
10.4.4.2 Travel gearbox (Zollern) . 490
10.4.5 Travel parking brake . 492
10.4.5.1 Travel parking brake (Zollern) . 492
10.4.5.2 Travel parking brake (L&S) . 493
10.5 Travel brake valve . 494
10.5.1 Electric / hydraulic flowchart “travel forward” 496
10.5.2 Electric / hydraulic flowchart “travel backward” . 498
10.5.3 Checks and adjustments . 500
10.5.3.1 Checks and adjustments for the travel circuit 500
10.5.3.2 Function check for the travel parking brake 504
11 Hydraulic track tensioning system 507
11.1 General 508
11.2 Functional description . 510
11.3 Double stage valve . 512
11.4 Tensioning cylinder 514
11.5 Adjustments / checks . 516
12 Access ladder, hydraulically operated 519
12.1 General 520
12.2 Function of the hydraulically operated access ladder . 522
12.3 Adjustments / checks . 526
13 Central refilling system (Service arm) . 529
13.1 General 530
13.2 Function . 532
14 Hints for reading the hydraulic diagram 535
14.1 General 536
14.2 Hydraulic symbols 538
14.2.1 Lines, unions 539
14.2.2 Components, valves . 541
14.2.3 Sensors 541
14.2.4 Valves, valve components . 542
14.2.5 Pump, motor, cylinder 546
15 Hints for reading the electric wiring diagram 551
15.1 General 552
15.2 Reference code of the electrical components 553
15.2.1 Area code 553
15.2.2 Component identifying letter . 555
15.3 Graphical symbols 556
15.4 Drawing concept 560
15.5 Cable marking 570
16 KOMTRAX Plus & MTC control system 571
16.1 General 572
16.2 Specifications for operators . 574
16.2.1 Sequence of displays . 575
16.2.2 Opening screen . 575
16.2.3 Main gauge screens 1 to 3 576
16.2.4 Fuel consumption screen 579
16.2.5 Failure message history for the operator . 581
16.2.6 Main gauge screens – Changing of Time / SMR / Date . 583
16.2.7 Maintenance monitor 584
16.2.8 Settings for operator 586
16.2.9 Automatic messages . 594
16.3 Tables of all provided messages 597
16.3.1 Table of G-Codes . 598
16.3.2 Table of available Instruction Messages 603
16.4 Table of C-codes – Diesel engine Tier2 . 606
16.5 Flow charts (1-4) of KOMTRAX Plus main screens . 616
16.6 KOMTRAX Plus service level . 620
16.6.1 Explanation of the button symbols (Service Level) 622
16.6.2 Service Menu Select Screen . 623
16.6.3 Real Time Menu Select Screen . 624
16.6.3.1 Real Time Menu, option: 01 Engine 1 625
16.6.3.2 Real Time Menu, option: 02 PTO 1 . 626
16.6.3.3 Real Time Menu, option: 03 Hydraulic . 627
16.6.3.4 Real Time Menu, option: 04 Slew 628
16.6.3.5 Real Time Menu, option: 05 Electrical Equipment 629
16.6.3.6 Real Time Menu, option: 06 Emergency Stop 630
16.6.3.7 Real Time Menu, option: 07 Manual Switch . 631
16.6.3.8 Real Time Menu, option: 08 Central Lube System 1 . 632
16.6.3.9 Real Time Menu, option: 09 Slew Ring Gear Lube System 633
16.6.3.10 Real Time Menu, option: 10 Windscreen Wiper . 634
16.6.3.11 Real Time Menu, option: 11 Ladder . 635
16.6.3.12 Real Time Menu, option: 12 Service Arm 636
16.6.3.13 Real Time Menu, option: 13 Pilot Control 637
16.6.3.14 Real Time Menu, option: 14 Other Items 638
16.6.3.15 Real Time Menu, option: 15 Output Signals . 639
16.6.3.16 Output signals with deactivated MTC evaluation 642
16.6.4 PM Clinic 643
16.6.4.1 General 643
16.6.4.2 Power Check 644
16.6.5 Serial/GCC no. setting . 645
16.6.6 Memory Clear . 646
16.6.6.1 Input Memory Clear ID 646
16.6.6.2 Memory Clear screen 647
16.6.7 Failure History 648
16.6.8 Maintenance Monitor 649
16.6.9 Snapshot . 650
16.6.10 Settings 651
16.6.10.1 Central Lubrication System (CLS 1), screen 1/8 651
16.6.10.2 Slew Lubrication System (SLS), screen 2/8 . 652
16.6.10.3 Qmin – Qmax setting, screen 3/8 . 653
16.6.10.4 Other Settings 1/2, screen 4/8 653
16.6.10.5 Hydraulic Oil & PTO Gear Oil Definition Tables 654
16.6.10.6 Hydraulic oil temperature charts 654
16.6.10.7 PTO gear oil temperature charts . 654
16.6.10.8 Other Settings 2/2, screen 5/8 655
16.6.10.9 PLC-evaluation ON/OFF . 657
16.6.10.10 Shutdown Bypass ON/OFF . 658
16.7 Interface-Connection KOMTRAX Plus controller & MTC . 662
16.7.1 KOMTRAX Plus controller 663
16.8 Wiring of the KOMTRAX Plus controller 664
16.9 MTC control system – global layout . 668
16.9.1 MTC (Master Turbo Controller) 670
16.9.1.1 MTC flowchart 670
16.9.1.2 MTC features . 670
16.9.1.3 MTC firmware and software 671
16.9.1.4 Connector and component location in the control system . 671
16.9.1.5 View onto the MTC unit and its connectors 672
16.9.1.6 LED indications at the MTC . 673
16.10 Global layout of the internal CAN BUS . 674
16.10.1 General information on a CAN BUS system . 674
16.10.1.1 General CAN BUS description . 675
16.10.1.2 CAN BUS troubleshooting . 675
16.10.1.3 Can BUS wiring 676
16.10.1.4 CAN BUS end resistor 678
16.11 The nodes in the CAN BUS system . 680
16.11.1 Global layout . 680
16.11.2 Introduction 682
16.11.2.1 ICN-V features 682
16.11.2.2 View onto an open ICN-V node with DIP switches & status LED . 684
16.11.2.3 General information on the LED control 685
16.11.2.4 ICN-D features 686
16.11.2.5 View onto an ICN-D node without wiring 687
16.11.2.6 View onto the Status LEDs at the ICN-D node . 688
16.11.2.7 General information on the LED control 688
16.11.2.8 Node DIP switches . 690
16.11.2.9 Detailed view onto the DIP switches . 691
16.11.3 Node box 692
16.11.4 Node locations on the machine . 694
16.11.4.1 Node & location chart . 695
16.11.4.2 View onto the CAN BUS control components in a cab base (example) 696
17 Lubrication system . 699
17.1 General overview (SLS & CLS 1) . 700
17.1.1 General description 701
17.2 Basic function of the lubrication systems 702
17.3 Lubrication systems (CLS 1 & SLS) 704
17.3.1 Lubrication pump station . 704
17.3.2 General Information on CLS 1 . 706
17.3.3 General information on the SLS . 706
17.3.4 Manual lube activation . 706
17.4 Lubrication cycle 707
17.4.1 Operation and control 707
17.4.2 Lubrication cycle – processing . 708
17.4.3 Time segments & switch points of a lubrication cycle . 709
17.4.4 Lubrication modes 710
17.4.4.1 Automatic lubrication mode . 710
17.4.4.2 Manual lubrication mode 710
17.4.4.3 Reduced pause time for service . 710
17.5 Hydraulically driven lube pump . 712
17.5.1 Adjustment of lube pump speed 714
17.5.1.1 Stroke speed adjustment 715
17.5.1.2 Working pressure . 715
17.6 Lubricant injectors 716
17.6.1 Tightening torques for fittings at grease injectors 717
17.6.2 Description 717
17.6.3 Adjustment of the lubricant output . 718
17.6.4 Operation principle of lubricant injectors . 720
17.6.4.1 Function description . 721
17.6.5 Connection of one or more injectors 722
17.7 Vent Valve and grease outlet filter 724
17.7.1 Vent valve description . 725
17.8 End-line switch 726
17.8.1 Description 727
17.8.2 CLS 1 end-line switch adjustment . 728
17.8.3 SLS end-line switch adjustment . 730
17.9 Lubricant level sensors 732
17.9.1 Description 733
17.9.1.1 Checks . 733
17.10 Commissioning . 734
17.10.1 Commissioning of the CLS 1 lubrication system . 734
17.10.2 Fine adjustment . 735
17.10.3 Commissioning of the SLS lubrication system . 736
18 Deep temperature equipment (option) 739
18.1 General information 740
18.1.1 Introduction . 740
18.1.2 Deep temperature components overview . 740
18.1.3 Power supply preconditions for preheating 741
18.1.4 Power requirements for preheating systems 742
18.2 Preheating procedure . 743
18.2.1 Global flow chart of the preheating procedure 743
18.2.2 Starting the preheating procedure 744
18.2.3 Preheating of operator’s cab and Diesel engine [coolant system] 745
18.2.4 Preheating of lubricants and superstructure (Diesel) [electric system] . 746
18.3 Constant heating of travel motors (TTT equipment below-40°C only) 747
18.4 Component location . 748
18.4.1 Electric heating elements for hydraulic & batteries [electric machine] . 748
18.4.2 Electric heating elements for hydraulics [Diesel machine] 750
18.4.3 Electric heating elements for engines & batteries [Diesel machine] . 752
18.5 Components of TT equipment . 754
18.5.1 Preheating components on a Diesel machine 754
18.5.2 Preheating components on an electric machine . 755
18.5.3 Wiring Diagrams (examples) for preheating systems 756
18.5.3.1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 . 756
18.5.3.2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 . 757
18.5.3.3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 . 758
18.5.3.4 Wiring diagram “Suction Oil Manifold Preheating” . 759
18.5.3.5 Wiring diagram “PTO Preheating” 760
18.5.3.6 Wiring diagram “Battery heater pads” . 761
40 TROUBLESHOOTING 763
TOC . 765
1 Introduction 779
1.1 Overview 780
1.1.1 General advice when using troubleshooting charts 780
1.2 General Precautions . 781
2 General Information for Troubleshooting . 783
2.1 Preparations For Work . 784
2.2 Precautions During Work . 784
2.3 Precautions When Carrying Out Any Operation . 785
2.3.1 Precautions when carrying out removal work 785
2.3.2 Precautions when carrying out installation work . 785
2.3.3 Precautions when completing the operation . 786
2.4 Fundamental Requirements for Troubleshooting 787
2.4.1 Technical documentation . 787
2.4.2 Tools . 787
2.4.2.1 Reference Guide for Deutsch Removal Tools . 790
2.4.3 Personnel . 791
2.5 Points To Remember When Troubleshooting . 791
2.6 Sequence Of Events In Troubleshooting . 793
2.7 Checks Before Troubleshooting . 794
2.8 Handling Of Electric Equipment And Hydraulic Components . 795
2.8.1 Points to remember when handling electric equipment . 795
2.8.2 Points To Remember When Handling Hydraulic Equipment 797
2.9 General working procedures 800
2.9.1 Air Bleeding of Various Hydraulic Parts . 800
2.9.2 Air bleeding from the hydraulic pumps . 800
2.9.3 Air bleeding from hydraulic cylinders . 800
2.10 Cylinder bypass test . 801
2.11 Basics about “How to crimp” (without strain relief) 802
2.11.1 Stripping a wire for use with the HDT 48 crimp tool 802
2.11.2 View onto the Deutsch crimp tool HDT 48 802
2.11.3 Adjustment of the wire size at the Deutsch crimp tool HDT 48 . 803
2.11.3.1 Wire cross section units in mm2 and AWG 803
2.11.4 Crimping instructions (for Deutsch crimp tool HDT 48) 804
2.12 Basics about “How to crimp” (with strain relief) . 806
2.12.1 Crimp tool & repair kit 806
2.12.2 General 807
2.12.3 Select the required connector components . 807
2.12.4 Stripping a wire . 808
2.12.5 Crimping . 809
2.12.6 Connector assembly after crimping 810
2.13 Cable Shielding 811
3 Mounting Locations and Connector Types 813
3.1 View onto the superstructure 814
3.2 Location of engine electrical parts . 816
3.3 Location of hydraulic components (1) 818
3.3.1 Location of hydraulic components (2) 820
3.3.2 Location of hydraulic components (3) 822
3.4 View onto the SLS or CLS 1 grease barrel and the lubrication cycle components . 824
3.5 Hydraulic oil tank & suction oil tank – Location of electrical components . 826
3.6 Hydraulically operated access ladder 828
3.7 Connector Types Overview 830
4 Standard Value Table for Electrical Components 835
5 References for Troubleshooting (CAN Bus & Node Outputs) . 847
5.1 CAN BUS trouble or Node Output Trouble 848
5.1.1 Trouble CAN BUS or CAN-Hardware (G00308) 849
5.1.2 Trouble output short-circuit (G00043) . 850
5.2 Sequence of the CAN nodes at the CAN BUS 852
5.3 Troubleshooting for Relay Monitored Node Outputs 853
5.3.1 Relay Check . 853
G00107 – Trouble slew parking brake control 56K250a . 854
View onto the CoDeSys HMI Visualization screen for message G00107 . 856
Wiring Diagram (56K250a & 56K250b) for message G00107 . 857
5.3.2 Output Check 858
G00108 – Trouble slew parking brake control Output to 56K250a . 859
View onto the CoDeSys HMI Visualization screen for message G00108 . 861
Wiring Diagram (56K250a & 56K250b) for message G00108 . 862
6 Tables for Testing and Troubleshooting 863
6.1 Test Value Tables for Transducers . 864
6.1.1 Pump press. transducers . 864
6.1.2 Hydraulic oil pressure transducers 865
6.1.3 Miscellaneous Pressure Transducers 866
6.1.4 Temperature Transducers . 867
6.2 Test Value Table for Temperature Sensors PT100 type g Centigrade – Ohm 868
6.3 Hydraulic oil temperature charts 869
6.4 PTO gear oil temperature charts . 869
6.5 Table of Trouble Codes (G-Codes) 870
6.6 Table of Instruction Messages . 876
6.7 Table of Binary Codes . 879
6.7.1 Table of Add-On Binary Codes for G00308 . 881
6.8 Table of symptom codes 882
6.8.1 Symptoms of the engines and related electrical systems 882
6.8.2 Symptoms of the Hydraulic System 882
6.8.3 Symptoms of the mechanical system . 883
6.8.4 Symptoms of Additional Systems 883
6.9 Table of Pump Controller Fault Codes 884
6.10 Table of C-codes – Diesel engine Tier 2 885
6.11 Power Supply . 895
6.12 Cable colour identification 895
7 Troubleshooting by G-Codes 897
G00001 – Trouble Shut-Off (gate) valve 898
View onto the gap of proximity switch 40B031 900
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR . 901
View onto the setting for SHUTDOWN BYPASS on the K+ monitor . 901
Wiring Diagram (40B031) for message G00001 (Main gate valve open) . 902
G00002 – Test speed 1800 1/min engine 1 . 903
Wiring Diagram (11S041-1) for message G00002 904
G00003 – Trouble pump controller 905
G00005 – Low hydraulic oil level 907
Wiring Diagram, oil level label, and defined position of the attachment (G00005) 909
G00007 – Trouble hydraulic oil level 910
Wiring Diagram of 40B004 and the defined position of the attachment (G00007) 911
G00012 – Central lubrication system grease level too low 912
G00013 – Slew ring gear lubr. system grease level too low . 912
Wiring Diagram (binary grease level sensor, refill warning) for G00012 & G00013 . 915
Wiring Diagram (junction box) for messages G00012 & G00013 916
G00020 – Trouble Shut-Off (gate) valve (Start blocked) 917
View onto the gap of proximity switch 40B031 (G00020) . 919
Wiring Diagram (40B031) for message G00020 (Main gate valve closed) . 920
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR . 921
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor . 921
G00031 – Set engine to low idle . 922
Wiring Diagram (20S030) for message G00031 923
Input signal of the engine speed switch 20S030 on the REAL TIME MONITOR . 923
G00032 – Trouble starter 924
Wiring Diagram (Cold Start Signal) for message G00032 . 925
Wiring Diagram (Engine running signal) for message G00032 . 926
G00033 – Trouble KOMTRAX Plus Controller 927
G00034 – Trouble KOMTRAX Plus Display . 928
G00035 – Trouble totally loss gear oil (PTO 1) 929
View onto the location of sensor 57B175-1 at the PTO (G00035) . 931
Input signal (analog) of the PTO 1 gear oil sensor 57B175-1 on the REAL TIME MONITOR 932
View onto the setting for SHUTDOWN BYPASS on the K+ Plus monitor 932
Wiring Diagram (57B175-1) for message G00035 (example) 933
G00039 – Actuate engine speed selector switch . 934
G00040 – Emergency shut-down pump compartment . 935
Wiring Diagram (safety line) for G00040, G00092, G00093, G00095 . 937
Wiring Diagram (emergency switches) for G00040, G00092, G00093, G00095 938
G00041 – Emergency shut-down pump compartment . 939
Wiring Diagram (safety line) for G00041, G00252, G00253, G00255 . 941
Wiring Diagram (emergency switches) for G00041, G00252, G00253, G00255 942
G00043 – Trouble output short-circuit . 943
G00048 – Trouble emergency safety circuit . 944
Wiring Diagram (11K044a) for message G00048 . 945
G00053 – Reset emergency safety circuit . 946
G00054 – Monitoring idle position cut off . 947
Wiring Diagram (11K032) for message G00054 948
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054) . 949
View onto a K+ Failure History (example) 949
G00060 – Fire in the power house 950
Wiring Diagram (fire alarm) for message G00060 951
Wiring Diagram (10B351 in the safety circuit) for G00060 952
G00061 – Trouble monitoring, engine 1 speed too low . 953
Input signal (analog) of 51K003b-1 on the REAL TIME MONITOR (G00061) 954
Wrong signal of the engine speed converter on the REAL TIME MONITOR (G00061) 955
Wiring Diagram (engine speed) for message G00061 955
G00062 – Trouble monitoring, engine 1 speed too high 956
Wiring Diagram (engine speed) for message G00062 957
G00063 – Trouble monitoring hydraulic oil temp 958
Wiring Diagram (59B015) and REAL TIME MONITOR for G00063 959
G00064 – Trouble monitoring hydraulic oil level . 960
Wiring Diagram (40B004) for message G00064 962
G00065 – Very low hydraulic oil level . 963
View onto the hydraulic oil level label . 963
G00066 – Trouble hydraulic oil temperature 964
Wiring Diagram (57K506a-1 & 57K506b-1) and location for G00066 966
G00067 – Trouble battery voltage too high . 967
Wiring Diagram (11T080) and component location for G00067 . 968
Input signal of 11T080 on the REAL TIME MONITOR (G00067) 968
G00069 – Trouble monitoring oil temperature gear (PTO 1) 969
Input of 57B049-1 on the REAL TIME MONITOR (G00069) . 970
Gear oil temperature (PTO 1) on the Main Gauge Screen (G00069) 970
Wiring Diagram (57B049-1) and component location for G00069 . 971
G00070 – Trouble oil temperature gear (PTO 1) . 972
Location of the PTO gear oil level dipstick and temperature sensor 57B049-1 . 974
G00071 – Trouble gear lubrication (PTO 1) . 976
Wiring Diagram (57B017-1) for message G00071 977
G00072 – Trouble monitoring hydraulic oil level . 978
Wiring Diagram (40B105) and REAL TIME MONITOR for G00072 979
G00073 – Trouble monitoring remote engine oil level 1 . 980
Wiring Diagram (63B106-1) and REAL TIME MONITOR for G00073 981
G00076 – Trouble monitoring pressure suction tank . 982
Wiring Diagram (59B162) and REAL TIME MONITOR for G00076 983
G00079 – Trouble monitoring pressure oil cooler 1 . 984
Wiring Diagram (40B165) and REAL TIME MONITOR for G00079 985
G00080 – Trouble monitoring pressure pre-load valve . 986
Wiring Diagram (40B166) and REAL TIME MONITOR for G00080 987
G00081 – Trouble lubrication system . 988
Operation cycles of the lubrication systems . 990
Wiring Diagram (11K050) for message G00081 991
G00086 – SHUTDOWN . 992
G00087 – Stop all movements for low idle 993
G00090 – Trouble power supply . 994
Wiring Diagram (stabilized power supply) for G00090 & G00099 995
G00091 – Pilot control cut out 996
View onto the lock lever and switch 20S105 (G00091) . 997
G00096 – Pilot control cut out 1000
Wiring Diagram (20S094) for message G00096 1001
G00099 – Trouble power supply .1001
G00100 – Maintenance Safety Switch 1002
Wiring Diagram (50S058) for message G00100 1003
G00103 – Faulty switch 20M004 .1004
Wiring Diagram 1 (windscreen wiper) for message G00103 1006
Wiring Diagram 2 (windscreen wiper) for message G00103 1007
G00104 – Trouble battery current 1008
Wiring Diagram (battery current) for message G00104 .1010
G00105 – Trouble battery charging current too low .1011
Wiring Diagram (11T080) for message G00105 1012
G00107 – Trouble slew parking brake control 56K250a .1013
View onto the CoDeSys HMI Visualization screen for message G00107 .1015
Wiring Diagram (56K250a) for message G00107 .1016
G00108 – Trouble slew parking brake control Output to 56K250a .1017
View onto the CoDeSys HMI Visualization screen for message G00108 .1019
Wiring Diagram (56K250a) for message G00108 .1020
G00109 – Trouble slew parking brake control 56K250b .1021
G00110 – Trouble slew parking brake control Output to 56K250b .1021
G00111 – Trouble travel parking brake control 56K251a .1021
51K251a-1 & 51K251b-1 (relay check) on the REAL TIME MONITOR 1021
G00112 – Trouble travel parking brake control Output to 56K251a .1022
51K251a-1 & 51K251b-1 (output check) on the REAL TIME MONITOR .1022
G00113 – Trouble travel parking brake control 56K251b .1023
G00114 – Trouble travel parking brake control Output to 56K251b .1023
G00115 – Trouble slew hydraulic brake control 56K252a .1024
51K252a-1 & 51K252b-1 (relay check) on the REAL TIME MONITOR 1024
G00116 – Trouble slew hydraulic brake control Output to 56K252a .1025
51K252a-1 & 51K252b-1 (output check) on the REAL TIME MONITOR .1025
G00117 – Trouble slew hydraulic brake control 56K252b .1026
G00118 – Trouble travel parking brake control Output to 56K251b .1026
G00141 – Trouble monitoring X2-pressure .1027
Wiring Diagram (57B086) for message G00141 1029
G00143 – Trouble monitoring 61B087a .1030
G00147 – Trouble monitoring gear lubrication (PTO 1) 1031
Wiring Diagram (57B017-1) for message G00147 1033
G00148 – Trouble monitoring fuel level 1034
Wiring Diagram (31B063) and component location for G00148 .1036
G00149 – Trouble monitoring ambient temperature .1037
Wiring Diagram (13B090) and REAL TIME MONITOR for G00149 1038
G00151 – Trouble monitoring gear (PTO) oil filter 1 .1039
Wiring Diagram (57B027-1) and component location for message G00151 .1041
G00154 – Trouble monitoring return oil filter .1042
Wiring Diagram (40B163) for message G00154 1044
G00155 – Trouble monitoring leak oil filter .1045
Wiring Diagram (40B164) for message G00155 1047
G00159 – Trouble monitoring breather filter .1048
Wiring Diagram (40B024) for message G00159 1050
G00160 – Trouble monitoring engine air cleaner 1 1051
Wiring diagram (52B018-1 & 52B019-1) for message G00160 .1053
G00161 – Trouble monitoring battery voltage .1054
Wiring Diagram (11T080) for message G00161 1056
G00162 – Trouble monitoring charging-/discharging current .1057
Wiring Diagram (battery charging current) for message G00162 1059
G00164 – Trouble air cleaner 1 1060
View onto the engine air cleaner (G00164) .1061
G00165 – Trouble breather filter hydraulic oil tank .1062
Location of 40B024 and label with defined positions (G00165) 1063
G00166 – Trouble oil filter gear (PTO 1) 1064
View onto the PTO 1 gear oil filter with pressure switch 57B027-1 (G00166) 1065
G00169 – Trouble return oil filter hydraulic oil tank .1066
G00170 – Trouble leak oil filter hydraulic oil tank .1067
G00176 – Trouble battery voltage too low 1068
Wiring Diagram (batteries) for message G00176 .1070
G00177 – Trouble battery charging circuit .1072
Wiring Diagram (measuring points 1-4) for message G00177 1073
G00178 – Trouble battery charging current too high 1074
Wiring Diagram (51T017) for message G00178 1075
G00180 – Trouble pilot pressure X2 too low 1076
Valve cartridge block with X2 pressure sensor 57B086 & M1.2 .1077
G00181 – Trouble pilot pressure X2 too high .1078
Valve cartridge block with X2 pressure sensor 57B086 & M1.2 .1079
G00184 – Central lubrication system empty .1080
Grease level (CLS & SLS) on the REAL TIME MONITOR .1082
G00185 – Trouble central lubrication system .1083
Allocation of vent valves and end-of-line switches 1084
Action chart for lube cycles 1085
Vent valve (62Q507a & 62Q509a) 1086
Wiring Diagram (80B043 & 62B046) for messages G00185 & G00188 .1087
G00186 – Trouble central lubrication system .1088
Allocation of vent valves .1088
Action chart for lube cycles 1089
Vent valve (62Q507a/62Q509a) 1090
G00187 – Slew ring gear lubrication system empty 1091
G00188 – Trouble slew ring gear lubrication system 1091
G00189 – Trouble slew ring gear lubrication system 1091
G00207 – Engine remote oil tank 1 empty .1092
G00216 – Trouble software not compatible 1093
G00218 – Switch off all motors for running transfer pump 1095
G00220 – Trouble transfer pump motor overheated .1096
Wiring Diagram (transfer pump) for message G00220 .1097
G00223 – Trouble starter control 51K001a-1 1098
51K001a-1 & 51K001b-1 (relay check) on the REAL TIME MONITOR 1098
G00224 – Trouble starter control Output to 51K001a-1 1099
51K001a-1 & 51K001b-1 (output check) on the REAL TIME MONITOR .1099
G00225 – Trouble starter control 51K001b-1 1100
G00226 – Trouble starter control Output to 51K001b-1 1100
G00231 – Trouble pilot control lever 20S019 .1101
G00232 – Trouble pilot control lever 20S020 .1101
Wiring Diagram (20S019) for message G00231 1102
Wiring Diagram (20S020) for message G00232 1103
G00233 – Trouble pilot control 11Q045 .1104
Wiring Diagram (11Q045) for message G00233 1105
G00234 – Trouble pilot control 11K111a 1106
11K111a & 11K111b (relay check) on the REAL TIME MONITOR 1106
G00235 – Trouble pilot control Output to 11K111a 1107
11K111a & 11K111b (output check) on the REAL TIME MONITOR .1107
G00236 – Trouble pilot control 11K111b 1108
G00237 – Trouble pilot control Output to 11K111b 1108
G00238 – Trouble supply by key switch 11Q044 1109
Input signal of 11Q044 on the REAL TIME MONITOR (G00238) 1109
Wiring Diagram (11Q044) for message G00238 1110
G00240 – Trouble hydraulic oil temperature 1111
Hydraulic oil temperature table .1112
G00242 – Engine 1 already running .1113
G00243 – Fill up fuel tank 1113
G00245 – Engine shutdown from ground 1114
Input signal of 54S007 & 54S008 on the REAL TIME MONITOR (G00245) .1115
G00246 – Hydraulic oil temperature 1116
G00252 – Emergency shut-down at access ladder .1117
G00253 – Emergency shut-down at valve block .1117
G00255 – Emergency shut-down in cabin .1117
G00256 – Operator warning system 1117
G00257 – Hydraulic oil temperature 1118
G00261 – Maintenance Safety Switch 1119
Wiring Diagram (50S058) for message G00261 1120
G00262 – Trouble screen at hydr. cooler entry clogged .1121
40B166 and 40B165 on the REAL TIME MONITOR (G00262) .1121
Location of 40B166 and 40B165 at the hydraulic oil tank (G00262) 1122
Wiring Diagram (40B166 & 40B165) for trouble code G00262 1123
G00308 – Trouble CAN-BUS or CAN-Hardware 1124
G00309 – Trouble ladder up 56K253a 1127
56K253a & 56K253b (relay check) on the REAL TIME MONITOR 1127
G00310 – Trouble ladder up Output to 56K253a 1128
56K253a & 56K253b (output check) on the REAL TIME MONITOR .1128
G00311 – Trouble ladder up redundant 56K253b 1129
G00312 – Trouble ladder up redundant Output to 56K253b 1129
G00313 – Trouble ladder down 56K254a 1130
56K254a & 56K254b (relay check) on the REAL TIME MONITOR 1130
G00314 – Trouble ladder down Output to 56K254a 1131
56K254a & 56K254b (output check) on the REAL TIME MONITOR .1131
G00315 – Trouble ladder down redundant 56K254b 1132
G00316 – Trouble ladder down redundant Output to 56K254b 1132
G00317 – Trouble service arm up 56K255a .1133
56K255a & 56K255b (relay check) on the REAL TIME MONITOR 1133
G00318 – Trouble service arm up Output to 56K255a .1134
56K255a & 56K255b (output check) on the REAL TIME MONITOR .1134
G00319 – Trouble service arm up redundant 56K255b .1135
G00320 – Trouble service arm up redundant Output to 56K255b .1135
G00321 – Trouble service arm down 56K256a .1136
56K256a & 56K256b (relay check) on the REAL TIME MONITOR 1136
G00322 – Trouble service arm down Output to 56K256a .1137
56K256a & 56K256b (output check) on the REAL TIME MONITOR .1137
G00323 – Trouble service arm down redundant 56K256b .1138
G00324 – Trouble service arm down redundant Output to 56K256b .1138
G00325 – Trouble service arm Input 1139
G00326 – Trouble ladder Input .1139
G00327 – Trouble parking brake Input 1139
G00328 – Trouble start Input 1139
G00330 – Trouble pilot control 11Q111 .1142
Wiring Diagram (11Q111a .d & 11K126) for message G00330 1144
G00331 – Automatic after_running engine 1 .1146
G00333 – Trouble battery charger relay 1147
Wiring Diagram (11Q122) for message G00333 1148
G00351 – Engine 1 running .1149
G00352 – Engine 1 standstill 1149
G00417 – Communication failure PLC <-> KOMTRAX Plus controller 1150
G00420 – Connector sel error 1151
G00421 – Farm sys error .1152
G00422 – Can-net sys (J1939) 1153
G00425 – Settings impossible to take over into the PLC 1154
Wiring Diagram for G00425 – KOMTRAX Plus controller .1155
Wiring Diagram for G00425 – MTC and KOMTRAX Plus monitor 1156
Wiring Diagram for G00425 – Pump controller (10K032) 1157
Wiring Diagram for G00425 – Multimonitor for pump controller 1158
Wiring Diagram for G00425 – Quantum engine controller .1159
G00491 – Communication failure MH800 <=> KOMTRAX Plus controller 1160
Wiring Diagram overview for G00491: K+ monitor (MH801) → K+ controller 1161
8 Troubleshooting by Symptoms .1163
8.1 Symptoms of the Engine and Related Electrical System 1164
SEL001 – Engine does not start (engine does not rotate) .1164
Wiring Diagram 1 (engine start) for symptom code SEL001 .1166
Wiring Diagram 2 (engine start) for symptom code SEL001 .1168
SEL002 – Engine stops while in operation 1169
View onto the fuel system water separator (SEL002) 1171
SEL003 – Engine speed is hunting during boom-up movement 1172
SEL004 – Engine does not stop .1174
SEL005 – Engine lacks output (no power) .1175
Judgment Table for SEL005 .1176
SEL006 – Exhaust smoke is black .1177
Judgment Table for SEL006 .1178
SEL007 – Oil consumption is excessive .1179
Judgment Table for SEL007 .1180
SEL008 – Oil becomes contaminated quickly .1181
Judgment Table for SEL008 .1182
SEL009 – Fuel consumption is excessive 1183
Judgment Table for SEL009 .1184
SEL010 – Oil is in engine coolant .1185
Judgment Table for SEL010 .1186
SEL011 – Oil level rises 1187
Judgment Table for SEL011 .1188
SEL012 – Coolant temperature becomes too high (overheating) .1189
Judgment Table for SEL012 .1190
8.2 Symptoms of the Hydraulic System 1191
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function) 1191
SHY002 – Engine speed sharply drops or engine stalls too much .1193
SHY003 – No work equipment, travel or slew movement .1194
SHY004 – Work equipment has too much hydraulic drift 1195
SHY005 – Work equipment has big time lag 1196
SHY006 – Machine deviates during travel movement 1197
SHY007 – Hydraulic system has lack of power .1198
SHY008 – Machine does not slew 1199
SHY009 – Slew acceleration is poor 1200
SHY010 – Excessive overrun when stopping slew movement 1202
SHY011 – Floating system without function .1204
SHY012 – Abnormal noise coming from SRV or MRV 1205
SHY013 – Track tensioning system without function .1206
View onto the elements of the hydraulic track tensioning system (SHY013) 1207
SHY014 – Ladder does not move, or slow movement .1208
SHY015 – Refilling arm does not move, or slow movement 1210
SHY016 – The hydraulic driven grease pump does not move .1212
SHY018 – Abnormal track chain movement during digging .1214
SHY019 – Slew parking brake without function 1215
SHY020 – Travel parking brake without function 1216
8.3 Symptoms of the Mechanical System .1217
SME001 – Abnormal noise is made .1217
Judgment Table for SME001 .1218
SME002 – Abnormal noise around the PTO / hydraulic pumps 1219
SME003 – Vibration is excessive (engine mountings) 1221
Judgment Table for SME003 .1222
SME004 – Vibration is excessive (engine torsion) 1223
SME005 – There is a big shock when stopping slew movement .1224
SME006 – There is a big abnormal noise when moving/stopping slew movement .1225
SME007 – Fan blades make abnormal noise .1227
SME008 – Abnormal noise coming from a travel gearbox 1228
SME009 – Abnormal noise coming from the work equipment (lack of grease) .1230
SME010 – Abnormal idler movement 1232
SME011 – Leak at the PTO shaft seal .1233
8.4 Symptoms of Additional Systems 1235
SAD001 – Air conditioner does not work 1235
View onto the A/C unit (SAD001) .1236
SAD002 – Air conditioner compressor clutch is burnt .1237
View onto the A/C compressor and its mounting (SAD002) 1238
SAD003 – Air conditioning system defective (pipes and hoses full of moisture) .1239
View onto the A/C filling and service station .1240
SAD004 – CAN BUS failure (message G00308 displayed) .1241
9 Troubleshooting by pump controller codes 1247
DXAAKA – Solenoid-1(Pump-1) open circuit 1248
DXABKA – Solenoid-2(Pump-2) open circuit 1248
DXACKA – Solenoid-3(Pump-3) open circuit 1248
DXADKA – Solenoid-4(Pump-4) open circuit 1248
DXAEKA – Solenoid-5(Pump-5) open circuit 1248
DXAFKA – Solenoid-6(Pump-6) open circuit 1248
DXAGKA – Solenoid-7(Pump-7) open circuit 1248
DXAHKA – Solenoid-8(Pump-8) open circuit 1248
Wiring Diagram – EPC solenoid valves 1249
DXAAKB – Solenoid-1(Pump-1) short circuit .1250
DXABKB – Solenoid-2(Pump-2) short circuit .1250
DXACKB – Solenoid-3(Pump-3) short circuit .1250
DXADKB – Solenoid-4(Pump-4) short circuit .1250
DXAEKB – Solenoid-5(Pump-5) short circuit .1250
DXAFKB – Solenoid-6(Pump-6) short circuit .1250
DXAGKB – Solenoid-7(Pump-7) short circuit .1250
DXAHKB – Solenoid-8(Pump-8) short circuit .1250
Wiring Diagram – EPC solenoid valves 1251
DHPEMA – Solenoid-1/2 pressure sensor abnormality .1252
DHPGMA – Solenoid-3/4 pressure sensor abnormality .1252
DHPJMA – Solenoid-5/6 pressure sensor abnormality .1252
DHPLMA – Solenoid-7/8 pressure sensor abnormality .1252
Wiring Diagram – pump pressure sensors 1253
DLE2MA – Engine speed sensor abnormality 1254
Wiring Diagram – engine RPM signal to pump controller .1255
DA25KP – 5V sensor1 power abnormality .1256
Wiring Diagram – 5V supply from pump controller .1258
DA22KK – Pump Solenoid Power Low Error 1259
DA29KQ – Model Selection Abnormality 1260
DA2RMC – CAN Disconnect .1261
Wiring Diagram – CAN BUS pump controller ↔ Multimonitor .1262
50 DISASSEMBLY & ASSEMBLY .1263
TOC 1265
1 Superstructure 1273
1.1 Superstructure overview .1274
1.2 Diesel engine .1276
1.2.1 Removal of the Diesel engine 1276
1.2.2 Replacement of the Diesel engine 1284
1.2.3 Engine torque support and engine/PTO mounts .1286
1.2.3.1 Flexible mounts .1287
1.2.3.2 Torque support 1289
1.2.4 Alternator 1290
1.2.4.1 Removal of the alternator .1290
1.2.4.2 Replacement of the alternator .1291
1.2.5 Starter system 1292
1.2.5.1 Removal of the starter motor 1292
1.2.5.2 Replacement of the starter motor 1293
1.2.6 Batteries .1293
1.2.6.1 Removal of the batteries 1293
1.2.6.2 Replacement of the batteries 1295
1.3 Engine radiator assembly 1296
1.3.1 Radiator fan assembly .1296
1.3.1.1 Removal of the radiator fan bearing block and motor .1297
1.3.1.2 Replacement of the radiator fan bearing block and motor .1301
1.3.1.3 Removal of the radiator fan .1303
1.3.1.4 Replacement of the radiator fan .1305
1.3.2 Radiator assembly .1306
1.3.2.1 Removal of the Radiator assembly 1306
1.3.2.2 Replacement of the radiator assembly 1311
1.3.3 Fuel cooler .1312
1.3.3.1 Removal of the fuel cooler 1312
1.3.3.2 Replacement of the fuel cooler 1314
1.4 Coupling assembly .1316
1.4.1 Geislinger coupling .1316
1.4.1.1 Removal of the Geislinger coupling 1317
1.4.1.2 Replacement of the Geislinger coupling 1321
1.5 PTO .1322
1.5.1 Overview of the PTO and the mounting of the pumps .1322
1.5.2 Main pumps 1324
1.5.2.1 Preparatory works for main pump removal .1324
1.5.2.2 Removal of main pump 1 1327
1.5.2.3 Replacement of main pump 1 1329
1.5.2.4 Removal of main pump 2 1330
1.5.2.5 Replacement of main pump 2 1332
1.5.2.6 Removal of main pump 3 1333
1.5.2.7 Replacement of main pump 3 1333
1.5.2.8 Removal of main pump 4 1333
1.5.2.9 Replacement of main pump 4 1333
1.5.3 PTO oil circulation pump (auxiliary pump) .1334
1.5.3.1 Removal of the oil circulation pump (auxiliary pump) 1334
1.5.3.2 Replacement of the oil circulation pump (auxiliary pump) 1336
1.5.4 Pilot oil pump 1337
1.5.4.1 Removal of the pilot oil pump .1337
1.5.4.2 Replacement of the pilot oil pump .1337
1.5.5 Radiator drive pump .1339
1.5.5.1 Removal of the radiator fan drive pump 1339
1.5.5.2 Replacement of the radiator fan drive pump 1341
1.5.6 Hydraulic oil cooler fan drive pump .1342
1.5.6.1 Removal of the hydraulic oil cooler fan drive pump 1342
1.5.6.2 Replacement of the hydraulic oil cooler fan drive pump 1342
1.5.7 Pump distributor gearbox (PTO) 1344
1.5.7.1 Removal of the pump distributor gearbox (PTO) .1346
1.5.7.2 Replacement of the pump distributor gearbox (PTO) .1349
1.6 Hydraulics 1350
1.6.1 Hydraulic oil cooler assembly .1350
1.6.1.1 Removal of hydraulic cooler fan .1351
1.6.1.2 Replacement of hydraulic cooler fan .1352
1.6.1.3 Removal of hydraulic cooler fan bearings and motors .1353
1.6.1.4 Replacement of hydraulic cooler fan bearings and motors .1355
1.6.1.5 Removal of the hydraulic oil coolers 1356
1.6.1.6 Replacement of the hydraulic oil coolers 1359
1.6.1.7 Removal of the hydraulic oil cooler assembly 1360
1.6.1.8 Replacement of the hydraulic oil cooler assembly 1365
1.6.2 Main gate valve .1366
1.6.2.1 Removal of the main gate valve 1366
1.6.2.2 Replacement of the main gate valve 1367
1.6.3 Hydraulic oil reservoir .1368
1.6.3.1 Removal of the hydraulic oil reservoir 1369
1.6.3.2 Replacement of the hydraulic oil reservoir 1375
1.6.4 Main control valve blocks .1378
1.6.4.1 General information .1378
1.6.4.2 Removal of the main control valve blocks 1386
1.6.4.3 Replacement of the main control valve blocks 1390
1.6.5 Main relief valves (MRV) 1391
1.6.5.1 Removal of the MRV at the main control valve blocks .1391
1.6.5.2 Replacement of the MRV at the main control valve blocks .1392
1.6.6 Service line relief valves (SRV) 1394
1.6.6.1 Removal of SRV on main control valve block 1394
1.6.6.2 Replacement of SRV on main control valve blocks .1395
1.6.7 Anti-cavitation valves (ACV) 1397
1.6.7.1 Removal of single ACV at the manifold .1399
1.6.7.2 Replacement of single ACV at the manifold .1402
1.6.7.3 Removal of ACV with attached check valve at the manifold 1403
1.6.7.4 Replacement of ACV with attached check valve at the manifold 1405
1.6.7.5 Removal of ACV on main control valve blocks .1407
1.6.7.6 Replacement of ACV on main control valve blocks .1408
1.6.8 Throttle check valves .1410
1.6.8.1 Removal of throttle check valves 1413
1.6.8.2 Replacement of throttle check valves 1415
1.6.9 Diffuser block (FSA only) .1416
1.6.9.1 Removal of the Diffuser block at the manifold .1416
1.6.9.2 Replacement of the Diffuser block at the manifold .1417
1.6.10 Manifold .1418
1.6.10.1 Removal of the manifold 1418
1.6.10.2 Replacement of the manifold 1420
1.7 Slew system .1421
1.7.1 Slew gear .1421
1.7.1.1 Removal of the slew gear 1423
1.7.1.2 Replacement of the slew gear 1426
1.7.2 Swing motor .1428
1.7.2.1 Removal of the swing motor 1429
1.7.2.2 Replacement of the swing motor 1431
1.7.3 Slew parking brake 1432
1.7.3.1 Removal/disassembly of the slew parking brake (L&S) .1433
1.7.3.2 Replacement/assembly of the slew parking brake (L&S) 1436
1.7.3.3 Removal of the slew parking brake (siebenhaar) 1438
1.7.3.4 Replacement of the slew parking brake (Siebenhaar) 1441
1.7.4 Dynamic slew brake 1444
1.7.4.1 Removal of the slew brake valve .1447
1.7.4.2 Replacement of the slew brake valve .1449
1.7.5 Swing circle 1450
1.7.5.1 Removal of the swing circle .1451
1.7.5.2 Replacement of the swing circle .1454
1.7.6 Swing circle lubrication pinion (dummy wheel) .1458
1.7.6.1 Removal of the lubrication pinion assembly 1459
1.7.6.2 Replacement of the lubrication pinion assembly 1461
1.8 Lubrication pumps .1462
1.8.1 Removal of the lubrication pump .1462
1.8.2 Replacement of the lubricating pump .1464
1.9 Operator’s cab 1466
1.9.1 Removal of the operator’s cab .1468
1.9.2 Replacement of the operator’s cab .1474
1.9.3 Cab-mounts 1476
1.9.3.1 Removal of the cab-mounts .1476
1.9.3.2 replacement of the cab-mounts .1478
1.9.4 Front window 1480
1.9.4.1 Removal of the front window .1480
1.9.4.2 Replacement of the front window .1481
1.9.5 Operator’s seat .1482
1.9.5.1 Removal of the operator’s seat 1482
1.9.5.2 Replacement of the operator’s seat 1483
1.10 Cab base .1484
1.10.1 Removal of the cab base 1484
1.10.2 Replacement of the cab base 1487
1.10.3 Pump controller 1489
1.10.3.1 Removal of the pump controller .1489
1.10.3.2 Replacement of the pump controller .1489
1.10.4 VHMS .1490
1.10.4.1 Removal of the VHMS-controller .1490
1.10.4.2 Replacement of the VHMS-controller .1491
1.11 Access ladder 1492
1.11.1 Removal of the access ladder .1493
1.11.2 Replacement of the access ladder .1495
1.11.3 Removal of the access ladder cylinder 1497
1.11.4 Replacement of the access ladder cylinder 1499
1.12 Counterweight 1500
1.12.1 Removal of the counterweight .1501
1.12.2 Replacement of the counterweight .1503
1.13 Superstructure Lifting .1504
1.13.1 Remove the superstructure from the undercarriage .1504
1.13.2 Install the superstructure onto the undercarriage 1508
1.14 Fuel tank 1512
1.14.1 General information 1513
1.14.2 Removal of the fuel tank .1514
1.14.3 Replacement of the fuel tank .1520
2 Undercarriage .1523
2.1 Undercarriage overview 1524
2.2 Travel system .1526
2.2.1 Track group .1526
2.2.1.1 Changing of the track group .1526
2.2.2 Sprocket 1531
2.2.2.1 Removal of the sprocket .1531
2.2.2.2 Replacement of the sprocket .1536
2.2.3 Guide wheels 1538
2.2.3.1 Removal of the guide wheel assembly .1538
2.2.3.2 Replacement of the guide wheel assembly .1540
2.2.4 Track tensioning accumulators .1542
2.2.4.1 Removal of the low pressure accumulators 1542
2.2.4.2 Replacement of the low pressure accumulators 1544
2.2.4.3 Removal of the high pressure accumulators .1545
2.2.4.4 Replacement of the high pressure accumulators .1546
2.2.5 Track tension valve block .1547
2.2.5.1 Removal of the track tensioning valve block .1547
2.2.5.2 Replacement of the track tensioning valve block .1549
2.2.6 Track tensioning cylinders 1550
2.2.6.1 Removal of the track tensioning cylinders .1550
2.2.6.2 Replacement of the track tensioning cylinders .1552
2.2.7 Hydraulic hoses of the track tensioning system 1553
2.2.7.1 Precursory work .1553
2.2.7.2 Substitute the hydraulic hoses inside the car body 1555
2.2.7.3 Substitute the hydraulic hoses between car body and crawler frame .1555
2.2.7.4 Substitute the hydraulic hoses inside the crawler frame .1557
2.2.7.5 Subsequent work .1557
2.2.8 Travel brake valve block (overspeed valve) 1559
2.2.8.1 Removal of the travel brake valve block .1562
2.2.8.2 Replacement of the travel brake valve block .1563
2.2.9 Travel motors .1564
2.2.9.1 Removal of the travel motors 1564
2.2.9.2 Replacement of the travel motors 1566
2.2.10 Travel parking brake .1568
2.2.10.1 Travel parking brake overview 1568
2.2.10.2 Removal/disassembly of the travel parking brake (L&S) 1573
2.2.10.3 Replacement/assembly of the travel parking brake (L&S) .1576
2.2.10.4 Removal/disassembly of the travel parking brake (Zollern) 1579
2.2.10.5 Replacement/assembly of the travel parking brake (Zollern) .1582
2.2.11 Travel gear box 1584
2.2.11.1 Removal of the travel gear box .1585
2.2.11.2 Replacement of the travel gear box .1587
2.2.12 Carrier roller .1589
2.2.12.1 Removal of the carrier roller assembly .1589
2.2.12.2 Replacement of the carrier roller assembly .1592
2.2.13 Track roller .1593
2.2.13.1 Removal of the track roller assembly .1593
2.2.13.2 Replacement of the track roller assembly .1595
2.3 Car body 1596
2.3.1 Removal of the car body and the crawler carriers (type with mounting pins) 1596
2.3.2 Replacement of the car body and the crawler carriers (type with mounting pins) 1600
2.3.3 Removal of the car Body and the crawler carriers (type with bolted connection) 1604
2.3.4 Replacement of the car body and the crawler carriers (type with bolted connection) 1610
2.3.5 Rotary joint 1619
2.3.5.1 Removal of the rotary joint .1621
2.3.5.2 Replacement of the rotary joint .1624
3 Attachment 1627
3.1 Backhoe .1628
3.1.1 Boom 1629
3.1.1.1 Removal of the Boom .1629
3.1.1.2 Replacement of the boom .1632
3.1.1.3 Removal of the boom cylinders .1634
3.1.1.4 Replacement of the boom cylinders .1639
3.1.2 Stick .1644
3.1.2.1 Removal of the Stick 1644
3.1.2.2 Replacement of the Stick 1648
3.1.2.3 Removal of the Stick Cylinders 1650
3.1.2.4 Replacement of the Stick cylinders 1655
3.1.3 Bucket 1660
3.1.3.1 Removal of the bucket .1660
3.1.3.2 Replacement of the bucket .1663
3.1.3.3 Removal of the Bucket Cylinders .1664
3.1.3.4 Replacement of the Bucket Cylinders .1670
3.1.4 Bucket link rod and steering rods .1673
3.1.4.1 Removal of the bucket link rod 1673
3.1.4.2 Replacement of the bucket link rod 1675
3.1.4.3 Removal of the steering rods 1676
3.1.4.4 Replacement of the steering rods 1679
3.1.5 Ground engaging tools (GET) .1680
3.1.5.1 Removal and replacement of the GET 1680
3.1.6 Hydraulic hoses at the backhoe attachment .1682
3.1.6.1 Substitute the boom arc hoses .1682
3.1.6.2 Substitute the boom cylinder hoses 1688
3.1.6.3 Substitute the stick cylinder hoses .1692
3.1.6.4 Substitute the bucket cylinder hoses 1696
3.2 Face Shovel .1700
3.2.1 Using the installation tools for hydraulic cylinders 1701
3.2.2 Boom 1702
3.2.2.1 Removal of the boom .1702
3.2.2.2 Replacement of the boom .1709
3.2.2.3 Removal of the boom cylinders .1714
3.2.2.4 Replacement of the boom cylinders .1718
3.2.3 Stick .1722
3.2.3.1 Removal of the stick 1722
3.2.3.2 Replacement of the stick 1726
3.2.3.3 Removal of the stick cylinders 1730
3.2.3.4 Replacement of the stick cylinders 1734
3.2.4 Bull Clam bucket 1738
3.2.4.1 Removal of the bull clam bucket .1738
3.2.4.2 Replacement of the bull clam bucket .1744
3.2.4.3 Removal of the bucket cylinders .1746
3.2.4.4 Replacement of the bucket cylinders .1750
3.2.4.5 Removal of the clam cylinders .1754
3.2.4.6 Replacement of the clam cylinders .1758
3.2.5 Ground engaging tools (GET) .1761
3.2.5.1 Removal and replacement of the GET 1761
3.2.6 Hydraulic hoses at the Faceshovel attachment 1762
3.2.6.1 Substitute the boom arc hoses .1762
3.2.6.2 Substitute the boom cylinder hoses 1768
3.2.6.3 Substitute the stick arc hoses 1772
3.2.6.4 Substitute the stick cylinder hoses .1776
3.2.6.5 Substitute the bucket cylinder hoses 1780
3.2.6.6 Substitute the clam cylinder hoses 1784
3.3 Metering valves (grease injectors) at the attachment 1792
3.3.1 Operation test of the metering valves (grease injectors) 1793
3.3.2 Removal of the metering valves (grease injectors) .1794
3.3.3 Replacement of the metering valves (grease injectors) .1796
3.4 Cylinder bypass test 1797
4 Service Information .1799
4.1 Fluids and lubricants .1800
4.2 Filling capacities 1801
4.3 Work instructions .1802
4.3.1 Remove / install the crawler carrier 1802
4.4 Weight tables .1803
4.4.1 Superstructure 1803
4.4.2 Undercarriage .1805
4.4.3 Backhoe attachment (BHA) 1806
4.4.4 Face shovel attachment (FSA) 1807
4.5 Torque charts according to KOMATSU company standard .1808
4.5.1 Metric standard thread 1808
4.5.2 Metric fine thread 1809
4.5.3 Cummins motor torques – metric 1810
4.5.4 Cummins motor torques – U.S. customary 1810
4.5.5 Flange connections 1811
4.6 Blind plugs .1812
4.6.1 Dummy plates for SAE–flanges 1812
4.6.2 Classification of threads to the nominal width 1814
4.6.3 Plugs and fittings according to DIN 2353 1815
4.7 Conversion table 1816
4.7.1 Method of using the conversion table 1816
4.7.2 Millimeter – inch & kilogram – pound 1817
4.7.3 Liter – U.S. gallon & liter – U.K. gallon .1818
4.7.4 Nm- ft.lb .1819
4.7.5 Bar – PSI – kPa – MPa .1820
4.7.6 Basic values in Ohm according to ISO 43 76 1821
4.7.7 Temperature .1822
4.8 Tools .1823
4.8.1 Standard tool case 1823
4.8.2 Used special tools (Overview) .1825
5 Parts & Service News 1827
5.1 List of the PARTS AND SERVICE NEWS 1828

DESCRIPTION:

Komatsu Hydraulic Mining Shovel PC4000-6 T2 Shop Manual 08205 –  PDF DOWNLOAD

• SERIAL NUMBER 08205 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.

G.B 27/12/24