Komatsu HYDRAULIC MINING SHOVEL PC7000-6 T2 Shop Manual – PDF DOWNLOAD
$35.95
Komatsu HYDRAULIC MINING SHOVEL PC7000-6 T2 Shop Manual – PDF DOWNLOAD
SERIAL NUMBER 35001 and up
Description
Komatsu HYDRAULIC MINING SHOVEL PC7000-6 T2 Shop Manual – PDF DOWNLOAD
FILE DETAILS:
Komatsu HYDRAULIC MINING SHOVEL PC7000-6 T2 Shop Manual – PDF DOWNLOAD
Language : English
Pages :2370
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu HYDRAULIC MINING SHOVEL PC7000-6 T2 Shop Manual – PDF DOWNLOAD
SERIAL NUMBER 35001 and up
SAFETY INFORMATION
To enable you to use this machine 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 machine 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 machine labels, the following signal words are
used.
The “Safety Alert Symbol” identifies important safety messages on machines, 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 SHOVEL PC7000-6 T2 Shop Manual – PDF DOWNLOAD
SERIAL NUMBER 35001 and up
SHOP MANUAL Cover 1
00 FOREWORD 3
1 Foreword 5
11 BEFORE READING THIS MANUAL 6
12 CONTENTS OF THIS BINDER 7
121 Contacting the Service 7
122 Guarantee 7
13 DIVISION OF THE BINDER 8
2 SAFETY 9
TOC 10
21 SAFETY INFORMATION 11
22 OVERVIEW 12
221 NORMAL OPERATIONS 12
222 REGULAR MAINTENANCE 12
223 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 12
224 ADDITIONAL SAFETY PRECAUTIONS 12
23 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 13
231 SOUND 13
232 VIBRATION 13
24 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 14
241 UNDERSTANDING THE MACHINE 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 MACHINE 14
2433 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 15
2434 KEEP MACHINE 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 18
2443 EMERGENCY EXIT FROM OPERATOR’S CAB 18
245 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 19
2451 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 19
2452 NO JUMPING ON OR OFF THE MACHINE 19
2453 NO PEOPLE ON THE ATTACHMENT 19
2454 WORKING IN HIGH PLACES 19
2455 LEAVING OPERATOR’S SEAT WITH LOCK 20
2456 LEAVING THE MACHINE 20
246 BURN PREVENTION 20
2461 Hot coolant 20
2462 Hot oil 21
247 PRECAUTIONS WHEN CLEANING CAB GLASS 21
248 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 21
249 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 22
2491 UNAUTHORIZED MODIFICATION 22
2492 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 22
2410 ELECTROMAGNETIC COMPATIBILITY (EMC) 22
2411 PRECAUTIONS AT JOBSITE 23
24111 VISIBILITY FROM OPERATOR’S SEAT 24
24112 CAMERA SYSTEM WITH MONITORS 24
24113 ENSURE GOOD VISIBILITY 24
24114 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 24
24115 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 25
24116 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 25
24117 Lightning Strikes 26
24118 WORKING ON LOOSE GROUND 26
24119 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 27
241110 VENTILATION OF ENCLOSED AREAS 28
2412 STARTING motor 29
24121 WARNING TAG 29
24122 CHECKS BEFORE STARTING motor 29
24123 PRECAUTION WHEN STARTING motor 29
24124 PRECAUTION IN COLD AREAS 30
2413 OPERATION 30
24131 CHECKS BEFORE OPERATION 30
24132 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 31
24133 PRECAUTIONS WHEN traveling 32
24134 TRAVELING ON SLOPES 33
24135 OPERATIONS ON SLOPES 34
24136 PROHIBITED OPERATIONS 34
24137 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 35
24138 PARKING THE MACHINE 35
24139 TRANSPORTATION 35
25 PRECAUTION FOR MAINTENANCE 36
251 GENERAL PRECAUTIONS 36
2511 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 37
2512 STOP motor FOR MAINTENANCE 38
2513 WARNING TAG 39
2514 KEEP WORKPLACE CLEAN AND TIDY 40
2515 APPOINT LEADER WHEN WORKING WITH OTHERS 40
2516 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 41
2517 INSTALLING, REMOVING OR STORING ATTACHMENTS 41
2518 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 42
2519 NOISE 42
25110 WHEN USING A HAMMER 42
25111 PROPER TOOLS 43
25112 ACCUMULATOR 43
25113 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 MACHINE 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 54
2753 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 56
2754 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 56
2755 INSTRUCTIONS FOR USE 58
01 SPECIFICATION 59
PC7000-6 60
10 STRUCTURE & FUNCTION 69
TOC 71
1 Introduction 83
11 Foreword 84
12 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 85
13 Explanation of abbreviations 86
14 Diagrams and illustrations in this manual 87
2 Specifications 89
21 Lifting Gears 90
22 Safety hints for sling accessory 92
23 Standard tightening torque chart 93
24 Conversion table 94
25 Blind plugs 100
26 Classification of threads to the nominal width 102
27 Plugs and fittings according to ISO 8434-1 / DIN 2353 103
3 Main assembly groups 105
31 General layout 106
32 Superstructure 108
321 Superstructure side view 108
322 Superstructure top view 110
33 Machine house 112
34 Hydraulic oil tank 114
35 Hydraulic oil cooler 116
36 Fuel tank 118
37 Cab support 120
38 Operator’s cab 122
39 Main control blocks (FSA) 124
310 Slew machinery 126
3101 Slew gear type 2063 / slew motor type A6VLM 126
3102 Slew gear type 632770 / Slew motor type A6VLM 128
311 Undercarriage 130
312 Slew ring 132
313 Attachment 134
3131 Front Shovel Attachment (FSA) 134
3132 Back hoe Attachment (BHA) 136
314 Counterweight 138
315 PPC safety circuit 140
4 Drive 143
41 Prime drive assembly 144
42 Engine and PTO mounts 146
421 Engine mounts 146
422 Checks and adjustments 147
423 Torque support 147
43 Flexible coupling (type A) 148
44 Flexible coupling (type B) 150
441 Information for maintenance 152
442 Coupling elements 153
443 Separation and assembly of the coupling inner and outer part 154
444 Operation troubles, causes, and rectification 155
45 Fan drive and radiator assembly 156
451 Radiator assembly 156
452 Fan motor 158
453 Expansion tanks 159
454 Radiator fan drive 160
4541 Flow chart of radiator fan control 162
4542 Hydraulic schematic of radiator fan drive 163
455 Fan pump type HPV190 164
456 Radiator fan speed testing & adjustment 166
4561 Testing & readjustment procedure 168
4562 Basic adjustment procedure 169
46 Pump distributor gearbox (PTO) 170
461 PTO oil filling, oil level, and ventilation 172
462 Pump spline lubrication 174
4621 Oil level in the main pump & gear oil pump drive shaft housing 175
463 PTO lubrication and cooling 176
4631 Hydraulic components and schematic of cooling circuit-1 176
4632 Schematic overview – PTO gear oil cooling circuit-1 178
4633 Checks and adjustments 180
47 Hydraulic pumps – location, drive speed and flow rates 182
48 Air cleaner 186
5 Hydraulic oil tank 189
51 General layout 190
52 Hydraulic oil tank, location of the electric equipment 192
53 Suction oil tank with strainers 194
54 Return oil collector pipe with strainer 196
55 Back pressure valve 198
56 Transfer pump 200
57 Return and leak oil filter 202
58 Breather filter 204
6 Hydraulic oil cooling 207
61 Overall view on the hydraulic oil cooling 208
62 Function of the hydraulic oil cooling circuit 210
63 Adjustment of the back pressure valve 212
64 Stepless cooler fan RPM control 214
641 Pressure limiting valves 216
642 Components of the fan drive circuits 218
643 Fan pump type HPV190 220
65 Oil cooler fan speed testing/adjustment 222
651 Testing & readjustment procedure 224
652 Basic adjustment procedure 225
66 OC fan resonance speed adjustment 226
661 Hydraulic oil temperature charts 228
7 Controlling 229
71 General layout 230
72 Control and filter panels – location of components 232
721 Control and filter panel engine 1 (rear) 232
722 Valve cartridge block engine 1 (rear) 234
723 Control and filter panel engine 2 (front) 236
73 Pilot pressure supply and adjustments 238
731 Pilot pressure control (PPC) circuit 238
732 Pilot pressure operating the main block spools 240
733 Checks and adjustment of pilot pressure 242
734 Remote control valves arrangement 244
74 Function of the electro hydraulic control system 246
741 Illustration of the joystick signal flow (example) 248
75 Hand lever (joystick) control 250
751 Voltage supply of hand lever 20S020 251
752 Direction signal course from hand lever to controllers 252
753 Double ratiometric* output diagram 253
76 Foot pedal control 254
761 Voltage supply of foot lever 20S021a 256
762 Direction signal course from foot pedal to controllers 257
763 Double ratiometric* output diagram for 2 direction pedal 258
764 Single ratiometric* output diagram for 1 direction pedal 259
77 Hand lever & foot pedal monitoring 260
771 Lever monitoring screens (example) 262
772 Valve monitoring screen (example) 264
78 Valve solenoid adjustment 266
781 Overview sol min/max current & adjustment range 267
79 ACCEL & DECEL time adjustment 268
791 Accel & Decel times 268
8 Components 271
81 Main control blocks and high pressure screens (FSA) 272
82 Main control blocks with valves and hp screens (FSA) 274
83 Main control blocks with valves and hp screens (BHA) 276
84 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) 278
85 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) 280
86 Restrictor block with secondary relief valve 282
87 Anti-cavitation valve (ACV) block 284
871 Single ACV block on the manifold 284
872 Double ACV block on the manifold 286
88 Remote control valves 288
89 4/3 Directional solenoid valves 290
810 Proportional solenoid valves 292
811 High-pressure screen 294
812 Control blocks and valves 296
8121 Main control blocks I, II, III (4 spool blocks) 296
81211 Spin lock for valve blocks (ND52) 297
8122 Hydraulic diagram of a 4-spool valve block 298
8123 Spool types 299
8124 Spool positions (control block) 302
8125 MRV, SRV, and ACV 304
8126 Load holding valve 306
8127 Main control block IV (slew) 308
813 Travel brake valve 310
814 Pressure reducing valve 312
815 4/2 Directional valves 314
816 Pressure double stage valve 316
817 Hydraulic cylinder 318
8171 Hydraulic cylinder – Chevron® sealing 318
8172 Hydraulic cylinder – Chesterton® 11KE sealing 320
8173 Cylinder data markings 322
9 Main hydraulic pumps, pump regulation, valve control & monitoring system 323
91 General 324
911 Pump data 326
92 Main pumps 330
921 Hydraulic pump type HPV375+375 330
9211 Main pump sectional drawings 332
922 Servo valve 334
9221 VC valve servo piston 335
923 EPC valve 340
93 Electronic pump regulation system 342
931 Cut-off function 344
932 Slew control 345
933 Temperature control 345
934 Diagnostics and monitoring 345
935 Hydraulic oil temperature charts 346
936 PTO gear oil temperature charts 346
94 Pump & valve controllers 348
95 Multimonitor 350
951 Service menu screen 353
96 Service menu – 01 Monitoring 353
961 Monitoring PUMP 1 controller 354
962 Monitoring PUMP 2 controller 355
963 Monitoring VALVE 0 controller 356
964 Monitoring VALVE 1 controller 358
965 Monitoring VALVE 2 controller 359
966 Monitoring all controllers 359
97 Using multimonitor functions for monitoring 360
971 Hold function 360
98 Service menu – 02 Abnormality Record 361
981 To delete any failure record from the display 362
982 Troubleshooting procedures 362
983 Failure codes for pumps & valve controllers & system connections 363
99 Service menu – 03 Default 371
910 Service menu – 04 Adjustment 372
9101 Adjustments for PUMP 1 controller 372
9102 Adjustments for PUMP 2 controller 374
9103 Adjustments for VALVE 0 controller 376
9104 Adjustments for VALVE 2 controller 377
9105 Details on the adjustable parameters 378
91051 PUMP 1 controller 378
91052 PUMP 2 controller 380
91053 VALVE 0 controller 382
91054 VALVE 1 & 2 controller 384
9106 Description of the primary p-factor 385
9107 Pump16F/R solenoid min current adjustment 386
9108 Pump16F/R solenoid max current adjustment 387
911 Accel & Decel time adjustment 388
9111 ACCEL & DECEL times 388
912 Service menu – 05 Controller Setting 390
913 Controller replacement procedure 390
9131 Controller setting → wiring input check 390
9132 Controller setting → memory 394
9133 Confirmation 396
914 Service menu – 06 Display Setup 397
915 Checks and adjustments 398
9151 Engine power check 398
9152 Cut-off function check 400
91521 Cut-off for clam close (FSA only) 401
916 Engine speed sensors (pick-up) 402
9161 General 403
9162 Engine speed sensor (pick-up) adjustment 403
10 Operating hydraulics 405
101 General 406
1011 Allocation of pumps and main valve blocks 408
102 Spool functions (FSA) 410
1021 Floating function for boom and stick cylinders 410
1022 Spool functions (BHA) 412
103 Hydraulics for the attachment cylinders 414
1031 Electric / hydraulic flowchart “Boom UP” (FSA) 414
1032 Electric / hydraulic flowchart “boom up” (BHA) 416
1033 Electric / hydraulic flowchart “boom down” (FSA), single movement and Auto-float ON 418
1034 Electric / hydraulic flowchart “boom down” (FSA), Auto-float OFF – button 20S095 pressed and single movement 420
1035 Electric / hydraulic flowchart “Boom down” (BHA) 422
1036 Electric / hydraulic flowchart “Stick out” (FSA) 424
1037 Electric / hydraulic flowchart “Stick out” (BHA) 426
1038 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float ON and single movement 428
1039 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float OFF – 20S098 pressed & single movement 430
10310 Electric / hydraulic flowchart “Stick in” (BHA) 432
10311 Electric / hydraulic flowchart “Bucket fill” (FSA) 434
10312 Electric / hydraulic flowchart “Bucket fill” (BHA) 436
10313 Electric / hydraulic flowchart “Bucket dump” (FSA) 438
10314 Electric / hydraulic flowchart “Bucket dump” (BHA) 440
10315 Electric / hydraulic flowchart “Clam open” (FSA) 442
10316 Electric / hydraulic flowchart “Clam close” (FSA) 444
10317 Checks and adjustments of the main relief valve (MRV) 446
10318 Checks and adjustments of the secondary relief valves (SRV) 448
103181 Boom cylinders, piston side (BHA & FSA), boom up 448
103182 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down 452
103183 Stick cylinders, piston side (FSA), stick out 456
103184 Stick cylinders, piston side (BHA), stick in 460
103185 Stick cylinders, piston rod side (FSA), stick in 464
103186 Stick cylinders, piston rod side (BHA), stick out 468
103187 Bucket cylinders, piston side (FSA), bucket fill 472
103188 Bucket cylinders, piston side (BHA), bucket fill 476
103189 Bucket cylinders, piston rod side (FSA), bucket dump 480
1031810 Bucket cylinders, piston rod side (BHA), bucket dump 484
1031811 Clam cylinders, piston rod side (FSA), clam open 488
1031812 Clam cylinders, piston side (FSA), clam close 492
10319 Checks and adjustments of cycle times 496
103191 Checks and adjustments of boom lowering speed (FSA) 496
103192 Checks and adjustments of boom lowering speed (BHA) 500
103193 Checks and adjustments of stick retract speed (FSA) 504
103194 Checks and adjustments of stick retract speed (BHA) 508
103195 Checks and adjustments of bucket dump speed (FSA) 512
103196 Checks and adjustments of bucket dump speed (BHA) 516
103197 Checks and Adjustment of bucket Curl Speed (BHA) 520
103198 Checks and adjustments of clam close speed (FSA) 524
104 Hydraulics for the slew circuit 526
1041 Slew circuit with variable slew motors 526
1042 Slew motor (variable displacement) 530
10421 Hydraulic slew motor – displacement control 532
1043 Slew gearbox type 2063 534
1044 Slew gearbox type 632770 536
1045 Slew parking brake (on slew gear type 2063) 538
1046 Slew parking brake (on slew gear type 632770) 540
1047 Slew brake valve 542
1048 Flushing circuit 546
1049 Electric / hydraulic flowchart “Slew left” FSA 548
10410 Electric / hydraulic flowchart “Slew left” BHA 550
10411 Electric / hydraulic flowchart “Slew right” FSA 552
10412 Electric / hydraulic flowchart “Slew right” BHA 554
10413 Checks and adjustments for the slew circuit 556
104131 Pressure checks & adjustments – double stage valve (DSV) 557
104132 Checks & adjustments – brake pilot pressure 559
104133 Checks & adjustments – slew speed 561
10414 Function check for the hydraulic slew brake 562
10415 Function check for the slew parking brake 564
104151 Parking brake release pressure check 564
104152 Function check of relays 56K250a & b 565
105 Hydraulics for the travel circuit 566
1051 Travel circuit 566
1052 Travel motor 570
1053 Rotary joint 572
1054 Travel gearbox 574
10541 Travel gearbox type 2063 574
10542 Travel gearbox type 631053 576
1055 Travel parking brake 578
10551 Travel parking brake on travel gear type 2063 578
10552 Travel parking brake on travel gear type 631053 579
10553 Travel brake valve 580
1056 Electric / hydraulic flowchart “travel forward” 582
1057 Electric / hydraulic flowchart “travel backwards” 584
1058 Checks and adjustments 586
10581 Checks and adjustments for the travel circuit 586
10582 Function check for the travel parking brake 589
11 Hydraulic track tensioning system 591
111 General 592
112 Functional description 594
1121 Hydraulic schematic for track tensioning 595
113 Double stage valve 596
114 Tensioning cylinder 598
115 Adjustments / checks 600
12 Access ladder, hydraulically operated 603
121 Overview 604
122 Function of the hydraulically operated access ladder 606
123 Adjustments / checks 612
13 Central refilling system (Service arm) 615
131 Refilling arm location 616
132 Function 618
15 Hints for reading the electric wiring diagram 637
151 General 638
152 Reference code of the electrical components 639
1521 Area code 639
1522 Component identifying letter 641
153 Graphical symbols 642
154 Drawing concept 646
155 Cable and connector marking 656
14 Hints for reading the hydraulic diagram 621
141 General 622
142 Hydraulic symbols 624
1421 Lines, unions 625
1422 Components, valves 627
1423 Sensors 627
1424 Valves, valve components 628
1425 Pump, motor, cylinder 632
16 KOMTRAX Plus & MTC control system 659
161 General 660
162 Specifications for operators 662
1621 Opening screen 663
1622 Main gauge screens 1 to 4 664
1623 Fuel consumption screen 668
1624 Failure messages for the operator 670
1625 Main gauge screens – changing of Time / SMR / Date 672
1626 Maintenance monitor 674
1627 Settings for operator 676
1628 Automatic messages 682
163 Tables of all provided messages 684
1631 Table of error codes & messages 685
1632 Table of 7-segment error codes 690
1633 Table of available instruction messages 691
164 Flow charts (1-4) of K+ main screens 694
165 KOMTRAX Plus service level 698
1651 Explanation of the button symbols (Service Level) 700
1652 Service Menu Select Screen 701
1653 Real Time Menu Select Screen 702
16531 Real Time Menu, option: 01 Engine 1 703
16532 Real Time Menu, option: 02 Engine 2 704
16533 Real Time Menu, option: 03 PTO 1 704
16534 Real Time Menu, option: 04 PTO 2 704
16535 Real Time Menu, option: 05 Hydraulic 705
16536 Real Time Menu, option: 06 Slew 706
16537 Real Time Menu, option: 07 Electrical Equipment 707
16538 Real Time Menu, option: 08 Emergency Stop 708
16539 Real Time Menu, option: 09 Manual Switch 709
165310 Real Time Menu, option: 10 Central Lube System 1 710
165311 Real Time Menu, option: 11 Slew Ring Gear Lube System 711
165312 Real Time Menu, option: 12 Central Lube System 2 712
165313 Real Time Menu, option: 13 Windscreen Wiper 713
165314 Real Time Menu, option: 14 Ladder 714
165315 Real Time Menu, option: 15 Service Arm 715
165316 Real Time Menu, option: 16 Pilot Control 716
165317 Real Time Menu, option: 17 Other Items 717
165318 Real Time Menu, option: 18 Output Signals 718
165319 Output signals with deactivated MTC evaluation 721
1654 PM-Clinic 722
16541 General 722
16542 Power Check 723
1655 Serial/GCC no setting 724
1656 Memory Clear 725
16561 Input Memory Clear ID 725
16562 Memory Clear screen 726
1657 Failure History 727
1658 Maintenance Monitor 728
1659 Snapshot 729
16510 Settings 730
165101 Central Lubrication System (CLS 1), screen 1/10 730
165102 Slew ring gear Lubrication System (SLS), screen 2/10 731
165103 Central Lubrication System (CLS 2), screen 3/10 732
165104 Qmin – Qmax setting, screen 4/10 733
165105 Other Settings 1/2, screen 5/10 733
165106 Hydraulic Oil & PTO Gear Oil Definition Table 734
165107 Hydraulic oil temperature charts 734
165108 PTO gear oil temperature charts 734
165109 Other Settings 2/2, screen 6/10 735
1651010 PLC-evaluation ON/OFF 737
1651011 Shutdown Bypass ON/OFF 738
166 Interface-connection KOMTRAX Plus controller & MTC 742
1661 KOMTRAX Plus controller 743
167 7-segment error code indication 744
168 Wiring of KOMTRAX Plus controller 746
169 MTC control system – global layout 750
1691 MTC (Master Turbo Controller) 752
16911 MTC flowchart 752
16912 MTC features 752
16913 MTC firmware and software 753
16914 Connector & component location in the control system 753
16915 View onto the MTC unit and its connectors 754
16916 LED indications at the MTC 755
1610 Global layout of the internal CAN BUS 756
16101 General information on a CAN BUS system 756
161011 General CAN BUS description 757
161012 CAN BUS troubleshooting 757
161013 Can BUS wiring 758
161014 CAN BUS end resistor 760
1611 The nodes in the CAN BUS system 762
16111 Global layout 762
16112 Introduction 764
161121 ICN-V features 764
161122 View onto an open ICN-V node with DIP switches & status LED 766
161123 General information on the LED control 767
161124 ICN-D features 768
161125 View onto an ICN-D node without wiring 769
161126 View onto the Status LEDs at the ICN-D node 770
161127 General information on the LED control 770
161128 Node DIP-switches 772
161129 Detailed view onto the DIP switches 773
16113 Node box 774
16114 Node locations on the machine 776
161141 Node & location chart 777
161142 View onto the control components in a cab base 778
17 Lubrication system 781
171 General overview – SLS & CLS1/2 782
1711 General description 783
172 Basic function of the lubrication systems 784
173 Lubrication systems (SLS & CLS1/2) 786
1731 Lubrication pump station 786
1732 General information on CLS1/2 788
1733 General information on SLS 788
1734 Manual lube activation 788
174 Lubrication cycle 789
1741 Operation and control 789
1742 Lubrication cycle – processing 790
1743 Time segments & switch points of a lubrication cycle 791
1744 Lubrication modes 792
17441 Automatic lubrication mode 792
17442 Manual lubrication mode 792
17443 Reduced pause time for service 792
175 Hydraulically driven lube pump 794
1751 Adjustment of lube pump speed 796
17511 Stroke speed adjustment 797
17512 Working pressure 797
176 Lubricant injectors 798
1761 Tightening torques for fittings at grease injectors 799
1762 Description 799
1763 Adjustment of lubricant output 800
1764 Operation principle of lubricant injectors 802
17641 Function description 803
1765 Connection of one or more injectors 804
177 Vent valve and grease outlet filter 806
1771 Vent valve description 807
178 End-line switch 808
1781 Description 809
1782 CLS1/2 end-line switch adjustment 810
1783 SLS end-line switch adjustment 812
179 Lubricant level sensors 814
1791 Description 815
17911 Checks 815
1710 Commissioning 816
17101 Commissioning of the CLS1/2 lubrication system 816
17102 Fine adjustment 817
17103 Commissioning of the SLS lubrication system 818
18 Deep temperature equipment (option) 821
181 General information 822
1811 Introduction 822
1812 Deep temperature components overview 822
1813 Power supply preconditions for preheating 823
1814 Power requirements for preheating systems 824
182 Preheating procedure 825
1821 Global flow chart of the preheating procedure 825
1822 Starting the preheating procedure 826
1823 Preheating of operator’s cab and Diesel engine [coolant system] 827
1824 Preheating of lubricants and superstructure (Diesel) [electric system] 828
183 Constant heating of travel motors (TTT equipment below-40°C only) 829
184 Component location 830
1841 Electric heating elements for hydraulic & batteries [electric machine] 830
1842 Electric heating elements for hydraulics [Diesel machine] 832
1843 Electric heating elements for engines & batteries [Diesel machine] 834
185 Components of TT equipment 836
1851 Preheating components on a Diesel machine 836
1852 Preheating components on an electric machine 837
1853 Wiring Diagrams for preheating systems 838
18531 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 838
18532 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 839
18533 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 840
18534 Wiring diagram “Suction Oil Manifold Preheating” 841
18535 Wiring diagram “PTO Preheating” 842
18536 Wiring diagram “Battery heater pads” 843
40 TROUBLESHOOTING 845
TOC 847
1 Introduction 873
11 Overview 874
111 General advice when using troubleshooting charts 874
12 General Precautions 875
2 General Information for Troubleshooting 877
21 Preparations For Work 878
22 Precautions During Work 878
23 Precautions When Carrying Out Any Operation 879
231 Precautions when carrying out removal work 879
232 Precautions when carrying out installation work 879
233 Precautions when completing the operation 880
24 Fundamental Requirements for Troubleshooting 881
241 Technical documentation 881
242 Tools 881
2421 Reference Guide for Deutsch Removal Tools 884
243 Personnel 885
25 Points To Remember When Trouble- shooting 885
26 Sequence Of Events In Troubleshooting 887
27 Checks Before Troubleshooting 888
28 Handling Of Electric Equipment And Hydraulic Components 889
281 Points to remember when handling electric equipment 889
282 Points To Remember When Handling Hydraulic Equipment 892
29 General working procedures 894
291 Air Bleeding of Various Hydraulic Parts 894
292 Air bleeding from hydraulic pumps 894
293 Air bleeding from hydraulic cylinders 894
210 Cylinder bypass test 895
211 Basics about “How to crimp” (with strain relief) 896
2111 Crimp tool & repair kit 896
2112 General 897
2113 Select the required connector components 897
2114 Stripping a wire 898
2115 Crimping 899
2116 Connector assembly after crimping 900
212 Cable Shielding 901
3 Mounting Locations and Connector Types 903
31 Superstructure 904
311 Superstructure side view 904
312 Superstructure top view 906
32 Location of engine electrical parts 908
321 Engine side view 908
322 Engine top view 909
323 Location of engine remote oil tank sensors 911
33 Location of hydraulic components 912
331 Control and filter panel engine 1 (rear) 912
332 Valve cartridge block engine 1 (rear) 914
333 Control and filter panel engine 2 (front) 916
334 Remote control valves arrangement 918
34 View onto SLS or CLS grease barrel and lubrication cycle components 920
35 Hydraulic oil tank & suction oil tank – Location of electrical components 922
36 Hydraulically operated access ladder 924
37 Refilling arm 926
38 Connector Types Overview 928
4 Standard Value Table for Electrical Components 935
5 References for Troubleshooting (CAN Bus & Node Outputs) 949
51 CAN BUS Trouble or Node Output Trouble 950
511 Trouble CAN BUS or CAN Hardware (#D0308) 951
512 Trouble output short circuit (#D0043) 952
52 Sequence of CAN nodes in the CAN BUS 954
53 Troubleshooting for Relay Monitored Node Outputs 955
531 Relay Check 955
#D0107 – Trouble slew parking brake control 56K250a 956
Example view onto CoDeSys Visualization screen for message #D0107 958
Wiring Diagram (56K250a & 56K250b) for message #D0107 959
532 Output Check 960
#D0108 – Trouble slew parking brake control Output to 56K250a 961
Example view onto CoDeSys Visualization screen for message #D0108 963
Wiring Diagram (56K250a & 56K250b) for message #D0108 964
6 Tables for Testing and Troubleshooting 965
61 Test Value Table for PT100 Temperature Sensors g Centigrade – Ohm 966
62 Test Value Tables for Transducers 967
621 Pump press transducers 967
622 Hydraulic oil pressure transducers 968
623 Miscellaneous Pressure Transducers 969
624 Temperature Transducers – signal voltage 0545V 970
6241 Temperature Transducers – signal voltage 0595V 971
63 Hydraulic oil temperature charts 972
64 PTO gear oil temperature charts 972
65 Table of Error Codes & Messages (K+ monitor) 973
66 Table of 7-segment error codes 979
67 Table of Instruction Messages 980
68 Table of Binary Codes 983
681 Table of Add-On Binary Codes for #D0308 988
69 Pump & Valve Controller Fault Codes 989
610 Table of Symptom Codes 996
6101 Symptoms of engines and related electrical systems 996
6102 Symptoms of Hydraulic System 997
6103 Symptoms of mechanical system 998
6104 Symptoms of Additional Systems 998
611 Engine Error Codes (Tier 2) 999
612 Power Supply1002
613 Cable colour identification1002
7 Troubleshooting by failure Codes1003
#D0001 – Trouble Shut-Off (gate) valve1004
View onto the gap of proximity switch 40B0311006
Input signal (digital) of proximity switch 40B031 on the REAL TIME MONITOR1007
View onto the setting for SHUTDOWN BYPASS on the K+ monitor1007
Wiring Diagram (40B031) for message #D0001 (Main gate valve open)1008
#D0004 – Trouble fuel filter1010
View onto the fuel filtration system1012
Wiring Diagram 1 – Control modules, LEDs, and node input for message #D00041014
Wiring Diagram 2 – Fuel pump for message #D00041015
Wiring Diagram 3 – Heating elements for the fuel filtration system1016
#D0005 – Low hydraulic oil level1017
Wiring Diagram, oil level label, and defined position of the attachment (#D0005)1019
#D0007 – Trouble hydraulic oil level1020
Wiring Diagram of 40B004 and the defined position of the attachment (#D0007)1021
#D0012 – Central lubrication system grease level too low1022
#D0013 – Slew ring gear lubr system grease level too low1022
Wiring Diagram (binary grease level sensor, refill warning) #D0012 / #D0013 / #D02021025
Wiring Diagram (junction box) for messages #D0012 / #D0013 / #D02021026
#D0020 – Trouble Shut-Off (gate) valve (Start blocked)1027
View onto the gap of proximity switch 40B031 (#D0020)1029
Wiring Diagram (40B031) for message #D0020 (Main gate valve closed)1030
Input signal (digital) of proximity switch 40B031 on the REAL TIME MONITOR1031
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor1031
#D0031 – Set engine to low idle1032
Wiring Diagram (20S030) for message #D00311033
#D0032 – Trouble starter1034
Wiring Diagram (Cold Start Signals) for message #D00321035
Wiring Diagram (Engine running signals) for message #D00321036
#D0033 – Trouble KOMTRAX Plus Controller1037
#D0034 – Trouble KOMTRAX Plus Display1038
#D0035 – Trouble totally loss gear oil (PTO 1)1039
#D0036 – Trouble totally loss gear oil (PTO 2)1039
View onto the location of sensor 57B175-1/-2 at the PTO (#D0035 & #D0036)1041
Input signal (analog) of PTO 1/2 gear oil sensor 57B175-1/-2 on REAL TIME MONITOR1042
View onto setting screens for SHUTDOWN BYPASS on K+ Plus monitor1042
Wiring Diagram (57B175-1/-2) for messages #D0035 and #D0036 (example)1043
#D0037 – Trouble monitoring, engine 2 speed too low1044
#D0038 – Trouble monitoring, engine 2 speed too high1044
#D0039 – Actuate engine speed selector switch1044
#D0040 – Emergency shut-down pump compartment1045
Wiring Diagram (emergency circuit) for #D0040, #D0092#D00951047
Wiring Diagram (emergency switches) for #D0040, #D0092#D00951048
#D0041 – Emergency shut-down pump compartment1049
Wiring Diagram (emergency circuit) for #D0041, #D0252#D02551051
Wiring Diagram (emergency switches) for #D0041, #D0252#D02551052
#D0043 – Trouble output short-circuit1053
#D0048 – Trouble emergency safety circuit1054
Wiring Diagram (11K044a) for message #D00481055
#D0053 – Reset emergency safety circuit1056
#D0060 – Fire in the power house1057
Wiring Diagram (fire alarm) for message #D00601058
#D0061 – Trouble monitoring, engine 1 speed too low1059
Input signal (digital) of 51K003b-1 & 51K003b-2 on the REAL TIME MONITOR1061
Wrong signal of engine 1/2 speed converter on the REAL TIME MONITOR1061
Wiring Diagram (51T018-1/-2) for messages #D0061 and #D00371062
#D0062 – Trouble monitoring, engine 1 speed too high1063
Wiring Diagram (51T018-1/-2) for messages #D0062 and #D00381064
#D0063 – Trouble monitoring hydraulic oil temp1065
Mounting location of 59B0151066
Wiring Diagram (59B015) for message #D00631067
Monitoring options for hydraulic oil temperature1068
#D0064 – Trouble monitoring hydraulic oil level1069
Wiring Diagram (40B004) for message #D00641071
#D0065 – Very low hydraulic oil level1072
View onto the hydraulic oil level label1072
#D0066 – Trouble hydraulic oil temperature1073
Hydraulic oil temperature on the REAL TIME MONITOR1074
Hydraulic oil temperature charts for message #D00661075
#D0067 – Trouble battery voltage too high1076
Wiring Diagram (11T080) and component location for #D00671077
Input signal of 11T080 on the REAL TIME MONITOR (#D0067)1078
#D0069 – Trouble monitoring oil temperature gear (PTO 1)1079
Mounting location of 57B049-1/-21080
Monitoring options for PTO gear oil temperature1081
Wiring Diagram (57B049-1 & 57B049-2) for messages #D0069 & #D00831082
#D0070 – Trouble oil temperature gear (PTO 1)1083
Location of PTO gear oil level dipstick and temperature sensor 57B049-1/-21085
PTO gear oil adjustment via K+1085
#D0071 – Trouble gear lubrication (PTO 1)1087
Wiring Diagram (57B017-1 & 57B017-2) for messages #D0071 & #D00681088
#D0072 – Trouble monitoring hydraulic oil level1089
Wiring Diagram (40B105) and REAL TIME MONITOR for message #D00721091
#D0073 – Trouble monitoring remote engine oil level 11092
Wiring Diagram (63B106-1/-2) and REAL TIME MONITOR for #D0073/#D00821094
#D0076 – Trouble monitoring pressure suction tank1095
Wiring Diagram (59B162) and REAL TIME MONITOR for #D00761097
#D0079 – Trouble monitoring pressure oil cooler 11098
Wiring Diagram (40B165) and REAL TIME MONITOR for #D00791100
#D0080 – Trouble monitoring pressure pre-load valve1101
Wiring Diagram (40B166) and REAL TIME MONITOR for #D00801103
#D0081 – Trouble lubrication system1104
Operation cycles of lubrication systems1105
Wiring Diagram (control signal line “bucket cut off”) for message #D00811106
#D0082 – Trouble monitoring remote engine oil level 21107
#D0083 – Trouble monitoring oil temperature (PTO 2)1107
#D0084 – Trouble oil temperature gear (PTO 2)1107
#D0086 – SHUTDOWN1108
#D0087 – Stop all movements for low idle1109
#D0090 – Trouble power supply1111
Wiring Diagram and REALT TIME MONITOR for messages #D0090 & #D00991112
#D0091 – Pilot control cut out1113
#D0092 – Emergency shut-down at access ladder1114
#D0093 – Emergency shut-down at valve block1114
#D0094 – Emergency shut-down at hydraulic control panel1114
#D0095 – Emergency shut-down in cabin1114
#D0096 – Pilot control cut out1115
Wiring Diagram (20S094) and REAL TIME MONITOR for message #D00961116
#D0099 – Trouble power supply1117
#D0100 – Maintenance Safety Switch1117
Wiring Diagram (emergency line & 50S058) for message #D01001118
#D0104 – Trouble battery current1119
Wiring Diagram (starter motors) for message #D01041121
Wiring Diagram (51T017 & 71T003) for message #D01041122
#D0105 – Trouble battery charging current too low1123
Wiring Diagram (11T080) for message #D01051124
#D0107 – Trouble slew parking brake control 56K250a1125
Example view onto CoDeSys visualization screen for message #D01071127
Wiring Diagram (56K250a & 56K250b) for message #D01071128
#D0108 – Trouble slew parking brake control Output to 56K250a1129
Example view onto CoDeSys visualization screen for message #D01081131
Wiring Diagram (56K250a & 56K250b) for message #D01081132
#D0109 – Trouble slew parking brake control 56K250b1133
#D0110 – Trouble slew parking brake control Output to 56K250b1133
#D0111 – Trouble travel parking brake control 56K251a1133
51K251a-1 & 51K251b-1 (relay check) on REAL TIME MONITOR1133
#D0112 – Trouble travel parking brake control Output to 56K251a1134
51K251a-1 & 51K251b-1 (output check) on REAL TIME MONITOR1134
#D0113 – Trouble travel parking brake control 56K251b1135
#D0114 – Trouble travel parking brake control Output to 56K251b1135
#D0115 – Trouble slew hydraulic brake control 56K252a1136
51K252a-1 & 51K252b-1 (relay check) on REAL TIME MONITOR1136
#D0116 – Trouble slew hydraulic brake control Output to 56K252a1137
51K252a-1 & 51K252b-1 (output check) on REAL TIME MONITOR1137
#D0117 – Trouble slew hydraulic brake control 56K252b1138
#D0118 – Trouble travel parking brake control Output to 56K251b1138
#D0141 – Trouble monitoring X2-pressure1139
Wiring Diagram (57B086) for message #D01411141
#D0147 – Trouble monitoring gear lubrication (PTO 1)1142
Wiring Diagram (57B017-1/-2) for messages #D0147 & #D001501145
#D0148 – Trouble monitoring fuel level1146
Wiring Diagram (31B063) for message #D01481148
#D0149 – Trouble monitoring ambient temperature1149
Wiring Diagram (13B090) and REAL TIME MONITOR for message #D01491151
#D0150 – Trouble monitoring gear lubrication (PTO 2)1152
#D0151 – Trouble monitoring gear (PTO) oil filter 11152
Wiring Diagram (57B027-1 & 57B027-2) for messages #D0151 and #D01931155
#D0154 – Trouble monitoring return oil filter1156
Wiring Diagram (40B163) for message #D01541158
#D0155 – Trouble monitoring leak oil filter1159
Wiring Diagram (40B164) for message #D01551161
#D0159 – Trouble monitoring breather filter1162
Wiring Diagram (40B024) for message #D01591164
#D0160 – Trouble monitoring engine air cleaner 11165
Wiring diagram (52B018-1/-2 & 52B019-1/-2) for messages #D0160 and #D01971168
#D0161 – Trouble monitoring battery voltage1169
11T080 on the REAL TIME MONITOR1170
Wiring Diagram (11T080) and component location for message #D01611171
#D0162 – Trouble monitoring charging-/discharging current1172
51T017 on REAL TIME MONITOR1173
Wiring Diagram (battery charging current) for message #D01621174
#D0164 – Trouble air cleaner 11175
View onto an engine air cleaner (#D0164 & #D0198)1176
#D0165 – Trouble breather filter hydraulic oil tank1177
Location of 40B024 and oil level label for message #D01651178
#D0166 – Trouble oil filter gear (PTO 1)1179
View onto PTO gear oil filter with pressure sensor 57B027-1/-2 (#D0166 & #D0191)1180
#D0169 – Trouble return oil filter hydraulic oil tank1181
40B163 on REAL TIME MONITOR (#D0169)1182
#D0170 – Trouble leak oil filter hydraulic oil tank1183
40B164 on REAL TIME MONITOR (#D0170)1184
#D0176 – Trouble battery voltage too low1185
Wiring Diagram (71T003 & batteries) for message #D01761186
#D0177 – Trouble battery charging circuit1187
Wiring Diagram (measuring points 1-4) for message #D01771188
#D0178 – Trouble battery charging current too high1189
Wiring Diagram (51T017) for message #D01781190
#D0180 – Trouble pilot pressure X2 too low1191
Valve cartridge block with X2 pressure sensor 57B086 (X2 pressure too low)1192
#D0181 – Trouble pilot pressure X2 too high1193
Valve cartridge block with X2 pressure sensor 57B086 (X2 pressure too high)1194
#D0184 – Central lubrication system empty1195
Grease level CLS 1 & SLS & CLS 2 on REAL TIME MONITOR1197
#D0185 – Trouble central lubrication system1198
Allocation of vent valves and end-line switches1199
Action chart for lube cycles1200
View onto vent valve (62Q507a / 62Q509a / 62Q642a)1201
Wiring Diagram (60B043 & 62B046 & 80B043) for #D0185 & #D0188 & #D02031202
#D0186 – Trouble central lubrication system1203
Allocation of vent valves1203
Action chart for lube cycles1204
View onto vent valve (62Q507a / 62Q509a / 62Q642a)1205
#D0187 – Slew ring gear lubrication system empty1206
#D0188 – Trouble slew ring gear lubrication system1206
#D0189 – Trouble slew ring gear lubrication system1206
#D0191 – Trouble oil filter gear (PTO 2)1206
#D0193 – Trouble monitoring gear (PTO) oil filter 21206
#D0197 – Trouble monitoring engine air cleaner 21206
#D0198 – Trouble air cleaner 21206
#D0201 – Attachment lubrication system empty1206
#D0202 – Attachment lubrication system grease level too low1206
#D0203- Trouble attachment lubrication system1206
#D0204 – Trouble attachment lubrication system1206
#D0207 – Engine remote oil tank 1 empty1207
#D0208 – Engine remote oil tank 2 empty1207
#D0216 – Trouble software not compatible1208
#D0218 – Switch off all motors for running transfer pump1210
#D0220 – Trouble transfer pump motor overheated1211
Wiring Diagram (transfer pump) for message #D02201212
#D0223 – Trouble starter control 51K001a-11213
51K001a-1 & 51K001b-1 (relay check) on REAL TIME MONITOR1213
#D0224 – Trouble starter control Output to 51K001a-11214
51K001a-1 & 51K001b-1 (output check) on REAL TIME MONITOR1214
#D0225 – Trouble starter control 51K001b-11215
#D0226 – Trouble starter control Output to 51K001b-11215
#D0227 – Trouble starter control 51K001a-21215
#D0228 – Trouble starter control Output to 51K001a-21215
#D0229 – Trouble starter control 51K001b-21215
#D0230 – Trouble starter control Output to 51K001b-21215
#D0238 – Trouble supply by key switch 11Q0441216
Input signal of 11Q044 on REAL TIME MONITOR (#D0238)1216
Wiring Diagram (11Q044) for message #D02381217
#D0239 – Trouble electrical matter1218
Wiring Diagram – signal line 10K3511219
#D0240 – Trouble hydraulic oil temperature1220
Hydraulic oil temperature charts1221
#D0242 – Engine 1 already running1222
#D0243 – Fill up fuel tank1222
#D0245 – Engine shutdown from ground1223
Input signal of 54S051 & 54S052 on the REAL TIME MONITOR (#D0245)1224
#D0246 – Hydraulic oil temperature1225
#D0248 – Engine 2 already running1226
#D0252 – Emergency shut-down at access ladder1226
#D0253 – Emergency shut-down at valve block1226
#D0254 – Emergency shut-down at hydraulic control panel1226
#D0255 – Emergency shut-down in cabin1226
#D0256 – Operator warning system1226
#D0257 – Hydraulic oil temperature1227
#D0261 – Maintenance Safety Switch1228
#D0262 – Trouble screen at hydr cooler entry clogged1229
40B166 and 40B165 on REAL TIME MONITOR (#D0262)1229
Location of 40B166 and 40B165 at hydraulic oil tank (#D0262)1230
Wiring Diagram (40B166 & 40B165) for message #D02621231
#D0308 – Trouble CAN-BUS or CAN-Hardware1232
#D0309 – Trouble ladder up 56K253a1235
Ladder up 56K253a & 56K253b (relay check) on REAL TIME MONITOR1235
#D0310 – Trouble ladder up Output to 56K253a1236
Ladder up 56K253a & 56K253b (output check) on REAL TIME MONITOR1236
#D0311 – Trouble ladder up redundant 56K253b1237
#D0312 – Trouble ladder up redundant Output to 56K253b1237
#D0313 – Trouble ladder down 56K254a1237
Ladder down 56K254a & 56K254b (relay check) on REAL TIME MONITOR1237
#D0314 – Trouble ladder down Output to 56K254a1238
Ladder down 56K254a & 56K254b (output check) on REAL TIME MONITOR1238
#D0315 – Trouble ladder down redundant 56K254b1239
#D0316 – Trouble ladder down redundant Output to 56K254b1239
#D0317 – Trouble service arm up 56K255a1239
Service arm up 56K255a & 56K255b (relay check) on REAL TIME MONITOR1239
#D0318 – Trouble service arm up Output to 56K255a1240
Service arm up 56K255a & 56K255b (output check) on REAL TIME MONITOR1240
#D0319 – Trouble service arm up redundant 56K255b1241
#D0320 – Trouble service arm up redundant Output to 56K255b1241
#D0321 – Trouble service arm down 56K256a1241
Service arm down 56K256a & 56K256b (relay check) on REAL TIME MONITOR1241
#D0322 – Trouble service arm down Output to 56K256a1242
Service arm down 56K256a & 56K256b (output check) on REAL TIME MONITOR1242
#D0323 – Trouble service arm down redundant 56K256b1243
#D0324 – Trouble service arm down redundant Output to 56K256b1243
#D0331 – Automatic after_running engine 11243
#D0332 – Automatic after_running engine 21243
#D0333 – Trouble battery charger relay1244
Relay 11Q122 on TIME MONITOR1244
Wiring Diagram (11Q122 & 11F019) for message #D03331245
#D0422 – Can-net sys (J1939)1246
Wiring Diagram (CAN BUS Quantum ↔ K+ controller) for message #D04221247
8 Troubleshooting for PUMP/VALVE controller fault codes1249
DA2UKR – Communication failure PLC <-> KOMTRAX Plus controller1250
DBB0KK – KOMTRAX Plus source voltage error1252
Wiring Diagram K+ controller 24V supply and GND connections1253
DBB0KQ – Connector sel error1254
DAFQKR – Communication failure MH800 <-> KOMTRAX Plus controller1256
Wiring Diagram for message DAFQKR1257
DA2QKR – CAN2 Discon (Pump1 Con)1258
Wiring Diagram for message DA2QKR1259
DBZQKR – CAN2 Discon (Pump2 Con)1260
Wiring Diagram for message DBZQKR1261
DBWQKR – CAN2 Discon (Valve/M Con)1262
Wiring Diagram for message DBWQKR1263
DBXQKR – CAN2 Discon (Valve/S1 Con)1264
Wiring Diagram for message DBXQKR1265
DBYQKR – CAN2 Discon (Valve/S2 Con)1266
Wiring Diagram for message DBYQKR1267
DXAAKA – Solenoid-1(Pump-1) open circuit1268
DXABKA – Solenoid-2(Pump-2) open circuit1268
DXACKA – Solenoid-3(Pump-3) open circuit1268
DXADKA – Solenoid-4(Pump-4) open circuit1268
DXAEKA – Solenoid-5(Pump-5) open circuit1268
DXAFKA – Solenoid-6(Pump-6) open circuit1268
DXAGKA – Solenoid-7(Pump-7) open circuit1268
DXAHKA – Solenoid-8(Pump-8) open circuit1268
DXAJKA – Solenoid-9(Pump-9) open circuit1268
DXAKKA – Solenoid-10(Pump-10) open circuit1268
DXALKA – Solenoid-11(Pump-11) open circuit1268
DXAMKA – Solenoid-12(Pump-12) open circuit1268
Wiring Diagram – EPC valve control (PUMP1 controller)1270
Wiring Diagram – EPC valve control (PUMP2 controller)1271
DXAAKB – Solenoid-1(Pump-1) short circuit1272
DXABKB – Solenoid-2(Pump-2) short circuit1272
DXACKB – Solenoid-3(Pump-3) short circuit1272
DXADKB – Solenoid-4(Pump-4) short circuit1272
DXAEKB – Solenoid-5(Pump-5) short circuit1272
DXAFKB – Solenoid-6(Pump-6) short circuit1272
DXAGKB – Solenoid-7(Pump-7) short circuit1272
DXAHKB – Solenoid-8(Pump-8) short circuit1272
DXAJKB – Solenoid-9(Pump-9) short circuit1272
DXAKKB – Solenoid-10(Pump-10) short circuit1272
DXALKB – Solenoid-11(Pump-11) short circuit1272
DXAMKB – Solenoid-12(Pump-12) short circuit1272
Wiring Diagram – EPC valve control (PUMP1 controller)1274
Wiring Diagram – EPC valve control (PUMP2 controller)1275
DHPEMA – Pump-1/2 pressure sensor abnormality1276
DHPGMA – Pump-3/4 pressure sensor abnormality1276
DHPJMA – Pump-5/6 pressure sensor abnormality1276
DHPLMA – Pump-7/8 pressure sensor abnormality1276
DHPNMA – Pump-9/10 pressure sensor abnormality1276
DHPQMA – Pump-11/12 pressure sensor abnormality1276
Wiring Diagram – PWR & GND supply for pressure transducers (pumps 13)1278
Wiring Diagram – PWR & GND supply for pressure transducers (pumps 46)1279
DLE2MA – Engine speed sensor abnormality1280
DLE6MA – Engine2 speed sensor abnormality1280
Wiring Diagram – engine speed sensors1282
DA25KP – 5V sensor1 power abnormality1283
DBZ5KP – 5V sensor1 power abnormality1283
Wiring Diagram – 5V sensor power supply (PC1_5V_1) for message DA25KP1284
Wiring Diagram – 5V sensor power supply (PC2_5V_1) for message DBZ5KP1285
DA22KK – Pump Solenoid Power Low Error1286
DBZ2KK – Pump2 Solenoid Power Low Error1286
Wiring Diagram – PUMP1/2 solenoid power1287
DA29KQ – Model Selection Abnormality1288
DBZ9KQ – Model Selection Abnormality1288
Wiring Diagram – PUMP1 machine selections1290
Wiring Diagram – PUMP2 machine selections1291
DA2YKQ – Motor/Engine Selection Abnormality1292
DBZWKQ – Motor/Engine Selection Abnormality1292
Wiring Diagram – Motor/engine selection PUMP1 & PUMP2 controller1293
DA20KQ – Pump1 Con Selection Abnormality1294
DBZ0KQ – Pump2 Con Selection Abnormality1294
Wiring Diagram – Controller selection PUMP1 & PUMP2 controller1296
DA20MC – Pump1 Con Error1297
DBZ0MC – Pump2 Con Error1297
DGT3MA – PTO1 oil temperature sensor abnormality1298
DGT8MA – PTO2 oil temperature sensor abnormality1298
Wiring Diagram (57B049-1 & 57B049-2) for DGT3MA & DGT8MA & #D0069 & #D00831299
Mounting location of 57B049-1/21300
DGH2MA – Hydraulic oil temp sensor abnormality1301
Wiring Diagram (59B015) for messages DGH2MA & #D00631302
DWNCKA – Hyd oil cooler fan pump1 solenoid open circuit1303
DWNUKA – Hyd oil cooler fan pump2 solenoid open circuit1303
Wiring Diagram – Hydraulic oil cooler fan pump1/2 EPC control1305
DWNCKB – Hyd oil cooler fan pump1 solenoid short circuit1306
DWNUKB – Hyd oil cooler fan pump2 solenoid short circuit1306
Wiring Diagram – Hydraulic oil cooler fan pump1/2 EPC control1307
DWN5KA – Radiator fan pump1 solenoid open circuit1308
DWNTKA – Radiator fan pump2 solenoid open circuit1308
Wiring Diagram – Radiator fan pump1/2 EPC control1310
DWN5KB – Radiator fan pump1 solenoid short circuit1311
DWNTKB – Radiator fan pump2 solenoid short circuit1311
Wiring Diagram – Radiator fan pump1/2 EPC control1312
DXQ0KA – X1 pilot pressure pump1 solenoid open circuit1313
DXQ1KA – X1 pilot pressure pump2 solenoid open circuit1313
Wiring Diagram – control oil (X1) pressure pump1/2 EPC control1315
DXQ0KB – X1 pilot pressure pump1 solenoid short circuit1316
DXQ1KB – X1 pilot pressure pump2 solenoid short circuit1316
Wiring Diagram – control oil (X1) pressure pump1/2 EPC control1317
DDABMC – Lock lever switch abnormality1318
Wiring Diagram – lock lever switch 20S105 (DDABMC)1319
DBW9KQ – Model Selection Abnormality1320
Wiring Diagram – VALVE0 machine selections1321
DBWZKQ – Lever control selection abnormality1322
Wiring Diagram – VALVE0 lever control selection1323
DBWYKQ – Attachment selection abnormality1324
Wiring Diagram – VALVE0 attachment selection1325
DBW2KK – Solenoid Power Low Error(VALVE/M)1326
Wiring Diagram for message DBW2KK1329
DBW0KQ – VALVE/M Con Selection Abnormality1330
Wiring Diagram – VALVE0 controller selection1331
DBW0MA – VALVE/M Con Error1332
DKURMA – R lever right-left potentio abnormality1334
Wiring Diagram – R lever right-left potentiometer input (DKURMA)1335
DKUSMA – R lever right-left redu pot abnorm(VALVE/M)1336
Wiring Diagram – R lever redundant right-left potentiometer input (DKUSMA)1337
DKUQL8 – R lever right-left potentio error1338
Wiring Diagram – R lever main + redundant right-left signal voltage at VALVE01340
DKUQL4 – R lever right-left sig mismatch(VALVE/M)1341
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE11343
DKUNMA – R lever front-back potentio abnormality1344
Wiring Diagram – R lever front-back potentiometer input (DKUNMA)1345
DKUPMA – R lever front-back redu pot abnorm(VALVE/M)1346
Wiring Diagram – R lever redundant front-back potentiometer input at VALVE01347
DKUML8 – R lever front-back potentio error1348
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8)1350
DKUML4 – R lever front-back sig mismatch(VALVE/M)1351
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE11353
DKUXMA – L lever right-left potentio abnormality1354
Wiring Diagram – L lever right-left potentiometer input (DKUXMA)1355
DKUYMA – L lever right-left redu pot abnorm(VALVE/M)1356
Wiring Diagram – L lever redundant right-left potentiometer input (DKUYMA)1357
DKUWL8 – L lever right-left potentio error1358
Wiring Diagram – L lever main + redundant right-left signal voltage at VALVE01360
DKUWL4 – L lever right-left sig mismatch(VALVE/M)1361
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE11363
DKUUMA – L lever front-back potentio abnormality1364
Wiring Diagram – L lever front-back potentiometer input (DKUUMA)1365
DKUVMA – L lever front-back redu pot abnorm(VALVE/M)1366
Wiring Diagram – L lever front-back redundant potentiometer input (VALVE0)1367
DKUTL8 – L lever front-back potentio error1368
Wiring Diagram – L lever front-back potentio error (DKUTL8)1370
DKUTL4 – L lever front-back sig mismatch(VALVE/M)1371
Wiring Diagram – L lever front-back sig mismatch(VALVE/M) for DKUTL41373
DKW1MA – R pedal potentio abnormality1374
Wiring Diagram – R pedal potentio abnormality (DKW1MA)1376
DKW2MA – R pedal redundant pot abnormality(VALVE/M)1377
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA1379
DKW0L8 – R pedal potentio error1380
Wiring Diagram – R pedal potentio error (DKW0L8)1382
DKW0L4 – R pedal signal mismatch(VALVE/M)1383
Wiring Diagram – R pedal signal mismatch(VALVE/M) for DKW0L41385
DKW4MA – L pedal potentio abnormality1386
Wiring Diagram – L pedal potentio abnormality (DKW4MA)1388
DKW5MA – L pedal redundant pot abnormality(VALVE/M)1389
Wiring Diagram – L pedal redundant pot abnormality(VALVE/M) for DKW5MA1391
DKW3L8 – L pedal potentio error1392
Wiring Diagram – L pedal potentio error (DKW3L8)1394
DKW3L4 – L pedal signal mismatch(VALVE/M)1395
Wiring Diagram – L pedal signal mismatch(VALVE/M) for DKW3L41397
DKW7MA – Clam open potentio abnormality1398
Wiring Diagram – Clam open potentio abnormality (DKW7MA)1399
DKW8MA – Clam open redu pot abnormality(VALVE/M)1400
Wiring Diagram – Clam open redu pot abnormality(VALVE/M) for DKW8MA1401
DKW6L8 – Clam open potentio error1402
Wiring Diagram – Clam open potentio error (DKW6L8)1404
DKW6L4 – Clam open signal mismatch(VALVE/M)1405
Wiring Diagram – Clam open signal mismatch(VALVE/M) for DKW6L41407
DKWAMA – Clam close potentio abnormality1408
Wiring Diagram – Clam close potentio abnormality (DKWAMA)1409
DKWBMA – Clam close redundant pot abnorm(VALVE/M)1410
Wiring Diagram – Clam close redundant pot abnorm(VALVE/M) for DKWBMA1411
DKW9L8 – Clam close potentio error1412
Wiring Diagram – Clam close potentio error (DKW9L8)1414
DKW9L4 – Clam close signal mismatch(VALVE/M)1415
Wiring Diagram – Clam close signal mismatch(VALVE/M) for DKW9L41417
DKWDMA – Hydraulic slew brake potentio abnormality1418
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA)1419
DKWEMA – Hyd slew brake redu pot abnorm(VALVE/M)1420
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/M) for DKWEMA1421
DKWCL8 – Hydraulic slew brake potentio error1422
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8)1424
DKWCL4 – Hyd slew brake sig mismatch(VALVE/M)1425
Wiring Diagram – Hyd slew brake sig mismatch(VALVE/M) for DKWCL41427
DXNHKA – Travel1 left epc solenoid open circuit1428
DXN3KA – Stick1 epc solenoid open circuit1428
DXNJKA – Bucket1 epc solenoid open circuit1428
DXN2KA – Boom1 epc solenoid open circuit1428
DXN5KA – Clam2 epc solenoid open circuit1428
DXN8KA – Bucket2 epc solenoid open circuit1428
DXN4KA – Boom2 epc solenoid open circuit1428
DXN6KA – Stick2 epc solenoid open circuit1428
DXNKKA – Travel3 right epc solenoid open circuit1428
DXNCKA – Boom3 epc solenoid open circuit1428
DXNBKA – Bucket3 epc solenoid open circuit1428
DXNLKA – Stick3 epc solenoid open circuit1428
DXNMKA – Slew4 epc solenoid open circuit1428
Details of above 6-digit failure codes1429
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623 (block I)1430
Wiring Diagram for EPC 61K624 – 61K625 – 61K626 – 61K627 (block II)1431
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 – 61K631 (block III)1432
Wiring Diagram for EPC 61K632 (block IV)1433
Monitoring screens for EPC with open circuit (block IIV)1434
DXNHKB – Travel1 left epc solenoid short circuit1435
DXN3KB – Stick1 epc solenoid short circuit1435
DXNJKB – Bucket1 epc solenoid short circuit1435
DXN2KB – Boom1 epc solenoid short circuit1435
DXN5KB – Clam2 epc solenoid short circuit1435
DXN8KB – Bucket2 epc solenoid short circuit1435
DXN4KB – Boom2 epc solenoid short circuit1435
DXN6KB – Stick2 epc solenoid short circuit1435
DXNKKB – Travel3 right epc solenoid short circuit1435
DXNCKB – Boom3 epc solenoid short circuit1435
DXNBKB – Bucket3 epc solenoid short circuit1435
DXNLKB – Stick3 epc solenoid short circuit1435
DXNMKB – Slew4 epc solenoid short circuit1435
Details of the above 6-digit failure codes1436
DXNHKY – Travel1 left epc solenoid hot short circuit1437
DXN3KY – Stick1 epc solenoid hot short circuit1437
DXNJKY – Bucket1 epc solenoid hot short circuit1437
DXN2KY – Boom1 epc solenoid hot short circuit1437
DXN5KY – Clam2 epc solenoid hot short circuit1437
DXN8KY – Bucket2 epc solenoid hot short circuit1437
DXN4KY – Boom2 epc solenoid hot short circuit1437
DXN6KY – Stick2 epc solenoid hot short circuit1437
DXNKKY – Travel3 right epc hot solenoid short circuit1437
DXNCKY – Boom3 epc solenoid hot short circuit1437
DXNBKY – Bucket3 epc solenoid hot short circuit1437
DXNLKY – Stick3 epc solenoid hot short circuit1437
DXNMKY – Slew4 epc solenoid hot short circuit1437
Details of the above 6-digit failure codes1438
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623 (block I)1439
Wiring Diagram for EPC 61K624 – 61K625 – 61K626 – 61K627 (block II)1440
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 – 61K631 (block III)1441
Wiring Diagram for EPC 61K632 (block IV)1442
D5Y3KB – Boom down on/off signal short circuit1443
D5Y2KB – Boom up on/off signal short circuit1443
D5Y5KB – Stick in on/off signal short circuit1443
D5Y4KB – Stick out on/off signal short circuit1443
D5Y7KB – Bucket dump on/off signal short circuit1443
Wiring Diagram – VALVE0 controller ON/OFF signal output to node 21444
DBW5MA – 5V sensor1 power abnormality1445
Wiring Diagram – 5V_1 power supply and GND_1 output at VALVE01446
DBW6MA – 5V sensor2 power abnormality1448
Wiring Diagram – 5V_2 power supply and GND_2 output at VALVE01449
DBX9KQ – Model Selection Abnormality1452
Wiring Diagram – VALVE1 machine selections1453
DBXZKQ – Lever Control Selection Abnormality1454
Wiring Diagram – VALVE1 lever control selection1455
DBXYKQ – Attachment selection abnormality1456
Wiring Diagram – VALVE1 attachment selection1457
DBX2KK – Solenoid Power Low Error(VALVE/S1)1458
Wiring Diagram for message DBX2KK – Solenoid Power Low Error(VALVE/S1)1460
PPC safety circuit – Wiring Diagram overview1461
DBX0KQ – VALVE/S1 Con Selection Abnormality1462
Wiring Diagram – VALVE1 controller selection1463
DBX0MA – VALVE/S1 Con Error1464
DKWHMA – R lever right-left redu pot abnorm(VALVE/S1)1465
Wiring Diagram – R lever redundant right-left potentiometer input (DKWHMA)1466
DKWFL4 – R lever right-left sig mismatch(VALVE/S1)1467
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE11469
DKWLMA – R lever front-back redu pot abnorm(VALVE/S1)1470
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA)1471
DKWJL4 – R lever front-back sig mismatch(VALVE/S1)1472
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE11474
DKWPMA – L lever right-left redu pot abnorm(VALVE/S1)1475
Wiring Diagram – L lever redundant right-left potentiometer input at VALVE11476
DKWML4 – L lever right-left sig mismatch(VALVE/S1)1477
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE11479
DKWSMA – L lever front-back redu pot abnorm(VALVE/S1)1480
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/S1) for DKWSMA1481
DKWQL4 – L lever front-back sig mismatch(VALVE/S1)1482
Wiring Diagram – L lever front-back sig mismatch (VALVE1) for DKWQL41484
DKWVMA – R pedal red pot abnormality(VALVE/S1)1485
Wiring Diagram – R pedal red pot abnormality (VALVE1) for DKWVMA1486
DKWTL4 – R pedal signal mismatch(VALVE/S1)1487
Wiring Diagram – R pedal signal mismatch(VALVE/S1) for DKWTL41489
DKWYMA – L pedal red pot abnormality(VALVE/S1)1490
Wiring Diagram – L pedal red pot abnormality(VALVE/S1) for DKWYMA1491
DKWWL4 – L pedal signal mismatch(VALVE/S1)1492
Wiring Diagram – L pedal signal mismatch(VALVE/S1) for DKWWL41494
DKX2MA – Clam open redu pot abnormality(VALVE/S1)1495
Wiring Diagram – Clam open redu pot abnormality(VALVE/S1)) for DKX2MA1496
DKX0L4 – Clam open signal mismatch(VALVE/S1)1497
Wiring Diagram – Clam open signal mismatch(VALVE/S1) for DKX0L41499
DKX5MA – Clam close redu pot abnormality(VALVE/S1)1500
Wiring Diagram – Clam close redu pot abnormality(VALVE/S1) for DKX5MA1501
DKX3L4 – Clam close signal mismatch(VALVE/S1)1502
Wiring Diagram – Clam close signal mismatch(VALVE/S1) for DKX3L41504
DKX8MA – Hyd slew brake redu pot abnorm(VALVE/S1)1505
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/S1) for DKX8MA1506
DKX6L4 – Hyd slew brake signal mismatch(VALVE/S1)1507
Wiring Diagram – Hyd slew brake signal mismatch(VALVE/S1) for DKX6L41509
DWKAKA – Travel1 left forward sol open circuit1510
DWKEKA – Travel1 left backward sol open circuit1510
DWBJKA – Stick1 out solenoid open circuit1510
DWBNKA – Stick1 in solenoid open circuit1510
DWASKA – Bucket1 fill solenoid open circuit1510
DWAWKA – Bucket1 dump solenoid open circuit1510
DWBAKA – Boom1 up solenoid open circuit1510
DWBEKA – Boom1 down solenoid open circuit1510
Details of above 6-digit failure codes1510
Monitoring screens for directional solenoids – VALVE11511
Wiring Diagram – directional solenoids at remote control block 451 (VALVE1)1512
DWKAKB – Travel1 left forward sol short circuit1513
DWKEKB – Travel1 left backward sol short circuit1513
DWBJKB – Stick1 out solenoid short circuit1513
DWBNKB – Stick1 in solenoid short circuit1513
DWASKB – Bucket1 fill solenoid short circuit1513
DWAWKB – Bucket1 dump solenoid short circuit1513
DWBAKB – Boom1 up solenoid short circuit1513
DWBEKB – Boom1 down solenoid short circuit1513
Details of above 6-digit failure codes1513
Monitoring screens for directional solenoids – VALVE11514
Wiring Diagram – directional solenoids at remote control block 451 (VALVE1)1515
DWKAKY – Travel1 left forward sol hot short circuit1516
DWKEKY – Travel1 left backward sol hot short circuit1516
DWBJKY – Stick1 out solenoid hot short circuit1516
DWBNKY – Stick1 in solenoid hot short circuit1516
DWASKY – Bucket1 fill solenoid hot short circuit1516
DWAWKY – Bucket1 dump solenoid hot short circuit1516
DWBAKY – Boom1 up solenoid hot short circuit1516
DWBEKY – Boom1 down solenoid hot short circuit1516
Details of above 6-digit failure codes1516
Monitoring screens for directional solenoids – VALVE11517
Wiring Diagram – directional solenoids at remote control block 451 (VALVE1)1518
DWBXKA – Clam2 close solenoid open circuit1519
DWBTKA – Clam2 open solenoid open circuit1519
DWATKA – Bucket2 fill solenoid open circuit1519
DWAXKA – Bucket2 dump solenoid open circuit1519
DWBBKA – Boom2 up solenoid open circuit1519
DWBFKA – Boom2 down solenoid open circuit1519
Details of above 6-digit failure codes1519
Monitoring screens for directional solenoids – VALVE11521
Wiring Diagram – directional solenoids at remote control block 452 (VALVE1)1522
DWBXKB – Clam2 close solenoid short circuit1523
DWBTKB – Clam2 open solenoid short circuit1523
DWATKB – Bucket2 fill solenoid short circuit1523
DWAXKB – Bucket2 dump solenoid short circuit1523
DWBBKB – Boom2 up solenoid short circuit1523
DWBFKB – Boom2 down solenoid short circuit1523
Details of above 6-digit failure codes1523
Monitoring screens for directional solenoids – VALVE11525
Wiring Diagram – directional solenoids at remote control block 452 (VALVE1)1526
DWBXKY – Clam2 close solenoid hot short circuit1527
DWBTKY – Clam2 open solenoid hot short circuit1527
DWATKY – Bucket2 fill solenoid hot short circuit1527
DWAXKY – Bucket2 dump solenoid hot short circuit1527
DWBBKY – Boom2 up solenoid hot short circuit1527
DWBFKY – Boom2 down solenoid hot short circuit1527
Details of above 6-digit failure codes1527
Monitoring screens for directional solenoids – VALVE11528
Wiring Diagram – directional solenoids at remote control block 452 (VALVE1)1529
D5Y6KB – Bucket fill on/off signal short circuit1530
D5Y9KB – Clam close on/off signal short circuit1530
D5YAKB – Hyd slew brake order signal short circuit1530
D5Y0KB – Slew left on/off signal short circuit1530
D5Y1KB – Slew right on/off signal short circuit1530
Wiring Diagram – VALVE1 controller ON/OFF signal output to node 21531
D5YAKY – Hyd slew brake order signal hot short circuit1532
Wiring Diagram – VALVE1 controller ON/OFF signal output to node 21533
DBY9KQ – Model Selection Abnormality1534
Wiring Diagram for message DBY9KQ1535
DBYZKQ – Lever Control Selection Abnormality1536
Wiring Diagram for message DBYZKQ1537
DBYYKQ – Attachment selection abnormality1538
Wiring Diagram for message DBYYKQ1539
DBY2KK – Solenoid Power Low Error(VALVE/S2)1540
Wiring Diagram for message DBY2KK – Solenoid Power Low Error(VALVE/S2)1542
PPC safety circuit – Wiring Diagram overview1543
DBY0KQ – VALVE/S2 Con Selection Abnormality1544
Wiring Diagram for message DBY0KQ1545
DBY0MA – VALVE/S2 Con Error1546
DWBKKA – Stick2 out solenoid open circuit1547
DWBKKB – Stick2 out solenoid short circuit1547
DWBPKA – Stick2 in solenoid open circuit1547
DWBPKB – Stick2 in solenoid short circuit1547
Details of above 6-digit failure codes1547
Wiring Diagram – 61K627a/b open circuit or short circuit to GND1549
DWBKKY – Stick2 out solenoid hot short circuit1550
DWBPKY – Stick2 in solenoid hot short circuit1550
Details of above 6-digit failure codes1550
Wiring Diagram – 61K627a/b hot short circuit1551
DWKQKA – Travel3 right backward sol open circuit1552
DWKLKA – Travel3 right forward sol open circuit1552
DWBCKA – Boom3 up solenoid open circuit1552
DWBGKA – Boom3 down solenoid open circuit1552
DWAUKA – Bucket3 fill solenoid open circuit1552
DWAYKA – Bucket3 dump solenoid open circuit1552
DWBLKA – Stick3 out solenoid open circuit1552
DWBQKA – Stick3 in solenoid open circuit1552
DWARKA – Slew4 right solenoid open circuit1552
DWAMKA – Slew4 left solenoid open circuit1552
Details of above 6-digit failure codes1552
Monitoring screens for directional solenoids (453 & 43) – VALVE21554
Wiring Diagram – directional solenoids at remote control blocks 453 & 431555
DWKQKB – Travel3 right backward sol short circuit1556
DWKLKB – Travel3 right forward sol short circuit1556
DWBCKB – Boom3 up solenoid short circuit1556
DWBGKB – Boom3 down solenoid short circuit1556
DWAUKB – Bucket3 fill solenoid short circuit1556
DWAYKB – Bucket3 dump solenoid short circuit1556
DWBLKB – Stick3 out solenoid short circuit1556
DWBQKB – Stick3 in solenoid short circuit1556
DWARKB – Slew4 right solenoid short circuit1556
DWAMKB – Slew4 left solenoid short circuit1556
Details of above 6-digit failure codes1556
Monitoring screens for directional solenoids (453 & 43) – VALVE21558
Wiring Diagram – directional solenoids at remote control blocks 453 & 431559
DWKQKY – Travel3 right backward sol hot short circuit1560
DWKLKY – Travel3 right forward sol hot short circuit1560
DWBCKY – Boom3 up solenoid hot short circuit1560
DWBGKY – Boom3 down solenoid hot short circuit1560
DWAUKY – Bucket3 fill solenoid hot short circuit1560
DWAYKY – Bucket3 dump solenoid hot short circuit1560
DWBLKY – Stick3 out solenoid hot short circuit1560
DWBQKY – Stick3 in solenoid hot short circuit1560
DWARKY – Slew4 right solenoid hot short circuit1560
DWAMKY – Slew4 left solenoid hot short circuit1560
Details of above 6-digit failure codes1560
Monitoring screens for directional solenoids (453 & 43) – VALVE21562
Wiring Diagram – directional solenoids at remote control blocks 453 & 431563
DXEDKA – Hyd slew brake epc sol open circuit1564
DXEDKB – Hyd slew brake epc sol short circuit1564
Wiring Diagram for messages DXEDKA & DXEDKB1565
DXEDKY – Hyd slew brake epc sol hot short circuit1566
Wiring Diagram for message DXEDKY1567
D5Z3KB – Travel right backward on/off signal short circuit1568
D5Z5KB – Travel right forward on/off signal short circuit1568
D5Z2KB – Travel left backward on/off signal short circuit1568
D5Z4KB – Travel left forward on/off signal short circuit1568
D5Y8KB – Clam open on/off signal short circuit1568
Wiring Diagram – VALVE2 controller ON/OFF signal output to node 21569
DBZRKR – CAN1 Discon (Pump2 Con)1570
Wiring Diagram for message DBZRKR1571
DBWRKR – CAN1 Discon (Valve/M Con)1572
Wiring Diagram for message DBWRKR1573
DBXRKR – CAN1 Discon (Valve/S1 Con)1574
Wiring Diagram for message DBXRKR1575
DBYRKR – CAN1 Discon (Valve/S2 Con)1576
Wiring Diagram for message DBYRKR1577
9 Troubleshooting by Symptoms1579
91 Symptoms of engine and electrical system1580
SEL001 – Engine does not start (engine does not rotate)1580
Wiring Diagram 1 (batteries & starter motors) for symptom code SEL0011582
Wiring Diagram 2 (20S105) for symptom code SEL0011583
Wiring Diagram 3 (20S030) for symptom code SEL0011584
SEL002 – Engine does not start (Pre-lube does not stop)1585
SEL003 – Engine stops while in operation1586
View onto the fuel system water separator (SEL003)1587
SEL004 – Engine speed is hunting during boom-up movement1588
SEL005 – Engine does not stop1590
SEL006 – Engine lacks output (low power)1592
Judgment Table for SEL0061593
SEL007 – Exhaust smoke is black1594
Judgment Table for SEL0071595
SEL008 – Oil consumption is excessive1596
Judgment Table for SEL0081597
SEL009 – Oil becomes contaminated quickly1598
Judgment Table for SEL0091599
SEL010 – Fuel consumption is excessive1600
Judgment Table for SEL0101601
SEL011 – Oil is in engine coolant1602
Judgment Table for SEL0111603
SEL012 – Oil level rises1604
Judgment Table for SEL0121605
SEL013 – Coolant temperature becomes too high (overheating)1606
Judgment Table for SEL0131607
92 Symptoms of Hydraulic System1608
SHY001 – All work equipment shows lack of power or slow movement (especially “boom up” function)1608
SHY002 – Engine speed sharply drops or engine stalls too much1610
SHY003 – No work equipment, travel or slew movement1611
SHY004 – Work equipment has too much hydraulic drift1612
SHY005 – Work equipment has time lag1613
SHY006 – Machine deviates during travel movement1614
SHY007 – Hydraulic system has lack of power1615
SHY008 – Machine does not slew1616
Slew brake valve block (SHY008)1617
SHY009 – Slew acceleration is poor1618
SHY010 – Excessive overrun when stopping slew movement1620
SHY011 – Floating system without function (FSA only)1622
SHY012 – Abnormal noise coming from SRV or MRV1623
SHY013 – Track tensioning system without function1624
Track tensioning – overview (SHY013)1625
SHY014 – Ladder does not move, or slow movement1626
SHY015 – Refilling arm does not move, or slow movement1628
SHY016 – Hydraulic driven grease pump does not move1630
SHY017 – Abnormal track chain movement during digging1632
SHY018 – Slew parking brake without function1633
SHY019 – Travel parking brake without function1634
93 Symptoms of Mechanical System1636
SME001 – Abnormal noise is made1636
Judgment Table for SME0011637
SME002 – Abnormal noise around PTO / hydraulic pumps1638
SME003 – Vibration is excessive (engine mountings)1640
Judgment Table for SME0031641
SME004 – Vibration is excessive (engine torsion)1642
SME005 – There is a big shock when stopping slew movement1643
SME006 – There is a big abnormal noise when moving/stopping slew movement1644
SME007 – Fan blades make abnormal noise1646
SME008 – Abnormal noise coming from a travel gearbox1647
SME009 – Abnormal noise coming from work equipment (lack of grease)1649
SME010 – Abnormal idler movement1651
SME011 – Leak at PTO drive shaft seal1652
94 Symptoms of Additional Systems1654
SAD001 – Air conditioner for cabin does not work1654
View onto A/C unit (SAD001)1655
SAD002 – Air conditioner compressor clutch is burnt1656
View onto A/C compressor and its mounting (SAD002)1657
SAD003 – Air conditioning system defective (pipes and hoses full of moisture)1658
View onto an A/C filling and service station1659
SAD004 – CAN BUS failure (message #D0308 displayed)1660
50 DISASSEMBLY & ASSEMBLY1667
TOC1669
1 Introduction1677
11 Foreword1678
12 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels1679
13 Diagrams and illustrations in this manual1679
14 Procedures for disassembling and assembling in this manual1680
2 Safety1681
21 Overview1683
211 Method of using this manual1683
22 General precautions1685
221 General1685
222 Personal protective clothing1685
223 When using a hammer1686
224 Proper tools1686
225 Personnel1686
226 Fire prevention1687
227 Unauthorized modification1687
23 Precautions for maintenance and repair1688
231 General precautions1688
232 Keep work place clean and tidy1688
233 Precautions when welding1689
234 Precaution with high pressure fluids1689
2341 Handling high pressure hoses and pipes1689
235 Compressed air1689
236 Waste materials1690
3 Superstructure1691
31 Superstructure overview1692
32 Machinery house1694
321 Disconnection plates1696
3211 RH-side disconnection plate [56XH01] – port allocations1696
3212 LH-side disconnection plate [50XH01] – port allocations1697
322 Machinery house roof1698
3221 Disassembling of the machinery house roof cover plates1700
3222 Assembling of the machinery house roof cover plates1704
323 Air intake system1710
3231 Disassembling of the air intake system1710
3232 Assembling of the air intake system1714
324 Exhaust system1719
3241 Disassembling of the exhaust system1719
3242 Assembling of the exhaust system1723
325 Lubrication pump station1726
3251 Disassembling of the lubrication pump station1726
3252 Assembling of the lubricating pump station1728
326 Diesel engines1730
3261 Disassembling of the Diesel engine (engine 1 or 2)1730
3262 Assembling of the Diesel engine (engine 1 or 2)1736
3263 Disassembling of the alternator1743
3264 Assembling of the alternator1744
3265 Disassembling of the starter motor1745
3266 Assembling of the starter motor1746
327 Batteries1747
3271 Disassembling of the batteries1747
3272 Assembling of the batteries1749
328 Engine cooling system1751
3281 Disassembling of the Radiator assembly1752
3282 Assembling of the radiator assembly1755
3283 Disassembling of the radiator fan assembly1758
3284 Assembling of the radiator fan assembly1761
329 Flexible drive coupling1764
3291 Disassembling of the Geislinger coupling1764
3292 Assembling of the Geislinger coupling1766
3293 Disassembling of the CentaFlex coupling assembly1768
3294 Assembling of the CentaFlex coupling assembly1771
3295 Replacing the rubber rollers of the CentaFlex coupling1773
3210 Main pump assemblies1776
32101 Disassembling of the main pump assemblies1777
32102 Assembling of the main pump assemblies1781
3211 Universal pump distributor gear box (PTO)1784
32111 Disassembling of the universal pump distributor gear box (PTO)1785
32112 Assembling of the universal pump distributor gear box (PTO)1789
32113 Disassembling of the control and filter plate assemblies1794
32114 Assembling of the control and filter plate assemblies1803
32115 Disassembling of the PTO gear oil pump1812
32116 Assembling of the PTO gear oil pump1814
33 Hydraulic system1816
331 Hydraulic oil cooler assembly1816
3311 Disassembling of hydraulic cooler fan1817
3312 Assembling of hydraulic cooler fan1818
3313 Disassembling of hydraulic cooler fan motor1819
3314 Assembling of hydraulic cooler fan motor1821
3315 Disassembling of the hydraulic oil coolers1823
3316 Assembling of the hydraulic oil coolers1826
3317 Disassembling of the hydraulic oil cooler assembly1829
3318 Assembling of the hydraulic oil cooler assembly1834
332 Hydraulic oil tank1840
3321 Disassembling of the main shut-off valve1842
3322 Assembling of the main shut-off valve1844
3323 Disassembling of the hydraulic oil tank1846
3324 Assembling of the hydraulic oil tank1857
333 Control frame assembly1870
3331 Disassembling of the main control valve blocks I, II and III1871
3332 Assembling of the main control valve blocks I, II and III1875
3333 Disassembling of the main control valve block IV (Slewing)1879
3334 Assembling of the main control valve block IV (Slewing)1881
3335 Disassembling of the high pressure filters at the main control valve blocks1883
3336 Assembling of the high pressure filters at the main control valve blocks1886
3337 Disassembling of the MRV at the main control valve blocks1889
3338 Assembling of the MRV at the main control valve blocks1890
3339 Disassembling of SRV on main control valve block1891
33310 Assembling of SRV on main control valve blocks1892
33311 Disassembling of ACV-/SRV-block on main control valve blocks1893
33312 Assembling of ACV-/SRV-block on main control valve blocks1894
334 Distributor Manifold1896
3341 Disassembling of throttle check valves at the distributor manifold1897
3342 Assembling of throttle check valves at the distributor manifold1899
3343 Disassembling of anti cavitation valves at the distributor manifold1901
3344 Assembling of anti cavitation valves at the distributor manifold1903
3345 Disassembling of the distributor manifold1907
3346 Assembling of the distributor manifold1910
34 Slew system1912
341 Slew gears1912
3411 Disassembling of the slew gear1913
3412 Assembling of the slew gear1916
342 Slew brake valve block1920
3421 Disassembling of the slew brake valve block1920
3422 Assembling of the slew brake valve block1922
343 Hydraulic slew motors1924
3431 Disassembling of the slew motor1924
3432 Assembling of the slew motor1926
344 Slew parking brake1928
3441 Disassembly of the slew parking brake of slew gear type 20631929
3442 Assembly of the slew parking brake of SLEW GEAR type 20631932
3443 Disassembling of the slew parking brake of SLEW GEAR type 6327701935
3444 Assembling of the slew parking brake of SLEW GEAR type 6327701939
345 Slew circle1942
3451 Disassembling of the slew circle1942
3452 Assembling of the slew circle1946
346 Slew circle lubrication pinion (dummy wheel)1947
3461 Disassembling of the lubrication pinion assembly1948
3462 Assembling of the lubrication pinion assembly1950
35 Operator’s cab1952
351 Disassembling of the operator’s cab1953
352 Assembling of the operator’s cab1957
353 Disassembling of the operator’s cab together with the cab support frame1961
354 Assembling of the operator’s cab together with the cab support frame1965
355 Cab-mounts1968
3551 Disassembling of the cab-mounts1968
3552 Assembling of the cab-mounts1970
356 Front window1972
3561 Disassembling of the front window1972
3562 Assembling of the front window1973
357 Operator’s seat1974
3571 Disassembling of the operator’s seat1974
3572 Assembling of the operator’s seat1975
36 Cab base1976
361 Disassembling of the cab support frame1977
362 Assembling of the cab support frame1979
363 Disassembling of the cab base1981
364 Assembling of the cab base1984
37 Ladders and platforms1988
371 Hydraulic access Ladder1988
3711 Disassembling of the hydraulic access ladder1988
3712 Assembling of the hydraulic access ladder1990
3713 Disassembling of the access ladder cylinder1992
3714 Assembling of the access ladder cylinder1994
372 Fuel tank step1995
3721 Disassembling of the fuel tank step1995
3722 Assembling of the fuel tank step1997
373 Access ladder platform1998
3731 Disassembling of the access ladder platform1998
3732 Assembling of the access ladder platform2000
374 Emergency escape ladders2002
3741 Disassembling of the emergency escape ladder assembly at the cab base2002
3742 Assembling of the emergency escape ladder assembly at the cab base2003
3743 Disassembling of the emergency escape ladder assembly at the machinery house2004
3744 Assembling of the emergency escape ladder assembly at the machinery house2005
38 Counterweight2007
381 Disassembling of the counterweight2008
382 Assembling of the counterweight2011
39 Fuel tank2016
391 General information regarding disassembling and assembling2016
392 Disassembling of the fuel tank2018
393 Assembling of the fuel tank2027
310 Superstructure Lifting2038
3101 Disassembling the superstructure from the undercarriage2038
3102 Assembling the superstructure onto the undercarriage2041
4 Undercarriage2045
41 Undercarriage overview2046
42 Travel system2048
421 Crawler Track2048
4211 Changing of the crawler track2048
422 Sprocket assembly2055
4221 Disassembling of the sprocket assembly2055
4222 Assembling of the sprocket assembly2060
423 Guide wheel assembly2063
4231 Disassembling of the guide wheel assembly2063
4232 Assembling of the guide wheel assembly2066
424 Track tensioning accumulators2069
4241 Disassembling of the low pressure accumulators2069
4242 Assembling of the low pressure accumulators2071
4243 Disassembling of the high pressure accumulators2073
4244 Assembling of the high pressure accumulators2074
425 Track tensioning valve block2075
4251 Disassembling of the track tensioning valve block2075
4252 Assembling of the track tensioning valve block2077
426 Track tensioning cylinders2078
4261 Disassembling of the track tensioning cylinders2078
4262 Assembling of the track tensioning cylinders2080
427 Replace the Hydraulic hoses of the track tensioning system2083
4271 Precursory work2083
4272 Replace the hydraulic hoses inside the undercarriage center body2085
4273 Replace the hydraulic hose between undercarriage center body and crawler frame2085
4274 Replace the hydraulic hoses inside the crawler frame2087
4275 Subsequent work2087
428 Travel brake valve block (overspeed valve)2088
4281 Disassembling of the travel brake valve block2088
4282 Assembling of the travel brake valve block2089
429 Travel motor2090
4291 Disassembling of the travel motors2090
4292 Assembling of the travel motors2092
4210 Travel parking brake2094
42101 Disassembling of the travel parking brake of type 631053 and 20632096
42102 Assembling of the travel parking brake of type 631053 and type 20632100
4211 Travel gearbox2105
42111 Disassembling of the travel gearbox2106
42112 Assembling of the travel gearbox2108
4212 Carrier rollers2111
42121 Disassembling of the carrier roller assembly2111
42122 Assembling of the carrier roller assembly2113
4213 Track rollers2115
42131 Disassembling of the track roller assembly2115
42132 Assembling of the track roller assembly2117
4214 Replace the hydraulic hoses of the traveling system2120
43 Undercarriage Center Body2124
431 Disassembling of the undercarriage center body and the crawler carriers2124
432 Assembling of the undercarriage center body and the crawler carriers2129
4321 Install crawler carrier mounting bolts2134
433 Rotary joint2135
4331 Disassembling of the rotary joint2135
4332 Assembling of the rotary joint2138
5 Attachment2141
51 Attachment bearings at superstructure2142
511 Boom foot bearings with full floating pins2142
5111 Disassembling of the boom foot bearings2143
5112 Assembling of the boom foot bearings2145
512 Boom cylinder foot bearings with full floating pins2148
5121 Disassembling of the boom cylinder foot bearings – BHA arrangement2150
5122 Assembling of the boom cylinder foot bearings – BHA arrangement2152
5123 Disassembling of the boom cylinder foot bearings – FSA arrangement2155
5124 Assembling of the boom cylinder foot bearings – FSA arrangement2157
52 Repair procedures2160
521 Replacement of bushings at the attachment2160
5211 Removal of the bushings2160
5212 Installation of the bushings2161
522 General installation instructions for attachment pins2162
53 Backhoe (BHA)2164
531 Overview2164
532 Pin Sealing bucket – Steering Rod – bucket link rod2166
533 Boom assembly2168
5331 Disassembling of the boom2168
5332 Assembling of the boom2170
5333 Disassembling of the boom cylinders2172
5334 Assembling of the boom cylinders2176
534 Stick assembly2181
5341 Disassembling of the Stick2181
5342 Assembling of the Stick2186
5343 Disassembling of the Stick Cylinders2191
5344 Assembling of the Stick cylinders2196
535 Bucket and steering2201
5351 Disassembling of the bucket2201
5352 Assembling of the bucket2205
5353 Disassembling of the Bucket Cylinders2208
5354 Assembling of the Bucket Cylinders2215
5355 Disassembling of the bucket link rod2222
5356 Assembling of the bucket link rod2225
5357 Disassembling of the steering rods2228
5358 Assembling of the steering rods2234
536 Hydraulic hoses at the backhoe attachment2238
5361 Replace the boom arc hoses2238
5362 Replace the boom cylinder hoses2242
5363 Replace the stick cylinder hoses2244
5364 Replace the bucket cylinder hoses2246
54 Front shovel (FSA)2248
541 Overview2248
542 Using the Cylinder Mounting Device for Front shovel attachments (PN 967 000 40)2250
5421 Designated usage2251
5422 Non-designated usage2251
543 Boom assembly2252
5431 Disassembling of the boom2252
5432 Assembling of the boom2254
5433 Disassembling of the boom cylinders2256
5434 Assembling of the boom cylinders2260
544 Stick assembly2266
5441 Disassembling of the stick2266
5442 Assembling of the stick2271
5443 Disassembling of the stick cylinders2276
5444 Assembling of the stick cylinders2280
545 Bull clam bucket2284
5451 Disassembling of the bull clam bucket2284
5452 Assembling of the bull clam bucket2288
5453 Disassembling of the bucket cylinders2292
5454 Assembling of the bucket cylinders2298
5455 Disassembling of the clam cylinders2304
5456 Assembling of the clam cylinders2309
546 Hydraulic hoses at the front shovel attachment2314
5461 Replace the boom arc hoses2314
5462 Replace the boom cylinder hoses2318
5463 Replace the stick arc hoses2320
5464 Replace the stick cylinder hoses2322
5465 Replace the bucket cylinder hoses2324
5466 Replace the clam cylinder hoses2326
55 Ground engaging tools (GET)2331
551 Replacement of the GET2331
56 Cylinder bypass test2332
6 Service Information2333
61 Fluids and lubricants2334
62 Lifting Gears2334
63 Safety hints for sling accessory2336
64 Weight tables2337
641 Superstructure2337
642 Undercarriage2339
643 Backhoe attachment (BHA)2340
644 Face shovel attachment (FSA)2341
65 Torque charts according to KOMATSU company standard2342
651 Metric standard thread2342
652 Metric fine thread2343
653 Cummins motor torques – metric2344
654 Cummins motor torques – US customary2344
655 SAE-flange connections2345
66 Blind plugs2346
661 Dummy plates for SAE–flanges2346
662 Classification of threads to the nominal width2348
663 Plugs and fittings according to DIN 23532349
67 Conversion table2350
671 Method of using the conversion table2350
672 Millimeter – inch & kilogram – pound2351
673 Liter – US gallon & liter – UK gallon2352
674 Nm- ftlb2353
675 Bar – PSI – kPa – MPa2354
676 Temperature2355
68 Tools2356
681 Standard tool case2356
682 Used special tools (Overview)2358
69 Work instructions2361
691 Bleeding the track tensioning system2361
692 Hints for hydraulic hose installation2363
693 Remove / install the crawler carrier2366
694 Repair procedure for the radiator assembly2367
7 Parts & Service News2369
71 List of the PARTS AND SERVICE NEWS2370
IMAGES PREVIEW OF THE MANUAL:
S.M 26/12/24
