Komatsu PC7000E-6 Mining Shovel Repair Manual PDF Download

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Komatsu HYDRAULIC MINING SHOVEL PC7000E-6 Shop Manual – PDF DOWNLOAD

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Komatsu HYDRAULIC MINING SHOVEL PC7000E-6 Shop Manual – PDF DOWNLOAD

Language : English
Pages :2484
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC MINING SHOVEL PC7000E-6 Shop Manual – PDF DOWNLOAD

SERIAL NUMBER 35003 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 PC7000E-6 Shop Manual – PDF DOWNLOAD

SERIAL NUMBER 35003 and up

SHOP MANUAL PC7000E-6 1
00 FOREWORD & SAFETY 3
1 Foreword 5
11 BEFORE READING THIS MANUAL 6
111 CAS (Canadian Standards Association) 6
12 CONTENTS OF THIS BINDER 7
121 Contacting the Service 7
122 Guarantee 7
13 DIVISION OF THE BINDER 8
2 SAFETY 13
TOC 9
21 SAFETY INFORMATION 14
22 OVERVIEW 15
221 NORMAL OPERATIONS 15
222 REGULAR MAINTENANCE 15
223 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 15
224 ADDITIONAL SAFETY PRECAUTIONS 15
23 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 16
231 SOUND 16
232 VIBRATION 16
24 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 17
241 UNDERSTANDING THE MACHINE 17
242 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 17
2421 ENSURING SAFE OPERATION 17
243 PREPARATIONS FOR SAFE OPERATION 17
2431 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 17
2432 INSPECTING THE MACHINE 17
2433 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 18
2434 KEEP MACHINE CLEAN 18
2435 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 18
2436 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 19
2437 IF A PROBLEM IS FOUND 19
244 FIRE PREVENTION 19
2441 PRECAUTIONS TO PREVENT FIRE 19
2442 ACTION IF FIRE OCCURS ON PC3000 20
2443 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000 21
2444 EMERGENCY EXIT FROM OPERATOR’S CAB 21
245 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 22
2451 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 22
2452 NO JUMPING ON OR OFF THE MACHINE 22
2453 NO PEOPLE ON THE ATTACHMENT 22
2454 WORKING IN HIGH PLACES 22
2455 LEAVING OPERATOR’S SEAT WITH LOCK 23
2456 LEAVING THE MACHINE 23
246 BURN PREVENTION 23
2461 Hot coolant 23
2462 Hot oil 24
247 PRECAUTIONS WHEN CLEANING CAB GLASS 24
248 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 24
249 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 25
2491 UNAUTHORIZED MODIFICATION 25
2492 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 25
2410 ELECTROMAGNETIC COMPATIBILITY (EMC) 25
2411 PRECAUTIONS AT JOBSITE 26
24111 VISIBILITY FROM OPERATOR’S SEAT 27
24112 CAMERA SYSTEM WITH MONITORS 27
24113 ENSURE GOOD VISIBILITY 27
24114 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 27
24115 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 28
24116 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 28
24117 Lightning Strikes 29
24118 WORKING ON LOOSE GROUND 29
24119 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 30
241110 VENTILATION OF ENCLOSED AREAS 31
2412 STARTING motor 32
24121 WARNING TAG 32
24122 CHECKS BEFORE STARTING motor 32
24123 PRECAUTION WHEN STARTING motor 32
24124 PRECAUTION IN COLD AREAS 33
2413 OPERATION 33
24131 CHECKS BEFORE OPERATION 33
24132 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 34
24133 PRECAUTIONS WHEN traveling 35
24134 TRAVELING ON SLOPES 36
24135 OPERATIONS ON SLOPES 37
24136 PROHIBITED OPERATIONS 37
24137 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 38
24138 PARKING THE MACHINE 38
24139 TRANSPORTATION 38
25 PRECAUTION FOR MAINTENANCE 39
251 GENERAL PRECAUTIONS 39
2511 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 40
2512 STOP motor FOR MAINTENANCE 41
2513 WARNING TAG 42
2514 KEEP WORKPLACE CLEAN AND TIDY 43
2515 APPOINT LEADER WHEN WORKING WITH OTHERS 43
2516 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 44
2517 INSTALLING, REMOVING OR STORING ATTACHMENTS 44
2518 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 45
2519 NOISE 45
25110 WHEN USING A HAMMER 45
25111 PROPER TOOLS 46
25112 ACCUMULATOR 46
25113 PERSONNEL 46
252 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 47
2521 PRECAUTION WHEN WELDING 47
2522 BATTERY HANDLING 47
253 PRECAUTIONS WITH HIGH PRESSURE FLUID 48
2531 PRECAUTIONS WITH HIGH FUEL PRESSURE 49
2532 HANDLING HIGH PRESSURES HOSES OR PIPES 50
2533 REPLACEMENT OF HOSE LINES 50
2534 INSPECTION OF HOSE LINES 50
2535 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 51
2536 PRECAUTIONS FOR HIGH VOLTAGE 51
2537 AIR CONDITIONING MAINTENANCE 51
2538 COMPRESSED AIR 52
2539 WASTE MATERIALS 52
26 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 53
261 INSPECTION OF THE HYDRAULIC SYSTEM 53
262 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 53
263 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 53
27 SPECIAL SAFETY EQUIPMENT 54
271 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB 55
272 OBJECT HANDLING 55
273 LIGHTING 55
274 WARNING BEACON 55
275 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 55
2751 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 55
2752 INSTRUCTIONS FOR USE 57
2753 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 59
2754 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 59
2755 INSTRUCTIONS FOR USE 61
28 HIGH VOLTAGE SAFETY INSTRUCTIONS FOR MACHINES WITH ELECTRIC MOTOR 63
281 QUALIFICATION OF PERSONNEL 63
282 ELECTRICAL TOOLS 63
283 GENERAL PREPARATION BEFORE WORKING ON ELECTRICAL EQUIPMENT 64
284 CONNECTION OF PILOT LINE (GROUND CHECK WIRE) 64
285 PREPARATION BEFORE WORKING ON THE CABLE DRUM 64
286 PREPARATION BEFORE WORKING ON THE CABLE GUIDE 65
287 MODIFICATION OF THE ELECTRICAL SYSTEM 65
288 FIRE 65
289 GENERAL INSTRUCTIONS 66
2810 GROUNDING PROCEDURE FOR THE HIGH VOLTAGE SYSTEM 66
28101 INTRODUCTION 66
28102 GENERAL PREPARATION BEFORE WORKING ON ELECTRICAL EQUIPMENT 67
28103 WORKING EQUIPMENT & PERSONAL PROTECTION 67
28104 SPECIAL TOOLS REQUIRED 67
28105 PERSONAL PROTECTION EQUIPMENT (PPE) 68
28106 PREPARING THE MACHINE FOR HIGH VOLTAGE MAINTENANCE 68
28107 POWER DISCONNECTION AND EARTHING 69
28108 THE THREE STEPS To DEACTIVATE POWER 70
28109 EARTHING PROCEDURES IN THE HV CABINET 72
281010 THREE STEPS TO RECONNECTING THE POWER AFTER MAINTENANCE WORK 80
281011 Step 1, inserting the key 80
281012 Step 2, Switching earthing off 80
281013 Step 3, Switching load on 81
01 SPECIFICATION 83
PC7000E-6 84
10 STRUCTURE & FUNCTION 93
TOC 95
1 Introduction 109
11 Foreword 110
12 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 111
13 Explanation of abbreviations 112
14 Diagrams and illustrations in this manual 113
2 Specifications 115
21 Lifting Gears 116
22 Safety hints for sling accessory 118
23 Standard Tightening Torque Chart 119
24 Conversion Table 120
25 Blind plugs 126
26 Classification of threads to the nominal width 128
27 Plugs and fittings according to ISO 8434-1 / DIN 2353 129
3 Main assembly groups 131
31 General layout 132
32 Superstructure 134
321 Superstructure side view 134
322 Superstructure top view 136
33 Machinery house 138
34 Hydraulic oil tank 140
35 Hydraulic oil cooler 142
36 High voltage switch cabinet 144
37 Cab support 150
371 View into cab base 156
38 Operator’s cab 158
39 Main control blocks (FSA) 160
310 Slew machinery 162
3101 Slew gear type 2063 / Slew motor type A6VLM 162
3102 Slew gear type 632770 / Slew motor type A6VLM 164
311 Slip ring unit & Rotary joint 166
3111 Slip Ring Unit in Detail 168
312 Undercarriage 170
313 Slew ring 172
314 Attachment 174
3141 Front Shovel Attachment (FSA) 174
3142 Back hoe Attachment (BHA) 176
315 Counterweight 178
316 PPC safety circuit 180
4 Drive 183
41 Electric drive – Safety and operation instruction documents 184
42 Prime drive assembly 186
43 Electric motor 188
431 Attaching parts 188
432 Grease equipment for motor bearings 190
433 Monitoring the motor bearing temperature 192
434 Monitoring the motor winding temperature 194
435 Temperature signal conversion 196
436 Anti-condensation heater 197
437 Ventilation 198
438 Checking the bearing condition 199
44 Capacitor mounting location 200
441 Capacitor assembly 201
45 Initial Start-up procedure 204
451 Main supply cable 205
452 Machine configuration (via CoDeSys) 206
453 Motor protection relays (type Multilin 369) 210
454 Motor alignment 212
455 Motor rotation direction 214
456 Starting & Re-starting the electric motor 214
457 Supervision during the first motor running period 215
46 Flexible coupling 216
461 Description of the flexible coupling 218
462 Coupling inspection 219
4621 Work to be performed during visual inspection 219
463 Coupling replacement information 219
464 Coupling run-out 219
47 Pump distributor gearbox (PTO) 220
471 PTO oil filling, oil level, and ventilation 222
472 Pump spline lubrication 224
4721 Oil level in the main pump & gear oil pump drive shaft housing 225
473 PTO lubrication and cooling 226
4731 Hydraulic components and schematic of cooling circuit-1 226
4732 Schematic overview – PTO gear oil cooling circuit-1 228
4733 Checks and adjustments 230
48 Hydraulic pumps – location, drive speed and flow rates 232
5 Hydraulic oil tank 237
51 General layout 238
52 Hydraulic oil tank, location of the electric equipment 240
53 Suction oil tank with strainers 242
54 Return oil collector pipe with strainer 244
55 Back pressure valve 246
56 Transfer pump 248
57 Return & leak oil filter 250
58 Breather filter 252
6 Hydraulic oil cooling 255
61 Overall view of the hydraulic oil cooling 256
62 Function of the hydraulic oil cooling circuit 258
63 Adjustment of the back pressure valve 260
64 Stepless cooler fan RPM control 262
641 Pressure limiting valves 264
642 Components of the fan drive circuits 266
643 Fan pump type HPV190 268
65 Oil cooler fan speed testing/adjustment 270
651 Testing & readjustment procedure 272
652 Basic adjustment procedure 273
66 OC fan resonance speed adjustment 274
661 Hydraulic oil temperature charts 276
7 Controlling 277
71 General layout 278
72 Control and filter panels – location of components 280
721 Control and filter panel motor-1 (rear) 280
722 Valve cartridge block motor-1 (rear) 282
723 Control and filter panel motor-2 (front) 284
73 Pilot pressure supply and adjustments 286
731 Pilot pressure control (PPC) circuit 286
732 Pilot pressure operating the main block spools 288
733 Checks and adjustment of pilot pressure 290
734 Remote control valves arrangement 292
74 Function of the electro hydraulic control system 294
741 Illustration of the joystick signal flow (example) 296
75 Hand lever (joystick) control 298
751 Voltage supply of hand lever 20S020 299
752 Direction signal course from hand lever to controllers 300
753 Double ratiometric* output diagram 301
76 Foot pedal control 302
761 Voltage supply of foot lever 20S021a 304
762 Direction signal course from foot pedal to controllers 305
763 Double ratiometric* output diagram for 2 direction pedal 306
764 Single ratiometric* output diagram for 1 direction pedal 307
77 Hand lever & foot pedal monitoring 308
771 Lever monitoring screens (example) 310
772 Solenoid valve monitoring screen (example) 312
78 Valve solenoid adjustment 314
781 Overview sol min/max current & adjustment range 315
79 ACCEL & DECEL time adjustment 316
791 Accel & Decel times 316
8 Components 319
81 Main control blocks and high pressure screens (FSA) 320
82 Main control blocks with valves and HP screens (FSA) 322
83 Main control blocks with valves and HP screens (BHA) 324
84 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) 326
85 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) 328
86 Restrictor block with secondary relief valve 330
87 Anti-cavitation valve (ACV) block 332
871 Single ACV block on the manifold 332
872 Double ACV block on the manifold 334
88 Remote control valves 336
89 4/3 Directional solenoid valves 338
810 Proportional solenoid valves 340
811 High-pressure screen 342
812 Control blocks and valves 344
8121 Main control blocks I, II, III (4 spool blocks) 344
81211 Spin lock for valve blocks (ND52) 345
8122 Hydraulic diagram of a 4-spool valve block 346
8123 Spool types 347
8124 Spool positions (control block) 350
8125 MRV, SRV, and ACV 352
8126 Load holding valve 354
8127 Main control block IV (slew) 356
813 Travel brake valve 358
814 Pressure reducing valve 360
815 4/2 Directional valves 362
816 Pressure double stage valve 364
817 Hydraulic cylinder 366
8171 Hydraulic cylinder – Chesterton® 11KE sealing 366
8172 Cylinder data markings 369
9 Main hydraulic pumps, pump regulation, valve control & monitoring system 371
91 General 372
911 Pump data 374
92 Main pumps 378
921 Hydraulic pump type HPV375+375 378
9211 Main pump sectional drawings 380
922 Servo valve 382
9221 VC valve  servo piston 383
923 EPC valve 388
93 Electronic pump regulation system 390
931 Cut-off function 392
932 Slew control 393
933 Temperature control 393
934 Diagnostics and monitoring 393
935 Hydraulic oil temperature charts 394
936 PTO gear oil temperature charts 394
94 Pump & valve controllers 396
95 Multimonitor 398
951 Service menu screen 401
96 Service menu – 01 Monitoring 401
961 Monitoring PUMP 1 controller 402
962 Monitoring PUMP 2 controller 403
963 Monitoring VALVE 0 controller 404
964 Monitoring VALVE 1 controller 406
965 Monitoring VALVE 2 controller 407
966 Monitoring all controllers 407
97 Using Multimonitor functions for monitoring 408
971 Hold function 408
98 Service menu – 02 Abnormality Record 409
981 To delete any failure record from the display 410
982 Troubleshooting procedures 410
983 Failure codes for pump & valve controllers & system connections 411
99 Service menu – 03 Default 419
910 Service menu – 04 Adjustment 420
9101 Adjustments for PUMP 1 controller 420
9102 Adjustments for PUMP 2 controller 422
9103 Adjustments for VALVE 0 controller 424
9104 Adjustments for VALVE 2 controller 425
9105 Details on the adjustable parameters 426
91051 PUMP 1 controller 426
91052 PUMP 2 controller 428
91053 VALVE0 controller 429
91054 VALVE 1 & 2 controller 432
9106 Description of the Primary P-Factor 433
9107 Pump16F/R Solenoid Min Current Adjustment 434
9108 Pump16F/R Solenoid Max Current Adjustment 435
911 Accel & Decel time adjustment 436
9111 Accel & Decel times 436
912 Service menu – 05 Controller Setting 438
913 Controller replacement procedure 438
9131 Controller Setting → Wiring Input Check 438
9132 Controller Setting → Memory 442
9133 Confirmation 444
914 Service menu – 06 Option Setting 445
915 Service menu – 07 Display Setup 446
916 Checks and adjustments 448
9161 Motor power check 448
9162 Cut-off function check 452
91621 Cut-off for clam close (FSA only) 453
917 Electronic load limiting control 454
9171 Load limiting control input signals at PUMP1/2 controllers 455
9172 Load limiting control output signals from PUMP1 controller to main pumps 13 456
9173 Signal rectifier module (12T431) 458
9174 Checks and adjustment of 12T431 460
91741 Testing the signal rectifier 12T431 for voltage 461
91742 Testing the signal rectifier 12T431 for current 461
10 Operating hydraulics 463
101 General 464
1011 Allocation of pumps and main valve blocks 466
102 Spool functions (FSA) 468
1021 Floating function for boom and stick cylinders 468
1022 Spool functions (BHA) 470
103 Hydraulics for the attachment cylinders 472
1031 Electric / hydraulic flowchart “Boom UP” (FSA) 472
1032 Electric / hydraulic flowchart “boom up” (BHA) 474
1033 Electric / hydraulic flowchart “boom down” (FSA), single movement and Auto-float ON 476
1034 Electric / hydraulic flowchart “boom down” (FSA), Auto-float OFF – button 20S095 pressed and single movement 478
1035 Electric / hydraulic flowchart “Boom down” (BHA) 480
1036 Electric / hydraulic flowchart “Stick out” (FSA) 482
1037 Electric / hydraulic flowchart “Stick out” (BHA) 484
1038 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float ON and single movement 486
1039 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float OFF – 20S098 pressed & single movement 488
10310 Electric / hydraulic flowchart “Stick in” (BHA) 490
10311 Electric / hydraulic flowchart “Bucket fill” (FSA) 492
10312 Electric / hydraulic flowchart “Bucket fill” (BHA) 494
10313 Electric / hydraulic flowchart “Bucket dump” (FSA) 496
10314 Electric / hydraulic flowchart “Bucket dump” (BHA) 498
10315 Electric / hydraulic flowchart “Clam open” (FSA) 500
10316 Electric / hydraulic flowchart “Clam close” (FSA) 502
10317 Checks and adjustments of the main relief valve (MRV) 504
10318 Checks and adjustments of the secondary relief valves (SRV) 506
103181 Boom cylinders, piston side (BHA & FSA), boom up 506
103182 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down 510
103183 Stick cylinders, piston side (FSA), stick out 514
103184 Stick cylinders, piston side (BHA), stick in 518
103185 Stick cylinders, piston rod side (FSA), stick in 522
103186 Stick cylinders, piston rod side (BHA), stick out 526
103187 Bucket cylinders, piston side (FSA), bucket fill 530
103188 Bucket cylinders, piston side (BHA), bucket fill 534
103189 Bucket cylinders, piston rod side (FSA), bucket dump 538
1031810 Bucket cylinders, piston rod side (BHA), bucket dump 542
1031811 Clam cylinders, piston rod side (FSA), clam open 546
1031812 Clam cylinders, piston side (FSA), clam close 550
10319 Checks and adjustments of cycle times 554
103191 Checks and adjustments of boom lowering speed (FSA) 554
103192 Checks and adjustments of boom lowering speed (BHA) 558
103193 Checks and adjustments of stick retract speed (FSA) 562
103194 Checks and adjustments of stick retract speed (BHA) 566
103195 Checks and adjustments of bucket dump speed (FSA) 570
103196 Checks and adjustments of bucket dump speed (BHA) 574
103197 Checks and adjustments of bucket curl speed (BHA) 578
103198 Checks and adjustments of clam close speed (FSA) 582
104 Hydraulics for the slew circuit 584
1041 Slew circuit with variable slew motors 584
1042 Slew motor (variable displacement) 588
10421 Hydraulic slew motor – displacement control 590
1043 Slew gearbox type 2063 592
1044 Slew gearbox type 632770 594
1045 Slew parking brake (on slew gear type 2063) 596
1046 Slew parking brake (on slew gear type 632770) 598
1047 Slew brake valve 600
1048 Flushing circuit 604
1049 Electric / hydraulic flowchart “Slew left” FSA 606
10410 Electric / hydraulic flowchart “Slew left” BHA 608
10411 Electric / hydraulic flowchart “Slew right” FSA 610
10412 Electric / hydraulic flowchart “Slew right” BHA 612
10413 Checks and adjustments for the slew circuit 614
104131 Pressure checks & adjustments – double stage valve (DSV) 615
104132 Checks & adjustments – brake pilot pressure 617
104133 Checks & adjustments – slew speed 619
10414 Function check for the hydraulic slew brake 620
10415 Function check for the slew parking brake 622
104151 Parking brake release pressure check 622
104152 Function check of relays 56K250a & b 623
105 Hydraulics for the travel circuit 624
1051 Travel circuit 624
1052 Travel motor 628
1053 Rotary joint 630
1054 Travel gearbox 632
10541 Travel gearbox Type 2063 632
10542 Travel gearbox type 631053 634
1055 Travel parking brake 636
10551 Travel parking brake on travel gear type 2063 636
10552 Travel parking brake on travel gear type 631053 637
10553 Travel brake valve 638
1056 Electric / hydraulic flowchart “travel forward” 640
1057 Electric / hydraulic flowchart “travel backwards” 642
1058 Checks and adjustments 644
10581 Checks and adjustments for the travel circuit 644
10582 Function check for the travel parking brake 647
11 Hydraulic track tensioning system 649
111 General 650
112 Functional description 652
1121 Hydraulic schematic for track tensioning 653
113 Double stage valve 654
114 Tensioning cylinder 656
115 Adjustments / checks 658
12 Stairway, hydraulically operated 661
121 Overview 662
122 Function of the hydraulically operated stairway 664
123 Adjustments / checks 670
13 Central refilling system 673
131 Central refilling equipment 674
132 Central refilling system overview 676
14 Hints for reading the hydraulic diagram 679
141 General 680
142 Hydraulic symbols 682
1421 Lines, unions 683
1422 Components, valves 685
1423 Sensors 685
1424 Valves, valve components 686
1425 Pump, motor, cylinder 690
15 Hints for reading the electric Wiring Diagram 695
151 General 696
152 Reference code of the electrical components 697
1521 Area code 697
1522 Component identifying letter 698
153 Graphical symbols 699
154 Concept of the Wiring Diagram 703
1541 Cover page of the Komatsu W/D 703
1542 Example 1 from the schematics in the W/D 705
1543 Example 2 from the schematics in the W/D 707
1544 Table of contents in the W/D (page 1 of 2) 709
1545 Location list 711
1546 Cross reference list for electr components in the W/D 712
1547 Cross reference list for terminals in the W/D 714
1548 Cross reference list for connectors in the W/D 716
1549 Cross reference list for terminal boards in the W/D 718
15410 Connection table 720
155 Cable and connector marking 722
156 Cable color identification 724
16 KOMTRAX Plus & MTC control system 725
161 General 726
1611 CAN overview 1 726
1612 CAN overview 2 727
1613 Description 728
162 Specifications for operators 730
1621 Opening screen 731
1622 Main gauge screens 1 to 3 732
1623 Energy consumption screen 736
1624 Failure messages for the operator 738
1625 Main gauge screens – Changing of Time / SMR / Date 740
1626 Maintenance monitor 742
1627 Settings for operator 744
1628 Automatic messages 750
163 Table of all provided messages 752
1631 Table of Error Codes & messages 753
1632 Table of available Instruction Messages 759
164 Flow charts (14) of KOMTRAX Plus main screens 762
165 KOMTRAX Plus service level 766
1651 Explanation of the button symbols (Service Level) 768
1652 Service Menu Select Screen 769
1653 Real Time Menu Select Screen 770
16531 Real Time Menu, option: 01 Motor 1 771
16532 Real Time Menu, option: 02 Motor 2 772
16533 Real Time Menu, option: 03 PTO 1 772
16534 Real Time Menu, option: 04 PTO 2 772
16535 Real Time Menu, option: 05 Hydraulic 773
16536 Real Time Menu, option: 06 Slew 774
16537 Real Time Menu, option: 07 Electrical Equipment 775
16538 Real Time Menu, option: 08 Emergency Stop 776
16539 Real Time Menu, option: 09 Heater 777
165310 Real Time Menu, option: 10 Manual Switch 778
165311 Real Time Menu, option: 11 Central Lube System 1 779
165312 Real Time Menu, option: 12 Slew Ring Gear Lube System 780
165313 Real Time Menu, option: 13 Central Lube System 2 781
165314 Real Time Menu, option: 14 Cable drum 782
165315 Real Time Menu, option: 15 Windscreen Wiper 783
165316 Real Time Menu, option: 16 Ladder (stairway) 784
165317 Real Time Menu, option: 17 Service Arm 785
165318 Real Time Menu, option: 18 Pilot Control 786
165319 Real Time Menu, option: 19 Other Items 787
165320 Real Time Menu, option: 20 Output Signals 788
165321 Output signals with deactivated MTC evaluation 791
1654 PM-Clinic 792
16541 General 792
16542 Power Check 793
1655 Serial/GCC no setting 794
1656 Memory Clear 795
16561 Input Memory Clear ID 795
16562 Memory Clear screen 796
1657 Failure History 797
1658 Maintenance Monitor 798
1659 Snapshot 799
16510 Setting 800
165101 Central Lubrication System (CLS 1), screen 1/12 800
165102 Slew ring gear Lubrication System (SLS), screen 2/12 801
165103 Central Lubrication System (CLS 2), screen 3/12 802
165104 Qmin – Qmax setting, screen 4/12 803
165105 Other Settings 1/2, screen 5/12 803
165106 Hydraulic Oil & PTO Gear Oil Definition Table 804
165107 Hydraulic oil temperature charts 804
165108 PTO gear oil temperature charts 804
165109 Other Settings 2/2, screen 6/12 805
1651010 PLC-evaluation ON/OFF 807
1651011 Shutdown Bypass ON/OFF 808
166 Interface-Connection KOMTRAX Plus controller & MTC 812
1661 KOMTRAX Plus controller 813
167 7-segment error code indication 814
168 View onto the KOMTRAX Plus controller 816
169 MTC control system – global layout 818
1691 MTC (Master Turbo Controller) 820
16911 MTC flowchart 820
16912 MTC features 820
16913 MTC firmware and software 821
16914 Connector and component location in the control system 821
16915 View onto the MTC unit and its connectors 822
16916 LED indications at the MTC 823
1610 Global layout of the internal CAN BUS 824
16101 General information on a CAN BUS system 824
161011 General CAN BUS description 825
161012 CAN BUS troubleshooting 825
161013 CAN BUS wiring 826
161014 CAN BUS end resistor 828
1611 The nodes in the CAN BUS system 830
16111 Global layout 830
16112 Introduction 832
161121 ICN-V features 832
161122 View onto an open ICN-V node with DIP switches & status LED 834
161123 General information on the LED control 835
161124 ICN-D features 836
161125 View onto an ICN-D node without wiring 837
161126 View onto the Status LEDs at the ICN-D node 838
161127 General information on the LED control 838
161128 Node DIP-switches 840
161129 Detailed view onto the DIP switches 841
16113 Node box 842
16114 Node location on the machine 844
161141 Node & location chart 845
16115 View onto the control components in a cab base 846
17 Lubrication system 849
171 General overview – SLS & CLS1/2 850
1711 General description 851
172 Basic function of the lubrication systems 852
173 Lubrication systems (SLS & CLS1/2) 854
1731 Lubrication pump station 854
1732 General Information on CLS1/2 856
1733 General information on SLS 856
1734 Manual lube activation 856
174 Lubrication cycle 857
1741 Operation and control 857
1742 Lubrication cycle – processing 858
1743 Time segments & switch points of a lubrication cycle 859
1744 Lubrication modes 860
17441 Automatic lubrication mode 860
17442 Manual lubrication mode 860
17443 Reduced pause time for service 860
175 Hydraulically driven lube pump 862
1751 Adjustment of lube pump speed 864
17511 Stroke speed adjustment 865
17512 Working pressure 865
176 Lubricant injectors 866
1761 Tightening torques for fittings at grease injectors 867
1762 Description 867
1763 Adjustment of the lubricant output 868
1764 Operation principle of lubricant injectors 870
17641 Function description 871
1765 Connection of one or more injectors 872
177 Vent valve and grease outlet filter 874
1771 Vent valve description 875
178 End-line switch 876
1781 Description 877
1782 CLS1/2 end-line switch adjustment 878
1783 SLS end-line switch adjustment 880
179 Lubricant level sensors 882
1791 Description 883
17911 Checks 883
1710 Commissioning 884
17101 Commissioning of the CLS1/2 lubrication system 884
17102 Fine adjustment 885
17103 Commissioning of the SLS lubrication system 886
18 Deep temperature equipment (option) 889
181 General information 890
1811 Introduction 890
1812 Deep temperature components overview 890
1813 Power supply preconditions for preheating 891
1814 Power requirements for preheating systems 892
182 Preheating procedure 893
1821 Global flow chart of the preheating procedure 893
1822 Starting the preheating procedure 894
1823 Preheating of operator’s cab and Diesel engine [coolant system] 895
1824 Preheating of lubricants and superstructure (Diesel) [electric system] 896
183 Constant heating of travel motors (TTT equipment below-40°C only) 897
184 Component location 898
1841 Electric heating elements for hydraulic & batteries [electric machine] 898
1842 Electric heating elements for hydraulics [Diesel machine] 900
1843 Electric heating elements for engines & batteries [Diesel machine] 902
185 Components of TT equipment 904
1851 Preheating components on a Diesel machine 904
1852 Preheating components on an electric machine 905
1853 Wiring Diagrams for preheating systems 906
18531 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 906
18532 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 907
18533 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 908
18534 Wiring diagram “Suction Oil Manifold Preheating” 909
18535 Wiring diagram “PTO Preheating” 910
18536 Wiring diagram “Battery heater pads” 911
19 Cable guide & Cable drum 913
191 General layout of the cable guide 914
1911 Safety 915
192 General layout of the cable drum 916
1921 Safety 918
193 Service switch 920
194 Drive system 922
1941 Drive motor 924
1942 Connecting the drive motor 926
1943 Drive motor resistor 926
1944 Drive torque regulation 926
1945 Cable strain 927
1946 Chain lubrication & chain tension 928
195 Drum Body 930
1951 Slip ring assembly 931
1952 Carbon graphite brushes 931
1953 Location of dryer and heater units in the drum body 932
1954 Dryer system 933
196 High voltage interlock system 934
197 Switch boxes for the cable drum 936
1971 Install and connect the cable 938
1972 Winding up the cable 940
198 Cable guide drive mechanism 942
1981 Proximity switches on the cable guide drive mechanism 944
1982 Cable deflection & drum full/empty control 946
19821 Monitoring the drum min/max winding status 948
1983 Checks and adjustments 950
199 Travel motion control 952
1991 Ground contact control 953
1910 Overview on switches & control elements on the cable drum 954
1911 Slew angle monitoring & Attention message 956
1912 Commissioning cable drum 958
19121 Cable drum configuration for the MTC (CoDeSys) 960
19122 Lubricate drum drive side bearing with grease 962
19123 Tool set for manual motor rotation 962
19124 Cable drum maintenance 962
1913 Shovel relocation 963
40 TROUBLESHOOTING 965
TOC 967
1 Introduction 995
11 Overview 996
111 General advice when using troubleshooting charts 996
12 General Precautions 997
2 General Information for Troubleshooting 999
21 Preparations For Work1000
22 Precautions During Work1000
23 Precautions When Carrying Out Any Operation1001
231 Precautions when carrying out removal work1001
232 Precautions when carrying out installation work1001
233 Precautions when completing the operation1002
24 Fundamental Requirements for Troubleshooting1003
241 Technical documentation1003
242 Tools1003
2421 Reference Guide for Deutsch Removal Tools1007
243 Personnel1008
25 Points To Remember When Trouble- shooting1008
26 Sequence Of Events In Troubleshooting1010
27 Checks Before Troubleshooting1011
28 Handling Of Electric Equipment And Hydraulic Components1012
281 Points to remember when handling electric equipment1012
282 Points To Remember When Handling Hydraulic Equipment1015
29 General working procedures1017
291 Air Bleeding of Various Hydraulic Parts1017
292 Air bleeding from the hydraulic pumps1017
293 Air bleeding from hydraulic cylinders1017
210 Cylinder bypass test1018
211 Basics about “How to crimp” (with strain relief)1019
2111 Crimp tool & repair kit1019
2112 General1020
2113 Select the required connector components1020
2114 Stripping a wire1021
2115 Crimping1022
2116 Connector assembly after crimping1023
212 Cable Shielding1024
3 Mounting Locations and Connector Types1025
31 Superstructure1026
311 General layout (FSA & BHA)1026
312 Superstructure side view1028
313 Superstructure top view1030
32 Machinery house1032
33 Slip ring unit & Rotary joint1034
331 Slip Ring Unit in Detail1036
34 Capacitor1038
35 High Voltage Switch Cabinet – view 11040
36 Cab support1046
361 View into cab base1052
37 Arrangement of Slew Angle Sensor1054
371 Slew angle sensor in the Wiring Diagram1055
38 Location of hydraulic components1056
381 Location of Control Blocks1056
382 Control and filter panel motor 1 (rear)1058
383 Valve cartridge block motor-1 (rear)1060
384 Control and filter panel motor-2 (front)1062
385 Remote control valves arrangement1064
39 View onto the SLS or CLS1/2 grease barrel and the lubrication cycle components1066
310 Hydraulic oil tank & suction oil tank – Location of electrical components1068
311 Hydraulically operated stairway1070
312 Central refilling equipment1072
313 Connector Types Overview1074
4 Standard Value Table for Electrical Components1081
5 References for Troubleshooting (CAN Bus & Node Outputs)1097
51 CAN BUS trouble or Node Output Trouble1098
511 Trouble CAN BUS or CAN Hardware (#D0308)1099
512 Trouble output short circuit (#D0043)1100
52 Sequence of CAN nodes in the CAN BUS1102
53 Troubleshooting for Relay Monitored Node Outputs1103
531 Relay Check1103
#D0107 – Trouble slew parking brake control 56K250a1104
Example view onto CoDeSys visualization screen for message #D01071106
Wiring Diagram (56K250a & 56K250b) for message #D01071107
532 Output Check1108
#D0108 – Trouble slew parking brake control Output to 56K250a1109
Example view onto CoDeSys visualization screen for message #D01081111
Wiring Diagram (56K250a & 56K250b) for message #D01081112
6 Tables for Testing and Troubleshooting1113
61 Test Value Tables for Transducers1114
611 Pump Press transducers1114
612 Hydraulic oil pressure transducers1115
613 Miscellaneous Pressure Transducers1116
614 Temperature Transducers (signal voltage 0545V)1117
6141 Temperature Transducers – signal voltage 0595V1118
62 Test Value Table for PT100 Temperature Sensors g Centigrade – Ohm1119
63 Hydraulic oil temperature charts1120
64 PTO gear oil temperature charts1120
65 Table of Trouble Codes (K+ monitor)1121
66 Table of 7-segment error codes1127
67 Table of Instruction Messages1128
68 Table of Binary Codes1131
681 Table of Add-On Binary Codes for #D03081136
69 Pump & Valve Controller Fault Codes1137
610 Table of symptom codes1145
6101 Symptoms of E-motors and related parts1145
6102 Symptoms of Hydraulic System1145
6103 Symptoms of mechanical system1146
6104 Symptoms of Additional Systems1146
611 Power Supply1147
612 Cable colour identification1147
7 Troubleshooting by failure codes1149
#D0001 – Trouble Shut-Off (gate) valve1150
View onto the gap of proximity switch 40B0311152
Input signal (digital) of proximity switch 40B031 on REAL TIME MONITOR1153
View onto setting for SHUTDOWN BYPASS on K+ monitor1153
Wiring Diagram (40B031) for message #D0001 (Main gate valve closed)1154
#D0005 – Low hydraulic oil level1155
Wiring Diagram, oil level label, and defined attachment position (#D0005)1157
#D0007 – Trouble hydraulic oil level1158
Wiring Diagram of 40B004 and defined attachment position (#D0007)1159
#D0012 – Central lubrication system grease level too low1160
#D0013 – Slew ring gear lubr system grease level too low1160
Wiring Diagram (binary grease level sensor, refill warning) #D0012 / #D0013 / #D02021163
Wiring Diagram (junction box) for messages #D0012 / #D0013 / #D02021164
#D0020 – Trouble Shut-Off (gate) valve (Start blocked)1165
View onto gap of proximity switch 40B031 (#D0020)1167
Wiring Diagram (40B031) for message #D0020 (Main gate valve closed)1168
Input signal (digital) of proximity switch 40B031 on REAL TIME MONITOR1169
View onto setting for SHUTDOWN BYPASS on KOMTRAX Plus monitor1169
#D0033 – Trouble KOMTRAX Plus Controller1170
#D0034 – Trouble KOMTRAX Plus Display1171
#D0035 – Trouble totally loss gear oil (PTO 1)1172
#D0036 – Trouble totally loss gear oil (PTO 2)1172
View onto the location of sensor 57B175-1/-2 at the PTO (#D0035 & #D0036)1174
Input signal (analog) of PTO-1/2 gear oil sensor 57B175-1/-2 on REAL TIME MONITOR1175
View onto setting screens for SHUTDOWN BYPASS on K+ monitor1175
Wiring Diagram (57B175-1/-2) for messages #D0035 and #D0036 (example drawing)1176
#D0040 – Emergency shut-down pump compartment1177
Emergency circuit line for #D0040, #D0092, #D0093, #D0094, #D0095, #D0097, #D03541179
Digital inputs of emergency stop switches1180
#D0041 – Emergency shut-down pump compartment1181
Emergency circuit line for #D0041, #D0252, #D0253, #D0254, #D0255, #D0258, #D03551183
Digital inputs of emergency stop switches1184
#D0043 – Trouble output short-circuit1185
#D0046 – Reverse travel cut out bypassed by horn1186
D#0047 – Travel cut out by cable drum1188
Screenshot and Wiring Diagram for monitoring motor temperature (D#0047)1189
#D0048 – Trouble emergency safety circuit1190
Wiring Diagram (11K044a) for message #D00481191
#D0049 – Trouble cab heating 11192
#D0050 – Trouble cab heating 21192
View onto heater air inlet & outlet grids in operator’s cab1193
Wiring Diagram – cab heater 1 and 21194
Wiring Diagram – control of heater overheat protection (100°C)1195
#D0051 – Trouble cab heating 11196
#D0052 – Trouble cab heating 21196
View onto heater air inlet & outlet grids in operator’s cab1197
Wiring Diagram – cab heater 1 and 21198
Wiring Diagram – control of heater overheat protection (60°C)1199
#D0053 – Reset emergency safety circuit1200
#D0055 – Trouble monitoring cable drum motor temperature1202
Wiring Diagram (91B979 & 95B980) for message #D00551203
#D0059 – Fire in the switch cabinet1204
Wiring Diagram for fire warning system1205
#D0060 – Fire in the power house1206
Wiring Diagram for fire warning system1207
#D0063 – Trouble monitoring hydraulic oil temp1208
Mounting location of 59B0151209
Wiring Diagram (59B015) for message #D00631210
Monitoring options for hydraulic oil temperature1211
#D0064 – Trouble monitoring hydraulic oil level1212
Wiring Diagram (40B004) for message #D00641214
#D0065 – Very low hydraulic oil level1215
View onto hydraulic oil level label1215
#D0066 – Trouble hydraulic oil temperature1216
Hydraulic oil temperature on REAL TIME MONITOR1217
Hydraulic oil temperature charts for message #D00661218
#D0067 – Trouble battery voltage too high1219
Wiring Diagram (11T080) and component location for #D00671220
Input signal of 11T080 on REAL TIME MONITOR (#D0067)1221
#D0069 – Trouble monitoring oil temperature gear (PTO 1)1222
Mounting location of 57B049-1/-21223
Monitoring options for PTO 1 gear oil temperature1224
Wiring Diagram (57B049-1 & 57B049-2) for messages #D0069 & #D00831225
#D0070 – Trouble oil temperature gear (PTO 1)1226
Location of PTO gear oil level dipstick and temperature sensor 57B049-1/-21228
PTO gear oil adjustment via K+1228
#D0071 – Trouble gear lubrication (PTO 1)1230
Wiring Diagram and location (57B017-1 & 57B017-2) for #D0071 & #D00681231
#D0072 – Trouble monitoring hydraulic oil level1232
Wiring Diagram (40B105) and REAL TIME MONITOR for message #D00721233
#D0076 – Trouble monitoring pressure suction tank1234
Wiring Diagram (59B162) and REAL TIME MONITOR for #D00761235
#D0079 – Trouble monitoring pressure oil cooler 11236
Wiring Diagram (40B165) and REAL TIME MONITOR for #D00791237
#D0080 – Trouble monitoring pressure pre-load valve1238
Wiring Diagram (40B166) and REAL TIME MONITOR for #D00801239
#D0081 – Trouble lubrication system1240
Operation cycles of lubrication systems1241
Wiring Diagram (control signal line “bucket cut off”) for message #D00811242
#D0083 – Trouble monitoring oil temperature (PTO 2)1242
#D0084 – Trouble oil temperature gear (PTO 2)1242
#D0086 – SHUTDOWN1243
#D0090 – Trouble power supply1244
Wiring Diagram and REALT TIME MONITOR for messages #D0090 & #D00991245
Wiring Diagram (battery chargers) for messages #D0090 & #D00991246
#D0091 – Pilot control cut out1248
#D0092 – Emergency shut-down at access ladder1249
#D0093 – Emergency shut-down at valve block1249
#D0094 – Emergency shut-down at hydraulic control panel1249
#D0095 – Emergency shut-down in cabin1249
#D0097 – Emergency shut-down at counterweight1249
#D0099 – Trouble power supply1250
#D0100 – Maintenance Safety Switch1250
Wiring Diagram (emergency line with 50S058) for message #D01001251
#D0107 – Trouble slew parking brake control 56K250a1252
Example view onto CoDeSys visualization screen for message #D01071254
Wiring Diagram (56K250a & 56K250b) for message #D01071255
#D0108 – Trouble slew parking brake control Output to 56K250a1256
Example view onto the CoDeSys visualization screen for message #D01081258
Wiring Diagram (56K250a & 56K250b) for message #D01081259
#D0109 – Trouble slew parking brake control 56K250b1259
#D0110 – Trouble slew parking brake control Output to 56K250b1259
#D0111 – Trouble travel parking brake control 56K251a1260
51K251a-1 & 51K251b-1 (relay check) on REAL TIME MONITOR1260
#D0112 – Trouble travel parking brake control Output to 56K251a1261
51K251a-1 & 51K251b-1 (output check) on REAL TIME MONITOR1261
#D0113 – Trouble travel parking brake control 56K251b1262
#D0114 – Trouble travel parking brake control Output to 56K251b1262
#D0115 – Trouble slew hydraulic brake control 56K252a1262
51K252a-1 & 51K252b-1 (relay check) on REAL TIME MONITOR1262
#D0116 – Trouble slew hydraulic brake control Output to 56K252a1263
51K252a-1 & 51K252b-1 (output check) on REAL TIME MONITOR1263
#D0117 – Trouble slew hydraulic brake control 56K252b1263
#D0118 – Trouble travel parking brake control Output to 56K251b1263
#D0141 – Trouble monitoring X2-pressure1264
Wiring Diagram (57B086) and monitoring screen for message #D01411265
#D0147 – Trouble monitoring gear lubrication (PTO 1)1266
#D0149 – Trouble monitoring ambient temperature1270
Wiring Diagram (13B090) and REAL TIME MONITOR for message #D01491271
#D0150 – Trouble monitoring gear lubrication (PTO 2)1272
#D0151 – Trouble monitoring gear (PTO) oil filter 11272
Wiring Diagram (57B027-1 & 57B027-2) for messages #D0151 and #D01931274
#D0154 – Trouble monitoring return oil filter1275
Wiring Diagram (40B163) and monitoring screen for message #D01541277
#D0155 – Trouble monitoring leak oil filter1278
Wiring Diagram (40B164) and monitoring screen for message #D01551280
#D0159 – Trouble monitoring breather filter1281
Wiring Diagram and monitoring screen for message #D01591283
#D0161 – Trouble monitoring battery voltage1284
11T080 on the REAL TIME MONITOR1285
Wiring Diagram (11T080) and component location for message #D01611286
#D0165 – Trouble breather filter hydraulic oil tank1288
Location of 40B024 and oil level label for message #D01651289
#D0166 – Trouble oil filter gear (PTO 1)1290
View onto PTO gear oil filter with pressure sensor 57B027-1/-2 (#D0166 & #D0191)1291
#D0169 – Trouble return oil filter hydraulic oil tank1292
40B163 on REAL TIME MONITOR (#D0169)1293
#D0170 – Trouble leak oil filter hydraulic oil tank1294
40B164 on the REAL TIME MONITOR (#D0170)1295
#D0176 – Trouble battery voltage too low1296
Real Time Monitor (11T080) for message #D01761297
Wiring Diagram (11T080) and component location for message #D01761298
Wiring Diagram (battery chargers) for message #D01761299
#D0180 – Trouble pilot pressure X2 too low1300
Valve cartridge block with X2 pressure sensor 57B086 for message #D01801301
#D0181 – Trouble pilot pressure X2 too high1302
Valve cartridge block with X2 pressure sensor 57B086 (X2 pressure too high)1303
#D0184 – Central lubrication system empty1304
Grease level CLS 1 & SLS & CLS 2 on REAL TIME MONITOR1306
#D0185 – Trouble central lubrication system1307
Allocation of vent valves and end-line switches1308
Action chart for lube cycles1309
View onto the vent valve (62Q507a / 62Q509a / 62Q642a)1310
Wiring Diagram (60B043 & 62B046 & 80B043) for #D0185 & #D0188 & #D02031311
#D0186 – Trouble central lubrication system1312
Allocation of vent valves1312
Action chart for lube cycles1313
View onto vent valve (62Q507a / 62Q509a / 62Q642a)1314
#D0187 – Slew ring gear lubrication system empty1315
#D0188 – Trouble slew ring gear lubrication system1315
#D0189 – Trouble slew ring gear lubrication system1315
#D0191 – Trouble oil filter gear (PTO 2)1315
#D0193 – Trouble monitoring gear (PTO) oil filter 21315
#D0201 – Attachment lubrication system empty1315
#D0202 – Attachment lubrication system grease level too low1315
#D0203- Trouble attachment lubrication system1315
#D0204 – Trouble attachment lubrication system1315
#D0210 – Trouble electric motor 1 winding temperature1316
#D0211 – Trouble electric motor 2 winding temperature1316
Wiring Diagram (motor 1 winding temperature monitoring) for #D02101317
Wiring Diagram (motor 2 winding temperature monitoring) for #D02111318
REAL TIME MONITOR for motor 1/2 winding temperature, #D0210 & #D02111319
#D0212 – Trouble electric motor 1 bearing temperature1320
#D0213 – Trouble electric motor 2 bearing temperature1320
REAL TIME MONITOR for motor 1/2 bearing temperature, #D0212 & #D02131321
Wiring Diagram (motor 1/2 bearing temperature monitoring) for #D0212 & #D02131322
#D0214 – Trouble transformer 1 temperature1323
#D0215 – Trouble transformer 2 temperature1323
Wiring Diagram (temperature control for transformer A), message #D02141324
REAL TIME MONITOR (net-line voltage & transformer temperature) for #D0214 & 2151325
#D0216 – Trouble software not compatible1326
#D0218 – Switch off all motors for running transfer pump1327
#D0220 – Trouble transfer pump motor overheated1328
Wiring Diagram (transfer pump) for message #D02201329
#D0238 – Trouble supply by key switch 11Q0441330
Input signal of 11Q044 on REAL TIME MONITOR (#D0238)1330
Wiring Diagram (11Q044) for message #D02381331
#D0239 – Trouble electrical matter1332
Wiring Diagram (signal input at node 02, X308) for message #D02391334
#D0240 – Trouble hydraulic oil temperature1336
Hydraulic oil temperature charts1337
#D0241 – Motor 1 already running1338
#D0244 – Motor shutdown from ground1339
Input signal of 54S007 & 54S008 on REAL TIME MONITOR (#D0244)1340
#D0246 – Hydraulic oil temperature1341
#D0252 – Emergency shut-down at access ladder1342
#D0253 – Emergency shut-down at valve block1342
#D0254 – Emergency shut-down at hydraulic control panel1342
#D0255 – Emergency shut-down in cabin1342
#D0256 – Operator warning system1342
#D0257 – Hydraulic oil temperature1343
#D0258 – Emergency shut-down at counterweight1343
#D0261 – Maintenance Safety Switch1344
#D0262 – Trouble screen at hydr cooler entry clogged1345
40B166 and 40B165 on REAL TIME MONITOR (#D0262)1345
Location of 40B166 and 40B165 at the hydraulic oil tank (message #D0262)1346
Wiring Diagram (40B166 & 40B165) for message #D02621347
#D0263 – Trouble monitoring motor 1 bearing temperature1348
#D0264 – Trouble monitoring motor 2 bearing temperature1348
View onto terminal box motor 11349
Wiring Diagram (motor 1/2 bearing temperature) for #D0263 & #D02641350
#D0265 – Trouble monitoring emergency voltage1351
Wiring Diagram and monitoring (12T082) for message #D02651353
#D0266 – Trouble emergency voltage too high1354
Wiring Diagram and monitoring (12T082) for message #D02661355
Wiring Diagram (13T003) for message #D02661356
#D0267 – Trouble emergency voltage too low1357
Wiring Diagram and monitoring (12T082) for message #D02671358
Wiring Diagram (13T003) for message #D02671359
#D0270 – Trouble monitoring motor 1 current1360
#D0271 – Trouble monitoring motor 2 current1360
Wiring Diagram (12T431) for messages #D0270 and #D02711363
#D0272 – Trouble monitoring high voltage1364
Wiring Diagram (12T431) for messages #D02721366
#D0274 – Trouble monitoring motor 1 winding temperature1368
#D0276 – Trouble monitoring motor 2 winding temperature1368
View onto terminal box motor 11369
Wiring Diagram (motor 1 winding temp monitoring) for message #D02741370
Wiring Diagram (motor 2 winding temp monitoring) for message #D02761371
#D0277 – Trouble high voltage capacitor 11372
Wiring Diagram capacitor pressure monitoring and monitoring screen (motor 1)1373
#D0278 – Earth fault tripped1374
#D0281 – Ground leakage tripped1375
Wiring Diagram and monitoring screen (12F431) for message #D02811375
#D0283 – Trouble monitoring motor 1 power1376
#D0284 – Trouble monitoring motor 2 power1376
Copy from User Instruction 12P004-1/-21377
Example view onto 12P004-1/-21378
Wiring Diagram (12P004-1 & 12P004-2) for messages #D0283 & #D02841379
#D0285 – Trouble motor 11380
#D0286 – Trouble motor 21380
Wiring Diagram (motor protection relays & node inputs) for message #D0285/2861381
Wiring Diagram (motor 1/2 protection relay) for messages #D0285/2861382
#D0287 – Trouble 3 phase current rotation direction1383
Wiring Diagram and phase sequence relay monitoring for message #D02871384
#D0288 – Trouble restart motor 1, temperature too high1385
#D0289 – Trouble restart motor 2, temperature too high1385
#D0290 – Trouble motor main relay 11386
Wiring Diagram (12K460/12K461) for messages #D0290 & #D03061387
Wiring Diagram (12K403a) for messages #D0290 & #D03061388
Wiring Diagram (signal input 32Q701-1/-2) for messages #D0290 & #D03061389
#D0291 – Reverse travel cut out by cable drum1390
Wiring Diagram (91B904a, 91B911, 91B919) for message #D02911391
#D0292 – Reverse travel left track cut out by cable drum1392
#D0293 – Reverse travel right track cut out by cable drum1392
Wiring Diagram (diagonal cable pull) for messages #D0292 & #D02931393
#D0294 – Forward travel cut out by cable drum1394
Wiring Diagram (91B904b) for message #D02941395
#D0295 – Trouble temperature cab base1396
Cab base temperature on REAL TIME MONITOR (#D0295)1396
Wiring Diagram (12B001 and 32B802) for messages #D0295 and #D02961397
#D0296 – Trouble temperature high voltage cabinet1398
HV-cabinet temperature on REAL TIME MONITOR (#D0296)1398
#D0301 – Trouble high voltage supply was interrupted1399
Motor voltage (12T431-3) on REAL TIME MONITOR (#D0301)1399
Wiring Diagram 12T431 – HV monitoring at pin 161400
Wiring Diagram 12T431 (continued) for message #D03011401
#D0304 – Start Motor 1 blocked1402
#D0305 – Start Motor 2 blocked1402
#D0307 – Attention ! Cable drum !1403
#D0308 – Trouble CAN-BUS or CAN-Hardware1404
#D0309 – Trouble ladder up 56K253a1407
Ladder (stairway) up 56K253a & 56K253b (relay check) on REAL TIME MONITOR1407
#D0310 – Trouble ladder up Output to 56K253a1408
Ladder (stairway) up 56K253a & 56K253b (output check) on REAL TIME MONITOR1408
#D0311 – Trouble ladder up redundant 56K253b1409
#D0312 – Trouble ladder up redundant Output to 56K253b1409
#D0313 – Trouble ladder down 56K254a1409
Ladder (stairway) down 56K254a & 56K254b (relay check) on REAL TIME MONITOR1409
#D0314 – Trouble ladder down Output to 56K254a1410
Ladder (stairway) down 56K254a & 56K254b (output check) on REAL TIME MONITOR1410
#D0315 – Trouble ladder down redundant 56K254b1410
#D0316 – Trouble ladder down redundant Output to 56K254b1410
#D0329 – Protection switch tripped1411
Additional protection switches on REAL TIME MONITOR (#D0329)1411
#D0334 -Trouble cab heater contactor1412
Wiring Diagram for cab heating – 3 step heater regulation1413
Wiring Diagram – additional cab heater (20E002) at cab wall1414
Wiring Diagram – operation panel 20S026a1415
#D0335 -Trouble cab heater safety relay1416
Wiring Diagram (heater safety relays) for message #D03351418
Temperature control (100°C) for heater on cabin wall1419
#D0337 – Trouble motor on control 12K408a-11420
12K408a-1/-2 & 12K408b-1/-2 (relay check) on REAL TIME MONITOR1420
#D0338 – Trouble motor on control Output to 12K408a-11421
12K408a-1/-2 & 12K408b-1/-2 (output check) on REAL TIME MONITOR1421
#D0354 – Emergency shut-down cable drum1422
#D0355 – Emergency shut-down cable drum1422
#D0356 – Trouble monitoring slew speed1422
Slew speed (11B144) on REAL TIME MONITOR1422
Wiring Diagram (11B144) for message #D03561423
#D0357 – Trouble monitoring slew angle1424
Slew angle (11B145) on REAL TIME MONITOR1424
Wiring Diagram (11B145) for message #D03571425
8 Troubleshooting for PUMP/VALVE controller fault codes1427
DA2UKR – Communication failure PLC <-> KOMTRAX Plus controller1428
DBB0KK – KOMTRAX Plus source voltage error1430
Wiring Diagram K+ controller 24V supply and GND connections1431
DBB0KQ – Connector sel error1432
DAFQKR – Communication failure MH800 <-> KOMTRAX Plus controller1434
Wiring Diagram for message DAFQKR1435
DA2QKR – CAN2 Discon (Pump1 Con)1436
Wiring Diagram for message DA2QKR1437
DBZQKR – CAN2 Discon (Pump2 Con)1438
Wiring Diagram for message DBZQKR1439
DBWQKR – CAN2 Discon (Valve/M Con)1440
Wiring Diagram for message DBWQKR1441
DBXQKR – CAN2 Discon (Valve/S1 Con)1442
Wiring Diagram for message DBXQKR1443
DBYQKR – CAN2 Discon (Valve/S2 Con)1444
Wiring Diagram for message DBYQKR1445
DXAAKA – Solenoid-1(Pump-1) open circuit1446
DXABKA – Solenoid-2(Pump-2) open circuit1446
DXACKA – Solenoid-3(Pump-3) open circuit1446
DXADKA – Solenoid-4(Pump-4) open circuit1446
DXAEKA – Solenoid-5(Pump-5) open circuit1446
DXAFKA – Solenoid-6(Pump-6) open circuit1446
DXAGKA – Solenoid-7(Pump-7) open circuit1446
DXAHKA – Solenoid-8(Pump-8) open circuit1446
DXAJKA – Solenoid-9(Pump-9) open circuit1446
DXAKKA – Solenoid-10(Pump-10) open circuit1446
DXALKA – Solenoid-11(Pump-11) open circuit1446
DXAMKA – Solenoid-12(Pump-12) open circuit1446
Wiring Diagram – EPC valve control (PUMP1 controller)1448
Wiring Diagram – EPC valve control (PUMP2 controller)1449
DXAAKB – Solenoid-1(Pump-1) short circuit1450
DXABKB – Solenoid-2(Pump-2) short circuit1450
DXACKB – Solenoid-3(Pump-3) short circuit1450
DXADKB – Solenoid-4(Pump-4) short circuit1450
DXAEKB – Solenoid-5(Pump-5) short circuit1450
DXAFKB – Solenoid-6(Pump-6) short circuit1450
DXAGKB – Solenoid-7(Pump-7) short circuit1450
DXAHKB – Solenoid-8(Pump-8) short circuit1450
DXAJKB – Solenoid-9(Pump-9) short circuit1450
DXAKKB – Solenoid-10(Pump-10) short circuit1450
DXALKB – Solenoid-11(Pump-11) short circuit1450
DXAMKB – Solenoid-12(Pump-12) short circuit1450
Wiring Diagram – EPC valve control (PUMP1 controller)1452
Wiring Diagram – EPC valve control (PUMP2 controller)1453
DHPEMA – Pump-1/2 pressure sensor abnormality1454
DHPGMA – Pump-3/4 pressure sensor abnormality1454
DHPJMA – Pump-5/6 pressure sensor abnormality1454
DHPLMA – Pump-7/8 pressure sensor abnormality1454
DHPNMA – Pump-9/10 pressure sensor abnormality1454
DHPQMA – Pump-11/12 pressure sensor abnormality1454
Wiring Diagram – PWR & GND supply for pressure transducers (pumps 13)1456
Wiring Diagram – PWR & GND supply for pressure transducers (pumps 46)1457
DA25KP – 5V sensor1 power abnormality1458
DBZ5KP – 5V sensor1 power abnormality1458
Wiring Diagram – 5V sensor power supply (PC1_5V_1) for message DA25KP1459
Wiring Diagram – 5V sensor power supply (PC2_5V_1) for message DBZ5KP1460
DA22KK – Pump Solenoid Power Low Error1461
DBZ2KK – Pump2 Solenoid Power Low Error1461
Wiring Diagram – PUMP1/2 solenoid power1462
DA29KQ – Model Selection Abnormality1463
DBZ9KQ – Model Selection Abnormality1463
Wiring Diagram – PUMP1 machine selections1465
Wiring Diagram – PUMP2 machine selections1466
DA2YKQ – Motor/Engine Selection Abnormality1467
DBZWKQ – Motor/Engine Selection Abnormality1467
Wiring Diagram – Motor/engine selection PUMP1 controller1468
Wiring Diagram – Motor/engine selection PUMP2 controller1469
DA20KQ – Pump1 Con Selection Abnormality1470
DBZ0KQ – Pump2 Con Selection Abnormality1470
Wiring Diagram – Controller selection PUMP1 controller1472
Wiring Diagram – Controller selection PUMP2 controller1473
DA2XKQ – Motor1 Frequency Select Abnormality1474
DBZXKQ – Motor2 Frequency Select Abnormality1474
Wiring Diagram – Controller selection PUMP1 controller (frequency)1476
Wiring Diagram – Controller selection PUMP2 controller (frequency)1477
DA20MC – Pump1 Con Error1478
DBZ0MC – Pump2 Con Error1478
DGT3MA – PTO1 oil temperature sensor abnormality1479
DGT8MA – PTO2 oil temperature sensor abnormality1479
Wiring Diagram (57B049-1 & 57B049-2) for DGT3MA & DGT8MA & #D0069 & #D00831480
Mounting location of 57B049-1/21481
DGH2MA – Hydraulic oil temp sensor abnormality1482
Wiring Diagram (59B015) for messages DGH2MA & #D00631483
DJK3MA – Motor voltage sensor abnormality1484
Wiring Diagram (12T431) for messages DJK3MA & #D02721485
DJK4MA – Motor1 current sensor abnormality1486
DJK6MA – Motor2 current sensor abnormality1486
Wiring Diagram (12T431) for messages DJK4MA, DJK6MA & #D0270, #D02711487
G@00KP – Motor1 voltage low error1488
Wiring Diagram (12T431) for message G@00KP1490
DWNCKA – Hyd oil cooler fan pump1 solenoid open circuit1491
DWNUKA – Hyd oil cooler fan pump2 solenoid open circuit1491
Wiring Diagram – Hydraulic oil cooler fan pump1/2 EPC control1493
DWNCKB – Hyd oil cooler fan pump1 solenoid short circuit1494
DWNUKB – Hyd oil cooler fan pump2 solenoid short circuit1494
Wiring Diagram – Hydraulic oil cooler fan pump1/2 EPC control1495
DXQ0KA – X1 pilot pressure pump1 solenoid open circuit1496
DXQ1KA – X1 pilot pressure pump2 solenoid open circuit1496
Wiring Diagram – control oil (X1) pressure pump1/2 EPC control1498
DXQ0KB – X1 pilot pressure pump1 solenoid short circuit1500
DXQ1KB – X1 pilot pressure pump2 solenoid short circuit1500
Wiring Diagram – control oil (X1) pressure pump1/2 EPC control1501
DDABMC – Lock lever switch abnormality1502
Wiring Diagram – lock lever switch 20S105 (DDABMC)1503
DBW9KQ – Model Selection Abnormality1504
Wiring Diagram – VALVE0 machine selection1505
DBWZKQ – Lever control selection abnormality1506
Wiring Diagram – VALVE0 lever control selection1507
DBWYKQ – Attachment selection abnormality1508
Wiring Diagram – VALVE0 attachment selection1509
DBW2KK – Solenoid Power Low Error(VALVE/M)1510
Wiring Diagram for message DBW2KK1512
DBW0KQ – VALVE/M Con Selection Abnormality1514
Wiring Diagram – VALVE0 controller selection1515
DBW0MA – VALVE/M Con Error1516
DKURMA – R lever right-left potentio abnormality1518
Wiring Diagram – R lever right-left potentiometer input (DKURMA)1519
DKUSMA – R lever right-left redu pot abnorm(VALVE/M)1520
Wiring Diagram – R lever redundant right-left potentiometer input (DKUSMA)1521
DKUQL8 – R lever right-left potentio error1522
Wiring Diagram – R lever main + redundant right-left signal voltage at VALVE01524
DKUQL4 – R lever right-left sig mismatch(VALVE/M)1525
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE11527
DKUNMA – R lever front-back potentio abnormality1528
Wiring Diagram – R lever front-back potentiometer input (DKUNMA)1529
DKUPMA – R lever front-back redu pot abnorm(VALVE/M)1530
Wiring Diagram – R lever redundant front-back potentiometer input at VALVE01531
DKUML8 – R lever front-back potentio error1532
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8)1534
DKUML4 – R lever front-back sig mismatch(VALVE/M)1535
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE11537
DKUXMA – L lever right-left potentio abnormality1538
Wiring Diagram – L lever right-left potentiometer input (DKUXMA)1539
DKUYMA – L lever right-left redu pot abnorm(VALVE/M)1540
Wiring Diagram – L lever redundant right-left potentiometer input (DKUYMA)1541
DKUWL8 – L lever right-left potentio error1542
Wiring Diagram – L lever main + redundant right-left signal voltage at VALVE01544
DKUWL4 – L lever right-left sig mismatch(VALVE/M)1545
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE11547
DKUUMA – L lever front-back potentio abnormality1548
Wiring Diagram – L lever front-back potentiometer input (DKUUMA)1549
DKUVMA – L lever front-back redu pot abnorm(VALVE/M)1550
Wiring Diagram – L lever front-back redundant potentiometer input (VALVE0)1551
DKUTL8 – L lever front-back potentio error1552
Wiring Diagram – L lever front-back potentio error (DKUTL8)1554
DKUTL4 – L lever front-back sig mismatch(VALVE/M)1555
Wiring Diagram – L lever front-back sig mismatch(VALVE/M) for DKUTL41557
DKW1MA – R pedal potentio abnormality1558
Wiring Diagram – R pedal potentio abnormality (DKW1MA)1559
DKW2MA – R pedal redundant pot abnormality(VALVE/M)1560
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA1561
DKW0L8 – R pedal potentio error1562
Wiring Diagram – R pedal potentio error (DKW0L8)1563
DKW0L4 – R pedal signal mismatch(VALVE/M)1564
Wiring Diagram – R pedal signal mismatch(VALVE/M) for DKW0L41566
DKW4MA – L pedal potentio abnormality1568
Wiring Diagram – L pedal potentio abnormality (DKW4MA)1569
DKW5MA – L pedal redundant pot abnormality(VALVE/M)1570
Wiring Diagram – L pedal redundant pot abnormality(VALVE/M) for DKW5MA1571
DKW3L8 – L pedal potentio error1572
Wiring Diagram – L pedal potentio error (DKW3L8)1573
DKW3L4 – L pedal signal mismatch(VALVE/M)1574
Wiring Diagram – L pedal signal mismatch(VALVE/M) for DKW3L41576
DKW7MA – Clam open potentio abnormality1578
Wiring Diagram – Clam open potentio abnormality (DKW7MA)1579
DKW8MA – Clam open redu pot abnormality(VALVE/M)1580
Wiring Diagram – Clam open redu pot abnormality(VALVE/M) for DKW8MA1581
DKW6L8 – Clam open potentio error1582
Wiring Diagram – Clam open potentio error (DKW6L8)1583
DKW6L4 – Clam open signal mismatch(VALVE/M)1584
Wiring Diagram – Clam open signal mismatch(VALVE/M) (DKW6L4)1585
DKWAMA – Clam close potentio abnormality1586
Wiring Diagram – Clam close potentio abnormality (DKWAMA)1587
DKWBMA – Clam close redundant pot abnorm(VALVE/M)1588
Wiring Diagram – Clam close redundant pot abnorm(VALVE/M) for DKWBMA1589
DKW9L8 – Clam close potentio error1590
Wiring Diagram – Clam close potentio error (DKW9L8)1591
DKW9L4 – Clam close signal mismatch(VALVE/M)1592
Wiring Diagram – Clam close signal mismatch(VALVE/M) for DKW9L41593
DKWDMA – Hydraulic slew brake potentio abnormality1594
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA)1595
DKWEMA – Hyd slew brake redu pot abnorm(VALVE/M)1596
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/M) for DKWEMA1597
DKWCL8 – Hydraulic slew brake potentio error1598
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8)1599
DKWCL4 – Hyd slew brake sig mismatch(VALVE/M)1600
Wiring Diagram – Hyd slew brake sig mismatch(VALVE/M) for DKWCL41601
DXNHKA – Travel1 left epc solenoid open circuit1602
DXN3KA – Stick1 epc solenoid open circuit1602
DXNJKA – Bucket1 epc solenoid open circuit1602
DXN2KA – Boom1 epc solenoid open circuit1602
DXN5KA – Clam2 epc solenoid open circuit1602
DXN8KA – Bucket2 epc solenoid open circuit1602
DXN4KA – Boom2 epc solenoid open circuit1602
DXN6KA – Stick2 epc solenoid open circuit1602
DXNKKA – Travel3 right epc solenoid open circuit1602
DXNCKA – Boom3 epc solenoid open circuit1602
DXNBKA – Bucket3 epc solenoid open circuit1602
DXNLKA – Stick3 epc solenoid open circuit1602
DXNMKA – Slew4 epc solenoid open circuit1602
Details of the above 6-digit failure codes1603
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623 (block I)1604
Wiring Diagram for EPC 61K624 – 61K625 – 61K626 – 61K627 (block II)1605
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 – 61K631 (block III)1606
Wiring Diagram for EPC 61K632 (block IV)1607
Monitoring screens for EPC with open circuit (block IIV)1608
DXNHKB – Travel1 left epc solenoid short circuit1609
DXN3KB – Stick1 epc solenoid short circuit1609
DXNJKB – Bucket1 epc solenoid short circuit1609
DXN2KB – Boom1 epc solenoid short circuit1609
DXN5KB – Clam2 epc solenoid short circuit1609
DXN8KB – Bucket2 epc solenoid short circuit1609
DXN4KB – Boom2 epc solenoid short circuit1609
DXN6KB – Stick2 epc solenoid short circuit1609
DXNKKB – Travel3 right epc solenoid short circuit1609
DXNCKB – Boom3 epc solenoid short circuit1609
DXNBKB – Bucket3 epc solenoid short circuit1609
DXNLKB – Stick3 epc solenoid short circuit1609
DXNMKB – Slew4 epc solenoid short circuit1609
Details of the above 6-digit failure codes1610
DXNHKY – Travel1 left epc solenoid hot short circuit1611
DXN3KY – Stick1 epc solenoid hot short circuit1611
DXNJKY – Bucket1 epc solenoid hot short circuit1611
DXN2KY – Boom1 epc solenoid hot short circuit1611
DXN5KY – Clam2 epc solenoid hot short circuit1611
DXN8KY – Bucket2 epc solenoid hot short circuit1611
DXN4KY – Boom2 epc solenoid hot short circuit1611
DXN6KY – Stick2 epc solenoid hot short circuit1611
DXNKKY – Travel3 right epc hot solenoid short circuit1611
DXNCKY – Boom3 epc solenoid hot short circuit1611
DXNBKY – Bucket3 epc solenoid hot short circuit1611
DXNLKY – Stick3 epc solenoid hot short circuit1611
DXNMKY – Slew4 epc solenoid hot short circuit1611
Details of the above 6-digit failure codes1612
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623 (block I)1613
Wiring Diagram for EPC 61K624 – 61K625 – 61K626 – 61K627 (block II)1614
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 – 61K631 (block III)1615
Wiring Diagram for EPC 61K632 (block IV)1616
D5Y3KB – Boom down on/off signal short circuit1617
D5Y2KB – Boom up on/off signal short circuit1617
D5Y5KB – Stick in on/off signal short circuit1617
D5Y4KB – Stick out on/off signal short circuit1617
D5Y7KB – Bucket dump on/off signal short circuit1617
Wiring Diagram – VALVE0 controller ON/OFF signal output to node 21618
DBW5MA – 5V sensor1 power abnormality1619
Wiring Diagram – 5V_1 power supply and GND_1 output at VALVE01620
DBW6MA – 5V sensor2 power abnormality1622
Wiring Diagram – 5V_2 power supply and GND_2 output at VALVE01623
DBX9KQ – Model Selection Abnormality1626
Wiring Diagram – VALVE1 machine selections1627
DBXZKQ – Lever Control Selection Abnormality1628
Wiring Diagram – VALVE1 lever control selection1629
DBXYKQ – Attachment selection abnormality1630
Wiring Diagram – VALVE1 attachment selection1631
DBX2KK – Solenoid Power Low Error(VALVE/S1)1632
Wiring Diagram for message DBX2KK – Solenoid Power Low Error(VALVE/S1)1634
Wiring Diagram for message DBX2KK – PPC safety circuit1635
DBX0KQ – VALVE/S1 Con Selection Abnormality1636
Wiring Diagram – VALVE1 controller selection1637
DBX0MA – VALVE/S1 Con Error1638
DKWHMA – R lever right-left redu pot abnorm(VALVE/S1)1640
Wiring Diagram – R lever redundant right-left potentiometer input (DKWHMA)1641
DKWFL4 – R lever right-left sig mismatch(VALVE/S1)1642
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE11643
DKWLMA – R lever front-back redu pot abnorm(VALVE/S1)1644
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA)1645
DKWJL4 – R lever front-back sig mismatch(VALVE/S1)1646
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE11647
DKWPMA – L lever right-left redu pot abnorm(VALVE/S1)1648
Wiring Diagram – L lever redundant right-left potentiometer input at VALVE11649
DKWML4 – L lever right-left sig mismatch(VALVE/S1)1650
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE11651
DKWSMA – L lever front-back redu pot abnorm(VALVE/S1)1652
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/S1) for DKWSMA1653
DKWQL4 – L lever front-back sig mismatch(VALVE/S1)1654
Wiring Diagram – L lever front-back sig mismatch (VALVE1) for DKWQL41655
DKWVMA – R pedal red pot abnormality(VALVE/S1)1656
Wiring Diagram – R pedal red pot abnormality (VALVE1) for DKWVMA1657
DKWTL4 – R pedal signal mismatch(VALVE/S1)1658
Wiring Diagram – R pedal signal mismatch(VALVE/S1) for DKWTL41659
DKWYMA – L pedal red pot abnormality(VALVE/S1)1660
Wiring Diagram – L pedal red pot abnormality(VALVE/S1) for DKWYMA1661
DKWWL4 – L pedal signal mismatch(VALVE/S1)1662
Wiring Diagram – L pedal signal mismatch(VALVE/S1) for DKWWL41663
DKX2MA – Clam open redu pot abnormality(VALVE/S1)1664
Wiring Diagram – Clam open redu pot abnormality(VALVE/S1)) for DKX2MA1665
DKX0L4 – Clam open signal mismatch(VALVE/S1)1666
Wiring Diagram – Clam open signal mismatch(VALVE/S1) for DKX0L41667
DKX5MA – Clam close redu pot abnormality(VALVE/S1)1668
Wiring Diagram – Clam close redu pot abnormality(VALVE/S1) for DKX5MA1669
DKX3L4 – Clam close signal mismatch(VALVE/S1)1670
Wiring Diagram – Clam close signal mismatch(VALVE/S1) for DKX3L41671
DKX8MA – Hyd slew brake redu pot abnorm(VALVE/S1)1672
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/S1) for DKX8MA1673
DKX6L4 – Hyd slew brake signal mismatch(VALVE/S1)1674
Wiring Diagram – Hyd slew brake signal mismatch(VALVE/S1) for DKX6L41675
DWKAKA – Travel1 left forward sol open circuit1676
DWKEKA – Travel1 left backward sol open circuit1676
DWBJKA – Stick1 out solenoid open circuit1676
DWBNKA – Stick1 in solenoid open circuit1676
DWASKA – Bucket1 fill solenoid open circuit1676
DWAWKA – Bucket1 dump solenoid open circuit1676
DWBAKA – Boom1 up solenoid open circuit1676
DWBEKA – Boom1 down solenoid open circuit1676
Details of above 6-digit failure codes1676
Monitoring screens for directional solenoids – VALVE11677
Wiring Diagram – directional solenoids at remote control block 451 (VALVE1)1678
DWKAKB – Travel1 left forward sol short circuit1679
DWKEKB – Travel1 left backward sol short circuit1679
DWBJKB – Stick1 out solenoid short circuit1679
DWBNKB – Stick1 in solenoid short circuit1679
DWASKB – Bucket1 fill solenoid short circuit1679
DWAWKB – Bucket1 dump solenoid short circuit1679
DWBAKB – Boom1 up solenoid short circuit1679
DWBEKB – Boom1 down solenoid short circuit1679
Details of above 6-digit failure codes1679
Monitoring screens for directional solenoids – VALVE11680
Wiring Diagram – directional solenoids at remote control block 451 (VALVE1)1681
DWKAKY – Travel1 left forward sol hot short circuit1682
DWKEKY – Travel1 left backward sol hot short circuit1682
DWBJKY – Stick1 out solenoid hot short circuit1682
DWBNKY – Stick1 in solenoid hot short circuit1682
DWASKY – Bucket1 fill solenoid hot short circuit1682
DWAWKY – Bucket1 dump solenoid hot short circuit1682
DWBAKY – Boom1 up solenoid hot short circuit1682
DWBEKY – Boom1 down solenoid hot short circuit1682
Details of above 6-digit failure codes1682
Monitoring screens for directional solenoids – VALVE11683
Wiring Diagram – directional solenoids at remote control block 451 (VALVE1)1684
DWBXKA – Clam2 close solenoid open circuit1685
DWBTKA – Clam2 open solenoid open circuit1685
DWATKA – Bucket2 fill solenoid open circuit1685
DWAXKA – Bucket2 dump solenoid open circuit1685
DWBBKA – Boom2 up solenoid open circuit1685
DWBFKA – Boom2 down solenoid open circuit1685
Details of above 6-digit failure codes1685
Monitoring screens for directional solenoids – VALVE11687
Wiring Diagram – directional solenoids at remote control block 452 (VALVE1)1688
DWBXKB – Clam2 close solenoid short circuit1689
DWBTKB – Clam2 open solenoid short circuit1689
DWATKB – Bucket2 fill solenoid short circuit1689
DWAXKB – Bucket2 dump solenoid short circuit1689
DWBBKB – Boom2 up solenoid short circuit1689
DWBFKB – Boom2 down solenoid short circuit1689
Details of above 6-digit failure codes1689
Monitoring screens for directional solenoids – VALVE11691
Wiring Diagram – directional solenoids at remote control block 452 (VALVE1)1692
DWBXKY – Clam2 close solenoid hot short circuit1693
DWBTKY – Clam2 open solenoid hot short circuit1693
DWATKY – Bucket2 fill solenoid hot short circuit1693
DWAXKY – Bucket2 dump solenoid hot short circuit1693
DWBBKY – Boom2 up solenoid hot short circuit1693
DWBFKY – Boom2 down solenoid hot short circuit1693
Details of above 6-digit failure codes1693
Monitoring screens for directional solenoids – VALVE11694
Wiring Diagram – directional solenoids at remote control block 452 (VALVE1)1695
D5Y6KB – Bucket fill on/off signal short circuit1696
D5Y9KB – Clam close on/off signal short circuit1696
D5YAKB – Hyd slew brake order signal short circuit1696
D5Y0KB – Slew left on/off signal short circuit1696
D5Y1KB – Slew right on/off signal short circuit1696
Wiring Diagram – VALVE1 controller ON/OFF signal output to node 21697
D5YAKY – Hyd slew brake order signal hot short circuit1698
Wiring Diagram – VALVE1 controller ON/OFF signal output to node 21699
DBY9KQ – Model Selection Abnormality1700
Wiring Diagram for message DBY9KQ1701
DBYZKQ – Lever Control Selection Abnormality1702
Wiring Diagram for message DBYZKQ1703
DBYYKQ – Attachment selection abnormality1704
Wiring Diagram for message DBYYKQ1705
DBY2KK – Solenoid Power Low Error(VALVE/S2)1706
Wiring Diagram for message DBY2KK1708
Wiring Diagram for message DBy2KK – PPC safety circuit1709
DBY0KQ – VALVE/S2 Con Selection Abnormality1710
Wiring Diagram for message DBY0KQ1711
DBY0MA – VALVE/S2 Con Error1712
DWBKKA – Stick2 out solenoid open circuit1713
DWBKKB – Stick2 out solenoid short circuit1713
DWBPKA – Stick2 in solenoid open circuit1713
DWBPKB – Stick2 in solenoid short circuit1713
Details of above 6-digit failure codes1713
Wiring Diagram – 61K627a/b open circuit or short circuit to GND1715
DWBKKY – Stick2 out solenoid hot short circuit1716
DWBPKY – Stick2 in solenoid hot short circuit1716
Details of above 6-digit failure codes1716
Wiring Diagram – 61K627a/b hot short circuit1717
DWKQKA – Travel3 right backward sol open circuit1718
DWKLKA – Travel3 right forward sol open circuit1718
DWBCKA – Boom3 up solenoid open circuit1718
DWBGKA – Boom3 down solenoid open circuit1718
DWAUKA – Bucket3 fill solenoid open circuit1718
DWAYKA – Bucket3 dump solenoid open circuit1718
DWBLKA – Stick3 out solenoid open circuit1718
DWBQKA – Stick3 in solenoid open circuit1718
DWARKA – Slew4 right solenoid open circuit1718
DWAMKA – Slew4 left solenoid open circuit1718
Details of above 6-digit failure codes1718
Monitoring screens for directional solenoids (453 & 43) – VALVE21720
Wiring Diagram – directional solenoids 61K628a/b & 61K629a/b1721
Wiring Diagram – directional solenoids 61K630a/b & 61K631a/b1722
Wiring Diagram – directional solenoids 61K632a/b1723
DWKQKB – Travel3 right backward sol short circuit1724
DWKLKB – Travel3 right forward sol short circuit1724
DWBCKB – Boom3 up solenoid short circuit1724
DWBGKB – Boom3 down solenoid short circuit1724
DWAUKB – Bucket3 fill solenoid short circuit1724
DWAYKB – Bucket3 dump solenoid short circuit1724
DWBLKB – Stick3 out solenoid short circuit1724
DWBQKB – Stick3 in solenoid short circuit1724
DWARKB – Slew4 right solenoid short circuit1724
DWAMKB – Slew4 left solenoid short circuit1724
Details of above 6-digit failure codes1724
Monitoring screens for directional solenoids (453 & 43) – VALVE21726
DWKQKY – Travel3 right backward sol hot short circuit1728
DWKLKY – Travel3 right forward sol hot short circuit1728
DWBCKY – Boom3 up solenoid hot short circuit1728
DWBGKY – Boom3 down solenoid hot short circuit1728
DWAUKY – Bucket3 fill solenoid hot short circuit1728
DWAYKY – Bucket3 dump solenoid hot short circuit1728
DWBLKY – Stick3 out solenoid hot short circuit1728
DWBQKY – Stick3 in solenoid hot short circuit1728
DWARKY – Slew4 right solenoid hot short circuit1728
DWAMKY – Slew4 left solenoid hot short circuit1728
Details of above 6-digit failure codes1728
Monitoring screens for directional solenoids (453 & 43) – VALVE21729
DXEDKA – Hyd slew brake epc sol open circuit1730
DXEDKB – Hyd slew brake epc sol short circuit1730
Wiring Diagram for messages DXEDKA & DXEDKB1731
DXEDKY – Hyd slew brake epc sol hot short circuit1732
Wiring Diagram for message DXEDKY1733
D5Z3KB – Travel right backward on/off signal short circuit1734
D5Z5KB – Travel right forward on/off signal short circuit1734
D5Z2KB – Travel left backward on/off signal short circuit1734
D5Z4KB – Travel left forward on/off signal short circuit1734
D5Y8KB – Clam open on/off signal short circuit1734
Wiring Diagram – VALVE2 controller ON/OFF signal output to node 21735
DBZRKR – CAN1 Discon (Pump2 Con)1736
Wiring Diagram for message DBZRKR1737
DBWRKR – CAN1 Discon (Valve/M Con)1738
Wiring Diagram for message DBWRKR1739
DBXRKR – CAN1 Discon (Valve/S1 Con)1740
Wiring Diagram for message DBXRKR1741
DBYRKR – CAN1 Discon (Valve/S2 Con)1742
Wiring Diagram for message DBYRKR1743
9 Troubleshooting by Symptoms1745
91 Symptoms of E-motors and related parts1746
SEM001 – Starting E-motor(s) is not possible1746
Wiring Diagram (main key switch & start buttons) for SEM0011747
SEM002 – Stopping E-motor(s) is not possible1748
Wiring Diagram (motor stop switches) for SEM0021749
SEM003 – E-motor has excessive vibration1750
View onto the coupling for SEM0031751
SEM004 – Abnormal noise coming from E-motor(s)1752
SEM005 – E-motor lacks output (low power)1754
View onto PM CLINIC sheet (power check) for SEM0051755
SEM007 – Motor shuts down during start1756
Wiring Diagram – Motor protection relay 12F404-1/-2 for message SEM0071757
SEM008 – Substation main circuit breaker tripped1758
Net-line supply overview (SEM008)1758
Electric energy consumption (SEM008)1759
Motor current overview with soft start (SEM008)1759
92 Symptoms of the Hydraulic System1760
SHY001 – All work equipment shows lack of power or slow movement (especially “boom up” function)1760
SHY002 – No work equipment, travel or slew movement1762
SHY003 – Work equipment has too much hydraulic drift1763
SHY004 – Work equipment has big time lag1764
SHY005 – Machine deviates during travel movement1765
SHY006 – Machine does not slew1766
Slew brake valve block (SHY006)1767
SHY007 – Slew acceleration is poor1768
SHY008 – Excessive overrun when stopping slew movement1770
SHY009 – Floating system without function (FSA only)1772
SHY010 – Abnormal noise coming from SRV or MRV1773
SHY011 – Track tensioning system without function1774
Track tensioning – overview (SHY011)1775
SHY012 – Stairway does not move, or slow movement1776
SHY013 – Hydraulic driven grease pump does not move1778
SHY014 – Abnormal track chain movement during digging1780
SHY015 – Slew parking brake without function1781
SHY016 – Travel parking brake without function1782
93 Symptoms of Mechanical System1784
SME001 – Abnormal noise around PTO / hydraulic pumps1784
SME002 – There is a big shock when stopping slew movement1786
SME003 – There is a big abnormal noise when moving/stopping slew movement1788
SME004 – Abnormal noise coming from a travel gearbox1790
SME005 – Abnormal noise coming from the work equipment (lack of grease)1792
SME006 – Abnormal idler movement1794
SME007 – Leak at the PTO drive shaft seal1796
94 Symptoms of Additional Systems1798
SAD001 – Air conditioner for cabin does not work1798
View onto the A/C unit (SAD001)1799
SAD002 – Air conditioner LV cabinet does not work1800
SAD003 – Air conditioner HV cabinet does not work1800
View onto an A/C filling and service station1801
SAD004 – CAN BUS failure (message #D0308 displayed)1802
50 DISASSEMBLY & ASSEMBLY1809
TOC 1811
1 Introduction1819
11 Foreword1820
12 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels1821
13 Diagrams and illustrations in this manual1821
14 Procedures for disassembling and assembling in this manual1822
2 Safety1823
21 Overview1825
211 Method of using this manual1825
22 General precautions1827
221 General1827
222 Personal protective clothing1827
223 When using a hammer1828
224 Proper tools1828
225 Personnel1828
226 Fire prevention1829
227 Unauthorized modification1829
23 Precautions for maintenance and repair1830
231 General precautions1830
232 Keep work place clean and tidy1830
233 Precautions when welding1831
234 Precaution with high pressure fluids1831
2341 Handling high pressure hoses and pipes1831
235 Compressed air1831
236 Waste materials1832
3 Superstructure1833
31 Superstructure overview1834
32 Machinery house1836
321 Disconnection plates1838
3211 RH-side disconnection plate [56XH01] – port allocations1838
3212 LH-side disconnection plate [58XH01] – connector allocations1839
322 Machinery house roof1840
3221 Disassembling of the machinery house roof cover plates1842
3222 Assembling of the machinery house roof cover plates1846
323 Lubrication pump station1852
3231 Disassembling of the lubrication pump station1852
3232 Assembling of the lubricating pump station1854
324 Electric motors1856
3241 Disassembling of the electric motor (motor 1 or 2)1856
3242 Assembling of thE electriC motor (motor 1 or 2)1860
325 Final alignment of the electric motors1864
3251 Disassembling of the capacitor assembly1868
3252 Assembling of the capacitor assembly1870
326 Batteries1871
3261 Disassembling of the batteries1871
3262 Assembling of the batteries1873
327 Flexible drive coupling1875
3271 Disassembling of the CENTALINK coupling1875
3272 Assembling of the CENTALINK coupling1877
328 Main pump assemblies1880
3281 Disassembling of the main pump assemblies1881
3282 Assembling of the main pump assemblies1885
329 Universal pump distributor gear box (PTO)1888
3291 Disassembling of the universal pump distributor gear box (PTO)1889
3292 Assembling of the universal pump distributor gear box (PTO)1892
3293 Disassembling of the control and filter plate assemblies1896
3294 Assembling of the control and filter plate assemblies1905
3295 Disassembling of the PTO gear oil pump1913
3296 Assembling of the PTO gear oil pump1915
33 Hydraulic system1918
331 Hydraulic oil cooler assembly1918
3311 Disassembling of hydraulic cooler fan1919
3312 Assembling of hydraulic cooler fan1920
3313 Disassembling of hydraulic cooler fan motor1921
3314 Assembling of hydraulic cooler fan motor1923
3315 Disassembling of the hydraulic oil coolers1925
3316 Assembling of the hydraulic oil coolers1928
3317 Disassembling of the hydraulic oil cooler assembly1931
3318 Assembling of the hydraulic oil cooler assembly1936
332 Hydraulic oil tank1942
3321 Disassembling of the main shut-off valve1944
3322 Assembling of the main shut-off valve1946
3323 Disassembling of the hydraulic oil tank1948
3324 Assembling of the hydraulic oil tank1959
333 Control frame assembly1972
3331 Disassembling of the main control valve blocks I, II and III1973
3332 Assembling of the main control valve blocks I, II and III1977
3333 Disassembling of the main control valve block IV (Slewing)1981
3334 Assembling of the main control valve block IV (Slewing)1983
3335 Disassembling of the high pressure filters at the main control valve blocks1985
3336 Assembling of the high pressure filters at the main control valve blocks1988
3337 Disassembling of the MRV at the main control valve blocks1991
3338 Assembling of the MRV at the main control valve blocks1992
3339 Disassembling of SRV on main control valve block1993
33310 Assembling of SRV on main control valve blocks1994
33311 Disassembling of ACV-/SRV-block on main control valve blocks1995
33312 Assembling of ACV-/SRV-block on main control valve blocks1996
334 Distributor Manifold1998
3341 Disassembling of throttle check valves at the distributor manifold1999
3342 Assembling of throttle check valves at the distributor manifold2001
3343 Disassembling of anti cavitation valves at the distributor manifold2003
3344 Assembling of anti cavitation valves at the distributor manifold2005
3345 Disassembling of the distributor manifold2009
3346 Assembling of the distributor manifold2012
34 Slew system2014
341 Slew gears2014
3411 Disassembling of the slew gear2015
3412 Assembling of the slew gear2018
342 Slew brake valve block2022
3421 Disassembling of the slew brake valve block2022
3422 Assembling of the slew brake valve block2024
343 Hydraulic slew motors2026
3431 Disassembling of the slew motor2026
3432 Assembling of the slew motor2028
344 Slew parking brake2030
3441 Disassembly of the slew parking brake (id code GFB 174)2031
3442 Assembly of the slew parking brake (id code GFB 174)2034
3443 Disassembling of the slew parking brake (id code 89DS03)2037
3444 Assembling of the slew parking brake (id code 89DS03)2040
345 Slew circle2043
3451 Disassembling of the slew circle2043
3452 Assembling of the slew circle2047
346 Slew circle lubrication pinion (dummy wheel)2049
3461 Disassembling of the lubrication pinion assembly2049
3462 Assembling of the lubrication pinion assembly2051
35 Operator’s cab2052
351 Disassembling of the operator’s cab2053
352 Assembling of the operator’s cab2057
353 Disassembling of the operator’s cab together with the cab support frame2061
354 Assembling of the operator’s cab together with the cab support frame2065
355 Cab-mounts2068
3551 Disassembling of the cab-mounts2068
3552 Assembling of the cab-mounts2070
356 Front window2072
3561 Disassembling of the front window2072
3562 Assembling of the front window2073
357 Operator’s seat2074
3571 Disassembling of the operator’s seat2074
3572 Assembling of the operator’s seat2075
36 Cab base (Medium voltage switch cabinet)2076
361 Disassembling of the cab support frame2077
362 Assembling of the cab support frame2079
363 Disassembling of the cab base2081
364 Assembling of the cab base2084
37 Ladders, stairways and platforms2088
371 Hydraulically operated stairway2088
3711 Disassembling of the hydraulically operated stairway2088
3712 Assembling of the hydraulically operated stairway2090
3713 Disassembling of the stairway cylinder2092
3714 Assembling of the stairway cylinder2094
372 High voltage switch cabinet stairway2095
3721 Disassembling of the high voltage switch cabinet stairway2095
3722 Assembling of the high voltage switch cabinet stairway2097
373 stairway platform2098
3731 Disassembling of the stairway platform2098
3732 Assembling of the stairway platform2101
374 Emergency escape ladders2104
3741 Disassembling of the emergency escape ladder assembly at the cab base2104
3742 Assembling of the emergency escape ladder assembly at the cab base2105
3743 Disassembling of the emergency escape ladder assembly at the machinery house2106
3744 Assembling of the emergency escape ladder assembly at the machinery house2107
38 Counterweight2109
381 Disassembling of the counterweight2110
382 Assembling of the counterweight2113
39 high voltage switch cabinet2118
391 General information regarding disassembling and assembling2118
392 Disassembling of the high voltage switch cabinet2121
393 Assembling of the high voltage switch cabinet2130
310 Slip ring unit2138
3101 Disassembling of the slip ring unit2138
3102 Assembling of the slip ring unit2141
311 Superstructure Lifting2144
3111 Disassembling the superstructure from the undercarriage2144
3112 Assembling the superstructure onto the undercarriage2148
4 Undercarriage2151
41 Undercarriage overview2152
4101 Changing of the crawler track2154
411 Sprocket assembly2161
4111 Disassembling of the sprocket assembly2161
4112 Assembling of the sprocket assembly2166
412 Guide wheel assembly2169
4121 Disassembling of the guide wheel assembly2169
4122 Assembling of the guide wheel assembly2172
413 Track tensioning accumulators2175
4131 Disassembling of the low pressure accumulators2175
4132 Assembling of the low pressure accumulators2177
4133 Disassembling of the high pressure accumulators2179
4134 Assembling of the high pressure accumulators2180
414 Track tensioning valve block2181
4141 Disassembling of the track tensioning valve block2181
4142 Assembling of the track tensioning valve block2183
415 Track tensioning cylinders2184
4151 Disassembling of the track tensioning cylinders2184
4152 Assembling of the track tensioning cylinders2186
416 Replace the Hydraulic hoses of the track tensioning system2189
4161 Precursory work2189
4162 Replace the hydraulic hoses inside the undercarriage center body2191
4163 Replace the hydraulic hose between undercarriage center body and crawler frame2191
4164 Replace the hydraulic hoses inside the crawler frame2193
4165 Subsequent work2193
417 Travel brake valve block (overspeed valve)2194
4171 Disassembling of the travel brake valve block2194
4172 Assembling of the travel brake valve block2195
418 Travel motor2196
4181 Disassembling of the travel motors2196
4182 Assembling of the travel motors2198
419 Travel parking brake2200
4191 Disassembling of the travel parking brake (id code ZHP 536 and id code GFA 350)2202
4192 Assembling of the travel parking brake (id code ZHP 536 and id code GFA 350)2206
4110 Travel gearbox2211
41101 Disassembling of the travel gearbox2212
41102 Assembling of the travel gearbox2214
4111 Carrier rollers2217
41111 Disassembling of the carrier roller assembly2217
41112 Assembling of the carrier roller assembly2219
4112 Track rollers2221
41121 Disassembling of the track roller assembly2221
41122 Assembling of the track roller assembly2223
4113 Replace the hydraulic hoses of the traveling system2226
42 Undercarriage Center Body2230
421 Disassembling of the undercarriage center body and the crawler carriers2230
422 Assembling of the undercarriage center body and the crawler carriers2235
4221 Install crawler carrier mounting bolts2240
423 Rotary joint2241
4231 Disassembling of the rotary joint2241
4232 Assembling of the rotary joint2245
43 Cable drum assembly2248
431 Disassembling of the cable drum assembly2249
432 Assembling of the cable drum assembly2251
5 Attachment2255
51 Attachment bearings at superstructure2256
511 Boom foot bearings with full floating pins2256
5111 Disassembling of the boom foot bearings2257
5112 Assembling of the boom foot bearings2259
512 Boom cylinder foot bearings with full floating pins2262
5121 Disassembling of the boom cylinder foot bearings – BHA arrangement2264
5122 Assembling of the boom cylinder foot bearings – BHA arrangement2266
5123 Disassembling of the boom cylinder foot bearings – FSA arrangement2269
5124 Assembling of the boom cylinder foot bearings – FSA arrangement2271
52 Repair procedures2274
521 Replacement of bushings at the attachment2274
5211 Removal of the bushings2274
5212 Installation of the bushings2275
522 General installation instructions for attachment pins2276
53 Backhoe (BHA)2278
531 Overview2278
532 Pin Sealing bucket – Steering Rod – bucket link rod2280
533 Boom assembly2282
5331 Disassembling of the boom2282
5332 Assembling of the boom2284
5333 Disassembling of the boom cylinders2286
5334 Assembling of the boom cylinders2290
534 Stick assembly2295
5341 Disassembling of the Stick2295
5342 Assembling of the Stick2300
5343 Disassembling of the Stick Cylinders2305
5344 Assembling of the Stick cylinders2310
535 Bucket and steering2315
5351 Disassembling of the bucket2315
5352 Assembling of the bucket2319
5353 Disassembling of the Bucket Cylinders2322
5354 Assembling of the Bucket Cylinders2329
5355 Disassembling of the bucket link rod2336
5356 Assembling of the bucket link rod2339
5357 Disassembling of the steering rods2342
5358 Assembling of the steering rods2348
536 Hydraulic hoses at the backhoe attachment2352
5361 Replace the boom arc hoses2352
5362 Replace the boom cylinder hoses2356
5363 Replace the stick cylinder hoses2358
5364 Replace the bucket cylinder hoses2360
54 Front shovel (FSA)2362
541 Overview2362
542 Using the Cylinder Mounting Device for Front shovel attachments (PN 967 000 40)2364
5421 Designated usage2365
5422 Non-designated usage2365
543 Boom assembly2366
5431 Disassembling of the boom2366
5432 Assembling of the boom2368
5433 Disassembling of the boom cylinders2370
5434 Assembling of the boom cylinders2374
544 Stick assembly2380
5441 Disassembling of the stick2380
5442 Assembling of the stick2385
5443 Disassembling of the stick cylinders2390
5444 Assembling of the stick cylinders2394
545 Bull clam bucket2398
5451 Disassembling of the bull clam bucket2398
5452 Assembling of the bull clam bucket2402
5453 Disassembling of the bucket cylinders2406
5454 Assembling of the bucket cylinders2412
5455 Disassembling of the clam cylinders2418
5456 Assembling of the clam cylinders2423
546 Hydraulic hoses at the front shovel attachment2428
5461 Replace the boom arc hoses2428
5462 Replace the boom cylinder hoses2432
5463 Replace the stick arc hoses2434
5464 Replace the stick cylinder hoses2436
5465 Replace the bucket cylinder hoses2438
5466 Replace the clam cylinder hoses2440
55 Ground engaging tools (GET)2445
551 Replacement of the GET2445
56 Cylinder bypass test2446
6 Service Information2447
61 Fluids and lubricants2448
62 Lifting Gears2448
63 Safety hints for sling accessory2450
64 Weight tables2451
641 Superstructure2451
642 Undercarriage2453
643 Backhoe attachment (BHA)2454
644 Face shovel attachment (FSA)2455
65 Torque charts according to KOMATSU company standard2456
651 Metric standard thread2456
652 Metric fine thread2457
653 Cummins motor torques – metric2458
654 Cummins motor torques – US customary2458
655 SAE-flange connections2459
66 Blind plugs2460
661 Dummy plates for SAE–flanges2460
662 Classification of threads to the nominal width2462
663 Plugs and fittings according to DIN 23532463
67 Conversion table2464
671 Method of using the conversion table2464
672 Millimeter – inch & kilogram – pound2465
673 Liter – US gallon & liter – UK gallon2466
674 Nm- ftlb2467
675 Bar – PSI – kPa – MPa2468
676 Temperature2469
68 Tools2470
681 Standard tool case2470
682 Used special tools (Overview)2472
69 Work instructions2475
691 Bleeding the track tensioning system2475
692 Hints for hydraulic hose installation2477
693 Remove / install the crawler carrier2480
694 Repair procedure for the radiator assembly2481
7 Parts & Service News2483
71 List of the PARTS AND SERVICE NEWS2484

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24