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Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267 PDF

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267 PDF

Name: Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267 PDF
SKU: 888434
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Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267 – PDF DOWNLOAD

SERIAL NUMBER

08267
08271
08273

Category: komatsu Tags: Komatsu PC4000-11 T2, Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267, Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267 - PDF DOWNLOAD Vendor: Body Repair Docs

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Description

Description

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267 – PDF DOWNLOAD

Language : English
Pages : 2348
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267 – PDF DOWNLOAD

SERIAL NUMBER

08267
08271
08273

Shop Manual . 1
00 Foreword & Safety 3
1 Foreword 5
1.1 BEFORE READING THIS MANUAL 6
1.2 CONTENTS OF THIS BINDER . 7
1.2.1 Contacting the Service 7
1.2.2 Guarantee . 7
1.3 DIVISION OF THE BINDER 8
2 SAFETY 9
2.1 SAFETY INFORMATION 10
2.2 OVERVIEW 11
2.2.1 NORMAL OPERATIONS . 11
2.2.2 REGULAR MAINTENANCE . 11
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR . 11
2.2.4 ADDITIONAL SAFETY PRECAUTIONS . 11
2.3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB . 12
2.3.1 SOUND . 12
2.3.2 VIBRATION . 12
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 13
2.4.1 UNDERSTANDING THE MACHINE . 13
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 13
2.4.2.1 ENSURING SAFE OPERATION . 13
2.4.3 PREPARATIONS FOR SAFE OPERATION . 13
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 13
2.4.3.2 INSPECTING THE MACHINE 13
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 14
2.4.3.4 KEEP MACHINE CLEAN 14
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT . 14
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT . 15
2.4.3.7 IF A PROBLEM IS FOUND . 15
2.4.4 FIRE PREVENTION . 15
2.4.4.1 PRECAUTIONS TO PREVENT FIRE . 15
2.4.4.2 ACTION IF FIRE OCCURS ON PC3000 . 16
2.4.4.3 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000 . 17
2.4.4.4 EMERGENCY EXIT FROM OPERATOR’S CAB 17
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 18
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 18
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE 18
2.4.5.3 NO PEOPLE ON THE ATTACHMENT . 18
2.4.5.4 WORKING IN HIGH PLACES 18
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK . 19
2.4.5.6 LEAVING THE MACHINE . 19
2.4.6 BURN PREVENTION . 19
2.4.6.1 Hot coolant . 19
2.4.6.2 Hot oil . 20
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS . 20
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 20
2.4.9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS . 21
2.4.9.1 UNAUTHORIZED MODIFICATION . 21
2.4.9.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 21
2.4.10 ELECTROMAGNETIC COMPATIBILITY (EMC) 21
2.4.11 PRECAUTIONS AT JOBSITE . 22
2.4.11.1 VISIBILITY FROM OPERATOR’S SEAT 23
2.4.11.2 CAMERA SYSTEM WITH MONITORS 23
2.4.11.3 ENSURE GOOD VISIBILITY . 23
2.4.11.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS . 23
2.4.11.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS . 24
2.4.11.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES . 24
2.4.11.7 Lightning Strikes 25
2.4.11.8 WORKING ON LOOSE GROUND 25
2.4.11.9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 26
2.4.11.10 VENTILATION OF ENCLOSED AREAS . 27
2.4.12 STARTING motor . 28
2.4.12.1 WARNING TAG 28
2.4.12.2 CHECKS BEFORE STARTING motor . 28
2.4.12.3 PRECAUTION WHEN STARTING motor . 28
2.4.12.4 PRECAUTION IN COLD AREAS . 29
2.4.13 OPERATION 29
2.4.13.1 CHECKS BEFORE OPERATION 29
2.4.13.2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE . 30
2.4.13.3 PRECAUTIONS WHEN traveling . 31
2.4.13.4 TRAVELING ON SLOPES 32
2.4.13.5 OPERATIONS ON SLOPES . 33
2.4.13.6 PROHIBITED OPERATIONS 33
2.4.13.7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES . 34
2.4.13.8 PARKING THE MACHINE 34
2.4.13.9 TRANSPORTATION . 34
2.5 PRECAUTION FOR MAINTENANCE 35
2.5.1 GENERAL PRECAUTIONS . 35
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES . 36
2.5.1.2 STOP motor FOR MAINTENANCE 37
2.5.1.3 WARNING TAG . 38
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY . 39
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS . 39
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING . 40
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS . 40
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT . 41
2.5.1.9 NOISE . 41
2.5.1.10 WHEN USING A HAMMER 41
2.5.1.11 PROPER TOOLS . 42
2.5.1.12 ACCUMULATOR 42
2.5.1.13 PERSONNEL 42
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 43
2.5.2.1 PRECAUTION WHEN WELDING . 43
2.5.2.2 BATTERY HANDLING 43
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID 44
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE . 45
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES 46
2.5.3.3 REPLACEMENT OF HOSE LINES . 46
2.5.3.4 INSPECTION OF HOSE LINES 46
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS . 47
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE 47
2.5.3.7 AIR CONDITIONING MAINTENANCE 47
2.5.3.8 COMPRESSED AIR 48
2.5.3.9 WASTE MATERIALS . 48
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS . 49
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM 49
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS . 49
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 49
2.7 SPECIAL SAFETY EQUIPMENT 50
2.7.1 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB 51
2.7.2 OBJECT HANDLING . 51
2.7.3 LIGHTING 51
2.7.4 WARNING BEACON 51
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 51
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 51
2.7.5.2 INSTRUCTIONS FOR USE 53
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 55
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS . 55
2.7.5.5 INSTRUCTIONS FOR USE 57
01 Specification 59
10 Structure & Function . 85
TOC . 87
1 Introduction 97
1.1 Foreword 98
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 99
1.3 Explanation of abbreviations 100
1.4 Diagrams and illustrations in this manual . 101
2 Specifications 103
2.1 Lifting Gears . 104
2.2 Safety hints for sling accessory 106
2.3 Standard Tightening Torque Chart 107
2.4 Conversion Table 108
2.5 Blind plugs . 114
2.6 Classification of threads to the nominal width 116
2.7 Plugs and fittings according to ISO 8434-1 / DIN 2353 . 117
3 Main assembly groups 119
3.1 General layout 120
3.2 Superstructure 122
3.3 Machine house . 124
3.4 Hydraulic oil tank 126
3.5 Hydraulic oil cooler 128
3.6 Fuel tank . 130
3.7 Cab base 132
3.8 Operator’s cab 134
3.9 Control blocks 136
3.10 Slew gear 138
3.10.1 Slew gear of type 2063 . 138
3.10.2 Slew gear of type 632770 . 140
3.11 Undercarriage 142
3.12 Slew ring 144
3.13 Attachment . 146
3.13.1 Front Shovel Attachment (FSA) 146
3.13.2 Backhoe Attachment (BHA) . 148
3.14 Counterweight 150
3.15 Safety circuit (pilot control circuit) . 152
3.15.0.1 Safety Circuit → with redundant switches . 153
3.15.0.2 Wiring Diagram of the safety circuit . 154
4 Drive . 155
4.1 Prime drive assembly 156
4.2 Engine and PTO mounts . 158
4.2.1 Engine Mounts . 158
4.2.2 Torque Support 159
4.3 Flexible coupling . 160
4.3.1 Information for maintenance . 162
4.3.2 Coupling elements . 163
4.3.3 Separation and assembly of the coupling inner and outer part 164
4.3.4 Operation troubles, causes, and rectification . 165
4.4 Fan drive and radiator assembly . 166
4.4.1 Radiator fan drive 168
4.4.2 Fan pump 170
4.4.3 Radiator fan drive speed adjustment . 172
4.5 Pump distributor gearbox (PTO) 174
4.5.1 Pump spline lubrication . 176
4.5.1.1 Oil level in the main pump drive shaft housing 177
4.5.2 PTO lubrication and cooling . 178
4.5.2.1 Checks and adjustments 180
4.6 Hydraulic pumps – location, drive speed and flow rates 182
4.6.1 Pump data . 184
4.7 Air filter 186
5 Hydraulic oil tank 189
5.1 General layout 190
5.2 Hydraulic oil tank, location of the electric equipment 192
5.3 Suction oil tank with strainers . 194
5.4 Return oil collector pipe with strainer . 196
5.5 Back pressure valve . 198
5.6 Transfer pump . 200
5.7 Return and leak oil filter 202
5.8 Breather filter . 204
6 Hydraulic oil cooling . 207
6.1 Overall view of the hydraulic oil cooling . 208
6.2 Function of the hydraulic oil cooling circuit . 210
6.3 Adjustment of the back pressure valve . 212
6.4 Two stage cooler fan RPM control 214
6.4.1 Pressure relief valve . 216
6.4.2 Solenoid valves . 218
6.4.3 Fan pump 220
6.5 Checks and Adjustments of the cooler fan drive speeds . 222
6.5.1 Function Check of Fan Speed Control . 226
7 Controlling . 227
7.1 General layout 228
7.2 Control and filter panel 230
7.3 Valve cartridge block . 232
7.4 Pilot pressure supply and adjustments . 234
7.4.1 Pilot pressure control (PPC) circuit 234
7.4.2 Checks and adjustment of pilot pressure . 238
7.4.3 Remote control valves arrangement . 240
7.5 Function of the electro-hydraulic control system 242
7.5.1 Electronic hand lever (joystick) 246
7.5.1.1 Voltage supply of hand lever 20S020 . 247
7.5.1.2 Direction signal course from hand lever to controllers 248
7.5.1.3 Double ratiometric* output diagram 249
7.6 Foot pedal control 250
7.6.1 Voltage supply of Foot lever (20S021a) 252
7.6.2 Direction signal course from foot pedal to controllers 253
7.6.3 Double ratiometric* output diagram for 2 direction pedal 254
7.6.4 Single ratiometric* output diagram for 1 direction pedal 254
7.7 Hand lever & foot pedal monitoring 255
7.7.1 Lever monitoring screens (example) 256
7.7.2 Valve monitoring screen (example) . 258
7.8 Valve solenoid adjustment . 260
7.8.1 Overview sol min/max current & adjustment range . 261
7.9 ACCEL & DECEL time adjustment . 262
7.9.1 Accel & Decel times . 262
8 Components 265
8.1 Main control blocks and high pressure screens (FSA) . 266
8.2 Main control blocks and high pressure screens (BHA) . 268
8.3 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) . 270
8.4 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) . 272
8.5 Single control blocks (floating) for stick and boom (FSA) . 274
8.6 Restrictor block with secondary relief valve 276
8.7 Anti-cavitation valve (ACV) block . 278
8.8 Remote control valves . 280
8.9 4/3 Directional solenoid valves . 282
8.10 Proportional solenoid valves . 284
8.11 High-pressure screen . 286
8.12 Control blocks and valves 288
8.12.1 Spool types 294
8.12.2 MRV, SRV and ACV . 296
8.12.3 Load holding valve . 298
8.13 Travel brake valve . 302
8.14 Pressure reducing valve 304
8.15 4/2 Directional valves . 306
8.16 Pressure double stage valve 308
8.17 Hydraulic cylinder with NOK-3 sealing 310
8.17.1 Cylinder data markings . 313
9 Main hydraulic pumps and pump regulation 315
9.1 General . 316
9.1.1 Pump locations and pump data 318
9.2 Main pumps 320
9.2.1 Hydraulic pump type HPV375+375 320
9.2.1.1 Main pump sectional drawings 322
9.2.2 Servo valve . 324
9.2.2.1 VC valve  servo piston . 325
9.2.2.2 EPC valve . 330
9.3 Electronic pump regulation system . 332
9.3.1 Cut-off function 334
9.3.2 Slew control 335
9.3.2.1 Function of slew speed switch 20S154 335
9.3.3 Temperature control . 336
9.3.3.1 Hydraulic oil temperature charts 336
9.3.4 Energy efficiency (economy mode) 337
9.4 Pump controller (14K305) 338
9.5 Monitoring, error indication, adjustment 340
9.5.1 Monitoring items of the pump controller . 340
9.5.2 Error indication of the pump controller . 343
9.5.3 Adjustable parameters of the pump controller 344
9.5.3.1 Description of the Primary P-Factor . 346
9.5.4 Pump sol ’min’ current values according to pump type plate 347
9.5.5 Pump sol ’max’ current values according to pump type plate 348
9.6 Checks and adjustments 350
9.6.1 Engine power check 350
9.6.2 Cut-off function check 352
9.6.2.1 Cut-off for clam close (FSA only) . 353
9.7 Engine speed sensor (pick-up) . 354
9.7.1 General . 355
9.7.2 Engine speed sensor (pick-up) adjustment 355
9.7.3 In case of problems – when correct speed sensor adjustment is guaranteed 356
10 Operating hydraulics . 357
10.1 General 358
10.1.1 Floating system (FSA only) . 360
10.2 Hydraulics for the attachment cylinders 364
10.2.1 Electric / hydraulic flowchart “Boom UP” (FSA) . 364
10.2.2 Electric / hydraulic flowchart “boom up” (BHA) . 366
10.2.3 Electric / hydraulic flowchart “boom down” (FSA) . 368
10.2.4 Electric / hydraulic flowchart “Boom down” (BHA) . 370
10.2.5 Electric / hydraulic flowchart “Stick out” (FSA) . 372
10.2.6 Electric / hydraulic flowchart “Stick out” (BHA) . 374
10.2.7 Electric / hydraulic flowchart “Stick in” (FSA) 376
10.2.8 Electric / hydraulic flowchart “Stick in” (BHA) 378
10.2.9 Electric / hydraulic flowchart “Bucket fill” (FSA) . 380
10.2.10 Electric / hydraulic flowchart “Bucket fill” (BHA) 382
10.2.11 Electric / hydraulic flowchart “Bucket dump” (FSA) 384
10.2.12 Electric / hydraulic flowchart “Bucket dump” (BHA) 386
10.2.13 Electric / hydraulic flowchart “Clam open” (FSA) 388
10.2.14 Electric / hydraulic flowchart “Clam close” (FSA) . 390
10.2.15 Checks & adjustments of the main relief valve (MRV) . 392
10.2.16 Checks and adjustments of the secondary relief valves (SRV) . 394
10.2.16.1 Boom cylinders, piston side (BHA & FSA), boom up 394
10.2.16.2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down . 398
10.2.16.3 Stick cylinders, piston side (FSA), stick out . 402
10.2.16.4 Stick cylinders, piston side (BHA), stick in 406
10.2.16.5 Stick cylinders, piston rod side (FSA), stick in 410
10.2.16.6 Stick cylinders, piston rod side (BHA), stick out . 414
10.2.16.7 Bucket cylinders, piston side (FSA), bucket fill 418
10.2.16.8 Bucket cylinders, piston side (BHA), bucket fill 422
10.2.16.9 Bucket cylinders, piston rod side (FSA), bucket dump 426
10.2.16.10 Bucket cylinders, piston rod side (BHA), bucket dump . 430
10.2.16.11 Clam cylinders, piston rod side (FSA), clam open . 434
10.2.16.12 Clam cylinders, piston side (FSA), clam close 438
10.2.17 Checks and adjustments of the lowering speed 442
10.2.17.1 Checks and adjustments of the lowering speed – boom (FSA) . 442
10.2.17.2 Checks and adjustments of the lowering speed – boom (BHA) . 448
10.2.17.3 Checks and adjustments of the lowering speed – stick (FSA) 450
10.2.17.4 Checks and adjustments of the lowering speed – stick (BHA) 456
10.2.17.5 Checks and adjustments of the lowering speed – bucket (FSA) . 458
10.2.17.6 Checks and adjustments of the lowering speed – bucket (BHA) . 460
10.2.17.7 Checks and adjustments of the lowering speed – clam (FSA) . 462
10.3 Hydraulics for the slew circuit 464
10.3.1 Hydraulic slew circuit with variable slew motors . 464
10.3.2 Information on the variable slew motors system . 465
10.3.2.1 Summary of modifications for variable slew motors 466
10.3.3 View onto the Wiring Diagram (variable slew motors) 467
10.3.4 Function description – slew circuit with variable slew motors 468
10.3.5 Slew motor (variable displacement) . 470
10.3.5.1 Hydraulic slew motor – displacement control 472
10.3.6 Slew gearbox (type 2063) . 476
10.3.7 Slew gearbox (type 632770) . 478
10.3.8 Slew parking brake (on slew gear type 2063) 480
10.3.9 Slew parking brake (on slew gear type 632770) 482
10.3.10 Slew brake valve 484
10.3.11 Electric / hydraulic flowchart “Slew left” 488
10.3.12 Electric / hydraulic flowchart “Slew right” . 490
10.3.13 Checks and adjustments for the slew circuit . 492
10.3.13.1 Pressure checks & adjustments – double stage valve (DSV) 493
10.3.13.2 Checks of the brake pilot pressure 496
10.3.14 Checks & adjustments, slew speed 497
10.3.15 Function check for hydraulic slew brake . 498
10.3.16 Slew parking brake release function check . 500
10.4 Hydraulics for the travel system . 502
10.4.1 Travel circuit . 502
10.4.2 Travel motor . 504
10.4.3 Rotary joint . 506
10.4.4 Travel gearbox . 508
10.4.4.1 Travel gearbox of type 2063 508
10.4.4.2 Travel gearbox of type 631053 510
10.4.5 Travel parking brake . 512
10.4.5.1 Travel parking brake of type 631053 512
10.4.5.2 Travel parking brake of type 2063 513
10.5 Travel brake valve . 514
10.5.1 Electric / hydraulic flowchart “travel forward” 516
10.5.2 Electric / hydraulic flowchart “travel backwards” 518
10.5.3 Checks and adjustments . 520
10.5.3.1 Checks and adjustments for the travel circuit 520
10.5.3.2 Function check for the travel parking brake 524
11 Hydraulic track tensioning system 527
11.1 General 528
11.2 Functional description . 530
11.3 Double stage valve . 532
11.4 Tensioning cylinder 534
11.5 Adjustments / checks . 536
12 Access stairway, hydraulically operated 539
12.1 General 540
12.2 Function of the hydraulically operated access stairway . 542
12.3 Adjustments / checks . 548
13 Central refilling system (Service arm) . 551
13.1 General 552
13.2 Function . 554
14 Hints for reading the Hydraulic Diagram 557
14.1 General 558
14.2 Hydraulic symbols 560
14.2.1 Lines, unions 561
14.2.2 Components, valves . 563
14.2.3 Sensors 563
14.2.4 Valves, valve components . 564
14.2.5 Pump, motor, cylinder 568
15 Hints for reading the electric Wiring Diagram 573
15.1 General 574
15.2 Reference code of the electrical components 575
15.2.1 Area code 575
15.2.2 Component identifying letter . 576
15.3 Graphical symbols 577
15.4 Concept of the Wiring Diagram 582
15.4.1 Cover page of the Komatsu W/D 582
15.4.2 Example 1 from the schematics in the W/D . 584
15.4.3 Example 2 from the schematics in the W/D . 586
15.4.4 Table of contents in the W/D (page 1 of 2) . 588
15.4.5 Location list 590
15.4.6 Cross reference list for electr. components in the W/D . 592
15.4.7 Cross reference list for terminals in the W/D 594
15.4.8 Cross reference list for connectors in the W/D . 596
15.4.9 Cross reference list for terminal boards in the W/D 598
15.4.10 Connection table 600
15.5 Cable and connector marking 602
15.6 Cable color identification . 604
16 Monitoring & Control System 605
16.1 General 606
16.1.1 Monitoring & control system – overview . 606
16.1.2 Global layout PC4000-11 T2 . 607
16.1.3 Controller system overview PC4000-11 T2 608
16.1.4 Interface connection . 610
16.1.5 General description 611
16.2 Machine monitor – Operator level . 612
16.2.1 Main gauge screens . 614
16.2.2 Operator menus & icons & functions of keys F1 .F6 . 618
16.2.2.1 Operator menu: ECO Guidance – Operation Records 620
16.2.2.2 Operator menu: ECO Guidance – Average Fuel Consumption Logs 622
16.2.2.3 Operator menu: Machine Setting . 624
16.2.2.4 Operator menu: Maintenance . 626
16.2.2.5 Reset of ’remaining time’ till next maintenance interval . 628
16.2.2.6 Usage limitation . 629
16.2.2.7 Operator menu: Monitor Setting – Screen Adjustment . 631
16.2.2.8 Operator menu: Monitor Setting – Clock Adjustment – Calender . 632
16.2.2.9 Operator menu: Monitor Setting – Clock Adjustment – Time . 633
16.2.2.10 Operator menu: Monitor Setting – Clock Adjustment – 12h/24h Mode 634
16.2.2.11 Operator menu: Monitor Setting – Clock Adjustment – Daylight Saving Time 635
16.2.2.12 Operator menu: Monitor Setting – Language . 636
16.3 Error and status indication on the operator level 637
16.3.1 Prompts (status indications) . 637
16.3.2 Cautions . 638
16.3.3 Emergency shutdown screen 639
16.3.4 Fault levels for error messages 641
16.3.5 Action code level L01 642
16.3.6 Action code level L02 643
16.3.7 Action code level L03 644
16.3.8 Action code level L04 645
16.3.9 Error list . 646
16.4 Table of failure codes . 648
16.4.1 Failure codes without monitor indication . 660
16.4.2 Additional text information for action codes . 660
16.5 Table of C-codes – Diesel engine Tier2 . 661
16.6 Flow charts of machine monitor screens . 672
16.6.1 Flow chart Operator Level 672
16.6.2 Flow chart Service Level . 673
16.7 Machine monitor – Service level 674
16.7.1 Entering the Service Level . 674
16.7.2 Key symbols (F1 .F6) on the Service Level . 676
16.7.3 Service Menu selection screens . 677
16.8 Service Menu – item 01 Monitoring / Custom . 678
16.8.1 Monitoring list for: ENG controller 678
16.8.2 Monitoring list for: PUMP controller . 680
16.8.3 Monitoring list for: VALVE0 controller . 683
16.8.4 Monitoring list for: VALVE1 controller . 686
16.8.5 Monitoring list for: VALVE2 controller . 690
16.8.6 Monitoring list for: MON (monitor) . 692
16.8.7 Monitoring list for: KOM PLS (K+ controller) . 694
16.8.8 How to perform the monitoring function . 696
16.9 Service Menu – item 02 PM Clinic . 698
16.9.1 PM Clinic (General) 698
16.9.2 PM Clinic (Power Check) 699
16.9.3 Functions of PM CLINIC (POWER CHECK) . 700
16.10 Service Menu – item 03 Memory Clear . 701
16.11 Service Menu – item 04 Abnormality record . 702
16.11.1 Reset error messages 703
16.12 Service Menu – item 05 Maintenance record . 704
16.13 Service Menu – item 06 Maintenance Mode Setting . 705
16.14 Service Menu – item 07 Snap Shot 706
16.15 Service Menu – item 08 Phone Number Entry . 707
16.16 Service Menu – item 09 Default 708
16.17 Service Menu – item 10 Unit . 710
16.18 Service Menu – item 11 Adjustment . 712
16.18.1 Adjustments for: PUMP controller 712
16.18.2 Pump sol ’min’ current values according to pump type plate 715
16.18.3 Pump sol ’max’ current values according to pump type plate 716
16.18.4 Adjustments for: VALVE0 controller 717
16.18.5 Accel & Decel times . 724
16.18.6 Adjustments for: VALVE2 controller 725
16.18.7 Adjustments for: MON (Monitor) 726
16.18.7.1 Using the Idling Stop Timer . 727
16.19 Service Menu – item 12 Machine Configuration 728
16.19.1 Details of Machine Configuration for PC4000-11 T2 . 729
16.19.2 Changing lever control from EURO to KMG . 730
16.19.2.1 Changing lever control from KMG to EURO . 730
16.19.3 Changing attachment type from FSA to BHA 732
16.19.3.1 Changing attachment type from BHA to FSA 732
16.19.4 In case of problems during changing procedure for lever control or attachment type 733
16.19.5 Hydraulic Oil & PTO Gear Oil Definition Tables 734
16.19.5.1 Hydraulic oil temperature charts 734
16.19.5.2 PTO gear oil temperature charts . 734
16.20 Automatic engine speed control 735
16.20.1 Auto-Deceleration mode 735
16.20.2 Auto Low Idle mode 735
16.20.3 Idling Stop Timer . 735
16.21 KOMTRAX Plus controller (UM600) . 736
16.22 CR720 controller 740
16.22.1 Location of CR720 controllers . 740
16.23 Controller replacement procedure 742
16.23.1 Sequence of the controller replacement procedure 742
16.23.2 After controller replacement 743
16.23.3 Controller location . 744
17 Lubrication system . 745
17.1 General overview (SLS & CLS ) 746
17.1.1 General description 747
17.2 Basic function of the lubrication systems 748
17.3 Lubrication systems (CLS 1 & SLS) 750
17.3.1 Lubrication pump station . 750
17.3.2 General Information on CLS 1 . 752
17.3.3 General information on the SLS . 752
17.3.4 Manual lube activation . 752
17.4 Lubrication cycle 753
17.4.1 Operation and control 753
17.4.2 Lubrication cycle – processing . 754
17.4.3 Time segments & switch points of a lubrication cycle . 755
17.4.4 Lubrication modes 756
17.4.4.1 Automatic lubrication mode . 756
17.4.4.2 Manual lubrication mode 756
17.4.4.3 REDUCED PAUSE TIME FOR SERVICE . 756
17.5 Hydraulically driven lube pump . 758
17.5.1 Adjustment of lube pump speed 760
17.5.1.1 Stroke speed adjustment 761
17.5.1.2 Working pressure . 761
17.6 Lubricant injectors 762
17.6.1 Tightening torques for fittings at grease injectors 763
17.6.2 Description 763
17.6.3 Adjustment of the lubricant output . 764
17.6.4 Operation principle of lubricant injectors . 766
17.6.4.1 Function description . 767
17.6.5 Connection of one or more injectors 768
17.7 Vent Valve and grease outlet filter 770
17.7.1 Vent valve description . 771
17.8 End-line switch 772
17.8.1 Description 773
17.8.2 CLS 1 end-line switch adjustment . 774
17.8.3 SLS end-line switch adjustment . 776
17.9 Lubricant level sensors 778
17.9.1 Description 779
17.9.1.1 Checks . 779
17.10 Commissioning . 780
17.10.1 Commissioning of the CLS 1 lubrication system . 780
17.10.2 Fine adjustment . 781
17.10.3 Commissioning of the SLS lubrication system . 782
18 Deep temperature equipment (option) 785
18.1 General information 786
18.1.1 Introduction . 786
18.1.2 Deep temperature components overview . 786
18.1.3 Power supply preconditions for preheating 787
18.1.4 Power requirements for preheating systems 788
18.2 Preheating procedure . 789
18.2.1 Global flow chart of the preheating procedure 789
18.2.2 Starting the preheating procedure 790
18.2.3 Preheating of operator’s cab and Diesel engine [coolant system] 791
18.2.4 Preheating of lubricants and superstructure (Diesel) [electric system] . 792
18.3 Constant heating of travel motors (TTT-equipment below-40°C only) 793
18.4 Component location . 794
18.4.1 Electric heating elements for hydraulic & batteries [electric machine] . 794
18.4.2 Electric heating elements for hydraulics [Diesel machine] 796
18.4.3 Electric heating elements for engines & batteries [Diesel machine] . 798
18.5 Components of TT equipment . 800
18.5.1 Preheating components on a Diesel machine 800
18.5.2 Preheating components on an electric machine . 801
18.5.3 Wiring Diagrams for preheating systems (examples) 802
18.5.3.1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 . 802
18.5.3.2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 . 803
18.5.3.3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 . 804
18.5.3.4 Wiring diagram “Suction Oil Manifold Preheating” . 805
18.5.3.5 Wiring diagram “PTO Preheating” 806
18.5.3.6 Wiring diagram “Battery heater pads” . 807
40 Troubleshooting 809
TOC . 811
1 Introduction 837
1.1 Overview 838
1.1.1 General advice when using troubleshooting charts 838
1.2 General Precautions . 839
2 General Information for Troubleshooting . 841
2.1 Preparations For Work . 842
2.2 Precautions During Work . 842
2.3 Precautions When Carrying Out Any Operation . 843
2.3.1 Precautions when carrying out removal work 843
2.3.2 Precautions when carrying out installation work . 843
2.3.3 Precautions when completing the operation . 844
2.4 Fundamental Requirements for Trouble shooting . 845
2.4.1 Technical documentation . 845
2.4.2 Tools . 845
2.4.2.1 Reference Guide for Deutsch Removal Tools . 848
2.4.3 Personnel . 849
2.5 Points To Remember When Trouble- shooting . 849
2.6 Sequence Of Events In Troubleshooting . 851
2.7 Checks Before Troubleshooting . 852
2.8 Handling Of Electric Equipment And Hydraulic Components . 853
2.8.1 Points to remember when handling electric equipment . 853
2.8.2 Points To Remember When Handling Hydraulic Equipment 855
2.9 General working procedures 858
2.9.1 Air Bleeding of Various Hydraulic Parts . 858
2.9.2 Air bleeding from the hydraulic pumps . 858
2.9.3 Air bleeding from hydraulic cylinders . 858
2.10 Cylinder bypass test . 859
2.11 Basics about “How to crimp” (with strain relief) . 860
2.11.1 Crimp tool & repair kit 860
2.11.2 General 861
2.11.3 Select the required connector components . 861
2.11.4 Stripping a wire . 862
2.11.5 Crimping . 863
2.11.6 Connector assembly after crimping 864
2.12 Cable Shielding 865
3 Mounting Locations and Connector Types 867
3.1 View onto the superstructure 868
3.2 Location of engine electrical parts . 870
3.2.1 Location of engine remote oil tank sensors 872
3.3 Location of hydraulic components (1) 874
3.3.1 Location of hydraulic components (2) 876
3.3.2 Location of hydraulic components (3) 878
3.4 View onto the SLS or CLS grease barrel and the lubrication cycle components . 880
3.5 Hydraulic oil tank & suction oil tank – Location of electrical components . 882
3.6 Hydraulically operated access stairway 884
3.7 Service arm . 886
3.8 Connector Types Overview 888
4 Standard Value Table for Electrical Components 893
5 Tables for Testing and Troubleshooting 907
5.1 Test Value Tables for Transducers . 908
5.1.1 Pump press. transducers . 908
5.1.2 Hydraulic oil pressure transducers 909
5.1.3 Miscellaneous Pressure Transducers 910
5.1.4 Temperature Transducers . 911
5.2 Hydraulic oil temperature charts 912
5.3 PTO gear oil temperature charts . 912
5.4 Table of failure codes 913
5.5 Table of C-codes – Diesel engine Tier2 925
5.6 Tables of Symptom Codes . 935
5.6.1 Symptoms of the engine and Related electrical systems . 935
5.6.2 Symptoms of the Hydraulic System 935
5.6.3 Symptoms of the Mechanical System . 936
5.6.4 SYMPTOMS OF ADDITIONAL SYSTEMS 936
5.7 Cable colour identification . 937
6 Troubleshooting by Trouble Code . 939
B@HANS – Hyd Oil Overheat . 940
Hydraulic diagram and location of 57K506a-1 / 57K506b-1 for message B@HANS 942
6A1BMA – Trouble Shut-Off (gate) valve not open error . 944
View onto the gap of proximity switch 40B031 945
Wiring Diagram (40B031) for message 6A1BMA 946
AA10NX – Air Cleaner1 Clogging 948
View onto the engine air cleaner (AA10NX) . 949
AB00KE – Charge Voltage Low . 950
Wiring Diagram (batteries) for message AB00KE . 951
K@3A00 – Fire In System . 952
Configuration information for Fire Suppression System Machinery House . 953
Monitoring information for Fire Suppression System Machinery House 953
Wiring Diagram (20K351) for message K@3A00 954
Wiring Diagram (controller input of fire suppression system MH) for K@3A00 955
B@F0MA – CLS1 Lubrication System Error 956
B@CPMA – SLS Lubrication System Error . 957
B@F0N9 – CLS1 pressure increase time too long . 958
B@CPN9 – SLS pressure increase time too long 958
Allocation of vent valves and end-of-line switches 959
Vent valve (62Q507a & 62Q509a) 960
Wiring Diagram – lube pump solenoid & vent valve (CLS1 & SLS) . 961
B@F0N0 – CLS1 pressure decrease time too long . 962
B@CPN0 – SLS pressure decrease time too long 962
Vent valve (62Q507a & 62Q509a) 963
B@F0ZK – CLS1 grease level too low 964
B@CPZK – SLS grease level too low . 964
Wiring Diagram – grease level sensors (CLS1) 966
Wiring Diagram – grease level sensors (SLS) . 967
B@HAZK – Hydraulic oil level too low 968
Hydraulic oil level in defined machine position . 969
Wiring Diagram – hydraulic oil level sensor 40B004 970
B@CBNS – PTO1 Gear Oil Temp High 971
View onto the universal pump distributor gearbox (PTO) 973
B@CBZG – PTO1 Gear Lubrication Error 974
Monitoring PTO lube oil pressure 975
Shutdown adjustment for PTO lube oil pressure . 975
B@H2NX – Breather Filter Clogging . 976
Location of 40B024 and hydraulic oil level definitions 977
B@M9NX – PTO1 Gear Oil Filter Clogging 978
View onto the PTO1 gear oil filter with pressure sensor 57B027-1 979
B@HBNX – Return Oil Filter Clogging . 980
B@L4NX – Leak Oil Filter Clogging . 981
B@L5N9 – Pilot Press X2 Too Low . 982
Valve cartridge block, location of components . 983
B@L5N0 – Pilot Press X2 Too High 984
Valve cartridge block, location of components . 985
B@BKPQ – Eng Remote Oil Tank1 Empty . 986
B@HANX – Screen At Hyd Cooler Entry Clogging 987
Hydraulic oil tank & return oil collector pipe with strainer – location of components . 988
AB30MA – Starter Circuit Abnormality 990
Wiring Diagram for AB30MA . 991
989HMA – Emergency stop line abnormality 992
Wiring Diagram – emergency line for 989HMA 993
Monitoring screens for message 989HMA . 994
DGT3MA – PTO1 oil temperature sensor abnormality 996
Wiring Diagram and location of 57B049-1 . 997
DGH2MA – Hydraulic oil temp sensor abnormality 998
Wiring Diagram and monitoring selection for 59B015 999
DHQ7MA – PTO1 lube pressure sensor abnormality 1000
Wiring Diagram and monitoring selection for 57B017-1 1001
D1E7KB – Starter cut relay short circuit 1002
Wiring Diagram – Starter cut relay for message D1E7KB .1003
D1E7KY – Starter cut relay hot short circuit 1004
Wiring Diagram – Starter cut relay for message D1E7KY .1005
DHPEMA – Pump-1/2 pressure sensor abnormality .1006
DHPGMA – Pump-3/4 pressure sensor abnormality .1006
DHPJMA – Pump-5/6 pressure sensor abnormality .1006
DHPLMA – Pump-7/8 pressure sensor abnormality .1006
Wiring Diagram – PWR and GND supply for pump pressure transducers .1008
DLE2MA – Engine speed sensor abnormality 1010
Wiring Diagram – 52B064 for message DLE2MA 1011
DA27KP – 24V sensor power abnormality .1012
Wiring Diagram – 24V sensor power supply for DA27KP .1013
DA26KP – 5V sensor2 power abnormality .1014
Wiring Diagram – 5V sensor power supply for DA26KP 1015
DA22KK – Solenoid Power Low Error(Pump Con) .1016
DA22MA – Solenoid Power Circuit Abnormality .1017
Wiring Diagram 1 – emergency stop line for DA22MA .1018
Wiring Diagram 2 for DA22MA .1019
DXAAKA – Pump1 Solenoid open circuit 1020
DXABKA – Pump2 Solenoid open circuit 1020
DXACKA – Pump3 Solenoid open circuit 1020
DXADKA – Pump4 Solenoid open circuit 1020
DXAEKA – Pump5 Solenoid open circuit 1020
DXAFKA – Pump6 Solenoid open circuit 1020
DXAGKA – Pump7 Solenoid open circuit 1020
DXAHKA – Pump8 Solenoid open circuit 1020
Wiring Diagram – EPC valve control 1022
DXAAKB – Pump1 Solenoid short circuit .1023
DXABKB – Pump2 Solenoid short circuit .1023
DXACKB – Pump3 Solenoid short circuit .1023
DXADKB – Pump4 Solenoid short circuit .1023
DXAEKB – Pump5 Solenoid short circuit .1023
DXAFKB – Pump6 Solenoid short circuit .1023
DXAGKB – Pump7 Solenoid short circuit .1023
DXAHKB – Pump8 Solenoid short circuit .1023
Wiring Diagram – EPC valve control 1025
DWA5KA – CLS pump solenoid open circuit .1026
DWA8KA – SLS pump solenoid open circuit .1026
Wiring Diagram – CLS/SLS pump solenoid control 1027
DWA5KB – CLS pump solenoid short circuit 1028
DWA8KB – SLS pump solenoid short circuit 1028
Wiring Diagram – CLS/SLS pump solenoid control 1029
DWA5KY – CLS pump solenoid hot short circuit 1030
DWA8KY – SLS pump solenoid hot short circuit 1030
Wiring Diagram – CLS/SLS pump solenoid / hot short circuit 1031
DWA7KA – CLS line release solenoid open circuit .1032
DWA9KA – SLS lube line release sol. open circuit 1032
Wiring Diagram – CLS/SLS lube line release solenoid control .1033
DWA7KB – CLS line release solenoid short circuit 1034
DWA9KB – SLS lube line release solenoid short circuit .1034
Wiring Diagram – CLS/SLS lube line release solenoid control .1035
DWA7KY – CLS line release sol. hot short circuit 1036
DWA9KY – SLS lube line release sol hot short circuit 1036
Wiring Diagram – CLS/SLS lube line release solenoid / hot short circuit .1037
DWAAKA – PTO lube preload solenoid open circuit .1038
Wiring Diagram and monitoring screen for message DWAAKA .1039
DWAAKB – PTO lube preload solenoid short circuit 1040
Wiring Diagram and monitoring screen for message DWAAKB .1041
DWAAKY – PTO lube preload sol. hot short circuit 1042
Wiring Diagram for message DWAAKY .1043
D166KB – Oil cooler fan sol(Min)relay short circuit .1044
Wiring Diagram – relay 11K068 for 57K506a (D166KB) 1045
D167KB – Oil cooler fan sol(Mid)relay short circuit .1046
Wiring Diagram – relay 11K069 for 57K506b (D167KB) 1047
D168KB – Oil cooler preload sol relay short circuit .1048
Wiring Diagram – relay 11K070 (D168KB) 1049
D1E9KB – Wiper fast relay short circuit .1050
D1ETKB – Wiper slow relay short circuit .1050
D1EBKB – Wiper stop relay short circuit .1050
Wiring Diagram – Wiper motor control 1051
D162KB – Horn relay short circuit .1052
Wiring Diagram – signal horn control 1053
D1F0KB – Engine1/motor1 shutdown relay short circuit 1054
Wiring Diagram 1 – engine1 shutdown relay 11K064-1 1055
D1F0KY – Engine1/motor1 shutdown relay hot short 1056
Wiring Diagram for D1F0KY .1057
D110KA – Battery relay open circuit .1058
Wiring Diagram – battery relay 11Q044d 1059
D110KB – Battery relay short circuit 1060
Wiring Diagram – battery relay 11Q044d 1061
DA29KQ – Model Selection Abnormality 1062
Monitoring screen for machine selection .1062
Wiring Diagram – model selection abnormality (DA29KQ) .1063
DA2YKQ – Motor/Engine Selection Abnormality .1064
Monitoring screen for motor/engine selection 1064
Wiring Diagram – motor/engine selection abnormality (DA2YKQ) 1065
DA20KQ – Pump Con Selection Abnormality .1066
Monitoring screen for pump controller selection .1066
DDABMC – Lock lever switch abnormality 1068
Wiring Diagram – lock lever switch 20S105 (DDABMC) 1069
DKURMA – R lever right-left potentio abnormality 1070
Wiring Diagram – right lever right-left potentiometer input (DKURMA) 1071
DKUSMA – R lever right-left redu pot abnorm(VALVE/M) 1072
Wiring Diagram – right lever redundant right-left potentiometer input (DKUSMA) 1073
DKUQL8 – R lever right-left potentio error 1074
Wiring Diagram – right lever main + redundant right-left signal voltage (DKUQL8) 1075
DKUQL4 – R lever right-left sig. mismatch(VALVE/M) 1076
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1 .1078
DKUNMA – R lever front-back potentio abnormality 1080
Wiring Diagram – right lever front-back potentiometer input (DKUNMA) 1081
DKUPMA – R lever front-back redu pot abnorm(VALVE/M) 1082
Wiring Diagram – right lever redundant front-back potentiometer input (DKUPMA) 1083
DKUML8 – R lever front-back potentio error 1084
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8) 1085
DKUML4 – R lever front-back sig. mismatch(VALVE/M) 1086
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1 .1088
DKUXMA – Left lever right-left potentio abnormality .1090
Wiring Diagram – left lever right-left potentiometer input (DKUXMA) .1091
DKUYMA – L lever right-left redu pot abnorm(VALVE/M) 1092
Wiring Diagram – left lever redundant right-left potentiometer input (DKUYMA) .1093
DKUWL8 – L lever right-left potentio error 1094
Wiring Diagram – left lever main + redundant right-left signal voltage (DKUWL8) .1095
DKUWL4 – L lever right-left sig. mismatch(VALVE/M) 1096
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1 .1098
DKUUMA – L lever front-back potentio abnormality 1100
Wiring Diagram – left lever front-back potentiometer input (DKUUMA) .1101
DKUVMA – L lever front-back redu pot abnorm(VALVE/M) 1102
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/M) for DKUVMA .1103
DKUTL8 – L lever front-back potentio error 1104
Wiring Diagram – L lever front-back potentio error (DKUTL8) .1105
DKUTL4 – L lever front-back sig. mismatch(VALVE/M) 1106
Wiring Diagram – L lever front-back sig. mismatch(VALVE/M) for DKUTL4 .1108
DKW1MA – R pedal potentio abnormality .1110
Wiring Diagram – R pedal potentio abnormality (DKW1MA) 1111
DKW2MA – R pedal redundant pot abnormality(VALVE/M) .1112
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA 1113
DKW0L8 – R pedal potentio error .1114
Wiring Diagram – R pedal potentio error (DKW0L8) 1115
DKW0L4 – R pedal signal mismatch (VALVE/M Con) 1116
Wiring Diagram – R pedal signal mismatch (VALVE/M Con) for DKW0L4 .1118
DKW4MA – L pedal potentio abnormality .1120
Wiring Diagram – L pedal potentio abnormality (DKW4MA) 1121
DKW5MA – L pedal redundant pot abnormality (VALVE/M) 1122
Wiring Diagram – L pedal redundant pot abnormality (VALVE/M) for DKW5MA .1123
DKW3L8 – L pedal potentio error .1124
Wiring Diagram – L pedal potentio error (DKW3L8) 1125
DKW3L4 – L pedal signal mismatch (VALVE/M Con) 1126
Wiring Diagram – L pedal signal mismatch (VALVE/M Con) for DKW3L4 .1128
DKW7MA – Clam open potentio abnormality .1130
Wiring Diagram – Clam open potentio abnormality (DKW7MA) 1131
DKW8MA – Clam open redu pot abnormality (VALVE/M) .1132
Wiring Diagram – Clam open redu pot abnormality (VALVE/M) for DKW8MA 1133
DKW6L8 – Clam open potentio error .1134
Wiring Diagram – Clam open potentio error (DKW6L8) 1135
DKW6L4 – Clam open signal mismatch (VALVE/M Con) 1136
Wiring Diagram – Clam open signal mismatch (VALVE/M Con) for DKW6L4 .1138
DKWAMA – Clam close potentio abnormality 1140
Wiring Diagram – Clam close potentio abnormality (DKWAMA) .1141
DKWBMA – Clam close redundant pot abnorm (VALVE/M) 1142
Wiring Diagram – Clam close redundant pot abnorm (VALVE/M) for DKWBMA .1143
DKW9L8 – Clam close potentio error 1144
Wiring Diagram – Clam close potentio error (DKW9L8) .1145
DKW9L4 – Clam close signal mismatch (VALVE/M Con) .1146
Wiring Diagram – Clam close signal mismatch (VALVE/M Con) for DKW9L4 1148
DKWDMA – Hydraulic slew brake potentio abnormality 1150
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA) .1151
DKWEMA – Hyd. slew brake redu pot abnorm (VALVE/M) 1152
Wiring Diagram – Hyd. slew brake redu pot abnorm (VALVE/M) for DKWEMA .1153
DKWCL8 – Hydraulic slew brake potentio error 1154
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8) .1155
DKWCL4 – Hyd. slew brake sig. mismatch (VALVE/M) 1156
Wiring Diagram – Hyd. slew brake sig. mismatch (VALVE/M) for DKWCL4 .1158
DWNPKA – Service arm up solenoid open circuit .1160
Wiring Diagram and monitoring screen for message DWNPKA .1161
DWNPKB – Service arm up solenoid short circuit 1162
Wiring Diagram and monitoring screen for message DWNPKB .1163
DWNPKY – Service arm up solenoid hot short circuit 1164
Wiring Diagram and monitoring screen for message DWNPKY .1165
DWNQKA – Service arm down solenoid open circuit .1166
Wiring Diagram and monitoring screen for message DWNQKA .1167
DWNQKB – Service arm down solenoid short circuit 1168
Wiring Diagram and monitoring screen for message DWNQKB .1169
DWNQKY – Service arm down solenoid hot short circuit 1170
Wiring Diagram and monitoring screen for message DWNQKY .1171
DW4BKA – Travel parking brake solenoid open circuit .1172
Wiring Diagram and monitoring screen for message DW4BKA .1173
DW4BKB – Travel parking brake sol. short circuit 1174
Wiring Diagram and monitoring screen for message DW4BKB .1175
DW4BKY – Travel parking brake sol. hot short circuit 1176
Wiring Diagram and monitoring screen for message DW4BKY .1177
DW45KA – Slew parking brake solenoid open circuit .1178
Wiring Diagram and monitoring screen for message DW45KA .1179
DW45KB – Slew parking brake solenoid short circuit 1180
Wiring Diagram and monitoring screen for message DW45KB .1181
DW45KY – Slew parking brake sol. hot short circuit 1182
Wiring Diagram and monitoring screen for message DW45KY .1183
DXN0KA – Slew1 epc solenoid open circuit 1184
DXN1KA – Bucket/Boom1 epc solenoid open circuit (FSA) .1184
DXN2KA – Boom1 epc solenoid open circuit (BHA) 1184
DXN3KA – Stick1 epc solenoid open circuit .1184
DXN4KA – Boom2 epc solenoid open circuit 1184
DXN5KA – Clam2 epc solenoid open circuit (FSA) 1184
DXN6KA – Stick2 epc solenoid open circuit (BHA) .1184
DXN7KA – Stick/Bucket2 epc solenoid open circuit (FSA) 1184
DXN8KA – Bucket2 epc solenoid open circuit (BHA) 1184
DXN9KA – Travel2 left epc solenoid open circuit .1184
DXNAKA – Slew3 epc solenoid open circuit 1184
DXNBKA – Bucket3 epc solenoid open circuit 1184
DXNCKA – Boom3 epc solenoid open circuit 1184
DXNDKA – Boom4 epc solenoid open circuit 1184
DXNEKA – Bucket4 epc solenoid open circuit 1184
DXNFKA – Stick4 epc solenoid open circuit .1184
DXNGKA – Travel4 right epc solenoid open circuit 1184
Details of the above 6-digit failure codes (FSA & BHA) 1185
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 .1186
Wiring Diagram for EPC 61K624 – 61K625 1187
Wiring Diagram for EPC 61K626 – 61K627 1188
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 .1189
Wiring Diagram for EPC 61K632 – 61K633 1190
Wiring Diagram for EPC 61K634 – 61K635 1191
Monitoring screens as an example 1192
DXN0KB – Slew1 epc solenoid short circuit .1194
DXN1KB – Bucket/Boom1 epc solenoid short circuit (FSA) 1194
DXN2KB – Boom1 epc solenoid short circuit (BHA) .1194
DXN3KB – Stick1 epc solenoid short circuit 1194
DXN4KB – Boom2 epc solenoid short circuit .1194
DXN5KB – Clam2 epc solenoid short circuit FSA) 1194
DXN6KB – Stick2 epc solenoid short circuit (BHA) 1194
DXN7KB – Stick/Bucket2 epc solenoid short circuit (FSA) .1194
DXN8KB – Bucket2 epc solenoid short circuit (BHA) .1194
DXN9KB – Travel2 left epc solenoid short circuit 1194
DXNAKB – Slew3 epc solenoid short circuit .1194
DXNBKB – Bucket3 epc solenoid short circuit .1194
DXNCKB – Boom3 epc solenoid short circuit .1194
DXNDKB – Boom4 epc solenoid short circuit .1194
DXNEKB – Bucket4 epc solenoid short circuit .1194
DXNFKB – Stick4 epc solenoid short circuit 1194
DXNGKB – Travel4 right epc solenoid short circuit .1194
Details of the above 6-digit failure codes (FSA & BHA) 1195
DXN0KY – Slew1 epc solenoid hot short circuit .1196
DXN1KY – Bucket/Boom1 epc sol. hot short circuit (FSA) 1196
DXN2KY – Boom1 epc solenoid hot short circuit (BHA) .1196
DXN3KY – Stick1 epc solenoid hot short circuit 1196
DXN4KY – Boom2 epc solenoid hot short circuit .1196
DXN5KY – Clam2 epc solenoid hot short circuit (FSA) .1196
DXN6KY – Stick2 epc solenoid hot short circuit (BHA) 1196
DXN7KY – Stick/Bucket2 epc sol. hot short circuit (FSA) .1196
DXN8KY – Bucket2 epc solenoid hot short circuit (BHA) .1196
DXN9KY – Travel2 left epc sol. hot short circuit 1196
DXNAKY – Slew3 epc solenoid hot short circuit .1196
DXNBKY – Bucket3 epc solenoid hot short circuit .1196
DXNCKY – Boom3 epc solenoid hot short circuit .1196
DXNDKY – Boom4 epc solenoid hot short circuit .1196
DXNEKY – Bucket4 epc solenoid hot short circuit .1196
DXNFKY – Stick4 epc solenoid hot short circuit 1196
DXNGKY – Travel4 right epc sol. hot short circuit .1196
Details of the above 6-digit failure codes (FSA & BHA) 1197
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 .1198
Wiring Diagram for EPC 61K624 – 61K625 1199
Wiring Diagram for EPC 61K626 – 61K627 1200
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 .1201
Wiring Diagram for EPC 61K632 – 61K633 1202
Wiring Diagram for EPC 61K634 – 61K635 1203
DWACKA – Service arm check valve sol. open circuit 1204
Wiring Diagram and monitoring screen for message DWACKA .1205
DWACKB – Service arm check valve sol. short circuit .1206
Wiring Diagram and monitoring screen for message DWACKB .1207
DWACKY – Service arm check valveSol hotShortCircuit .1208
Wiring Diagram and monitoring screen for message DWACKY .1209
DWADKA – Ladder speed control solenoid open circuit .1210
Wiring Diagram and monitoring screen for message DWADKA .1211
DWADKB – Ladder speed control sol. short circuit 1212
Wiring Diagram and monitoring screen for message DWADKB .1213
DWADKY – Ladder speed control sol. hot short circuit 1214
Wiring Diagram – Ladder speed control sol. hot short circuit (DWADKY) .1215
DBW5MA – 5V sensor1 power abnormality .1216
DBW6MA – 5V sensor2 power abnormality .1216
Wiring Diagram – 5V power supply and GND output at VALVE0 .1220
DBW9KQ – Model Selection Abnormality 1222
Monitoring screen for machine selection .1222
Wiring Diagram – model selection abnormality (DBW9KQ) .1223
DBWZKQ – Lever control selection abnormality 1224
Monitoring screen & Wiring Diagram – Lever control selection abnormality (DBWZKQ) .1225
DBWYKQ – Attachment selection abnormality .1226
Monitoring screen & Wiring Diagram – Attachment selection abnormality (DBWYKQ) 1227
DBW2KK – Solenoid Power Low Error (VALVE/M Con) .1228
Wiring Diagram 1 for message DBW2KK .1230
Wiring Diagram 2 for message DBW2KK .1231
DBW0KQ – VALVE/M Con Selection Abnormality 1232
Monitoring screen & Wiring Diagram for message DBW0KQ .1233
DDDWMC – Ladder operation switch abnormality 1234
Wiring Diagram and monitoring screen for message DDDWMC .1235
DKWHMA – R lever right-left redu pot abnorm (VLV/S1) 1236
Wiring Diagram – right lever redundant right-left potentiometer input (DKWHMA) 1237
DKWFL4 – R lever right-left sig. mismatch (VALVE/S1) 1238
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1 .1240
DKWLMA – R lever front-back redu pot abnorm (VLV/S1) 1242
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA) 1243
DKWJL4 – R lever front-back sig. mismatch (VALVE/S1) 1244
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1 .1246
DKWPMA – L lever right-left redu pot abnorm (VLV/S1) 1248
Wiring Diagram – left lever redundant right-left potentiometer input (DKWPMA) .1249
DKWML4 – L lever right-left sig. mismatch (VALVE/S1) 1250
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1 .1252
DKWSMA – L lever front-back redu pot abnorm (VLV/S1) 1254
Wiring Diagram – L lever front-back redu pot abnorm (VLV/S1) for DKWSMA .1255
DKWQL4 – L lever front-back sig. mismatch (VALVE/S1) 1256
Wiring Diagram – L lever front-back sig. mismatch (VALVE/S1) for DKWQL4 .1258
DKWVMA – R pedal red pot abnormality (VALVE/S1) .1260
Wiring Diagram – R pedal red pot abnormality (VALVE/S1) for DKWVMA 1261
DKWTL4 – R pedal signal mismatch (VALVE/S1 Con) .1262
Wiring Diagram – R pedal signal mismatch (VALVE/S1 Con) for DKWTL4 1264
DKWYMA – L pedal red pot abnormality (VALVE/S1) .1266
Wiring Diagram – L pedal red pot abnormality (VALVE/S1) for DKWYMA 1267
DKWWL4 – L pedal signal mismatch (VALVE/S1 Con) .1268
Wiring Diagram – L pedal signal mismatch (VALVE/S1 Con) for DKWWL4 1270
DKX2MA – Clam open redu pot abnormality (VALVE/S1) 1272
Wiring Diagram – Clam open redu pot abnormality (VALVE/S1)) for DKX2MA 1273
DKX0L4 – Clam open signal mismatch (VALVE/S1 Con) .1274
Wiring Diagram – Clam open signal mismatch (VALVE/S1 Con) for DKX0L4 1276
DKX5MA – Clam close redu pot abnormality (VALVE/S1) .1278
Wiring Diagram – Clam close redu pot abnormality (VALVE/S1) for DKX5MA 1279
DKX3L4 – Clam close signal mismatch (VALVE/S1 Con) 1280
Wiring Diagram – Clam close signal mismatch (VALVE/S1 Con) for DKX3L4 .1282
DKX8MA – Hyd. slew brake redu pot abnorm (VALVE/S1) .1284
Wiring Diagram – Hyd. slew brake redu pot abnorm (VALVE/S1) for DKX8MA 1285
DKX6L4 – Hyd. slew brake signal mismatch (VALVE/S1) .1286
Wiring Diagram – Hyd. slew brake signal mismatch (VALVE/S1) for DKX6L4 1288
DWNRKA – Ladder up solenoid open circuit 1290
Wiring Diagram and monitoring screen for message DWNRKA .1291
DWNRKB – Ladder up solenoid short circuit .1292
Wiring Diagram and monitoring screen for message DWNRKB .1293
DWNRKY – Ladder up solenoid hot short circuit .1294
Wiring Diagram – Ladder up solenoid hot short circuit (DWNRKY) 1295
DW7RKA – Hydraulic slew brake solenoid open circuit .1296
Wiring Diagram and monitoring screen for message DW7RKA .1297
DW7RKB – Hydraulic slew brake sol. short circuit 1298
Wiring Diagram and monitoring screen for message DW7RKB .1299
DW7RKY – Hyd. slew brake sol. hot short circuit .1300
Wiring Diagram – Hyd. slew brake sol. hot short circuit (DW7RKY) 1301
DWANKA – Slew1 right solenoid open circuit 1302
Wiring Diagram and monitoring screen for message DWANKA .1303
DWANKB – Slew1 right solenoid short circuit .1304
Wiring Diagram and monitoring screen for message DWANKB .1305
DWANKY – Slew1 right solenoid hot short circuit .1306
Wiring Diagram and monitoring screen for message DWANKY .1307
DWAJKA – Slew1 left solenoid open circuit .1308
Wiring Diagram and monitoring screen for message DWAJKA .1309
DWAJKB – Slew1 left solenoid short circuit 1310
Wiring Diagram and monitoring screen for message DWAJKB .1311
DWAJKY – Slew1 left solenoid hot short circuit 1312
Wiring Diagram and monitoring screen for message DWAJKY .1313
DWASKA – Bucket1 fill solenoid open circuit .1314
Wiring Diagram and monitoring screen for message DWASKA .1315
DWASKB – Bucket1 fill solenoid short circuit 1316
Wiring Diagram and monitoring screen for message DWASKB .1317
DWASKY – Bucket1 fill solenoid hot short circuit 1318
Wiring Diagram and monitoring screen for message DWASKY .1319
DWBEKA – Boom1 down solenoid open circuit .1320
Wiring Diagram and monitoring screen for message DWBEKA .1321
DWBEKB – Boom1 down solenoid short circuit 1322
Wiring Diagram and monitoring screen for message DWBEKB .1323
DWBEKY – Boom1 down solenoid hot short circuit 1324
Wiring Diagram and monitoring screen for message DWBEKY .1325
DWBAKA – Boom1 up solenoid open circuit .1326
Wiring Diagram and monitoring screen for message DWBAKA .1327
DWBAKB – Boom1 up solenoid short circuit 1328
Wiring Diagram and monitoring screen for message DWBAKB .1329
DWBAKY – Boom1 up solenoid hot short circuit 1330
Wiring Diagram and monitoring screen for message DWBAKY .1331
DWBJKA – Stick1 out solenoid open circuit .1332
Wiring Diagram and monitoring screen for message DWBJKA .1333
DWBJKB – Stick1 out solenoid short circuit 1334
Wiring Diagram and monitoring screen for message DWBJKB .1335
DWBJKY – Stick1 out solenoid hot short circuit 1336
Wiring Diagram and monitoring screen for message DWBJKY .1337
DWBNKA – Stick1 in solenoid open circuit 1338
Wiring Diagram and monitoring screen for message DWBNKA .1339
DWBNKB – Stick1 in solenoid short circuit .1340
Wiring Diagram and monitoring screen for message DWBNKB .1341
DWBNKY – Stick1 in solenoid hot short circuit .1342
Wiring Diagram and monitoring screen for message DWBNKY .1343
DWBBKA – Boom2 up solenoid open circuit .1344
Wiring Diagram and monitoring screen for message DWBBKA .1345
DWBBKB – Boom2 up solenoid short circuit 1346
Wiring Diagram and monitoring screen for message DWBBKB .1347
DWBBKY – Boom2 up solenoid hot short circuit 1348
Wiring Diagram and monitoring screen for message DWBBKY .1349
DWBFKA – Boom2 down solenoid open circuit .1350
Wiring Diagram and monitoring screen for message DWBFKA .1351
DWBFKB – Boom2 down solenoid short circuit 1352
Wiring Diagram and monitoring screen for message DWBFKB .1353
DWBFKY – Boom2 down solenoid hot short circuit 1354
Wiring Diagram and monitoring screen for message DWBFKY .1355
DWBXKA – Clam2 close solenoid open circuit 1356
Wiring Diagram and monitoring screen for message DWBXKA .1357
DWBXKB – Clam2 close solenoid short circuit .1358
Wiring Diagram and monitoring screen for message DWBXKB .1359
DWBXKY – Clam2 close solenoid hot short circuit .1360
Wiring Diagram and monitoring screen for message DWBXKY .1361
DWBKKA – Stick2 out solenoid open circuit .1362
Wiring Diagram and monitoring screen for message DWBKKA (FSA only) 1363
DWBKKB – Stick2 out solenoid short circuit 1364
Wiring Diagram and monitoring screen for message DWBKKB .1365
DWBKKY – Stick2 out solenoid hot short circuit 1366
Wiring Diagram and monitoring screen for message DWBKKY .1367
DWBTKA – Clam2 open solenoid open circuit .1368
Wiring Diagram and monitoring screen for message DWBTKA .1369
DWBTKB – Clam2 open solenoid short circuit 1370
Wiring Diagram and monitoring screen for message DWBTKB .1371
DWBTKY – Clam2 open solenoid hot short circuit 1372
Wiring Diagram and monitoring screen for message DWBTKY .1373
DWBPKA – Stick2 in solenoid open circuit 1374
Wiring Diagram and monitoring screen for message DWBPKA .1375
DWBPKB – Stick2 in solenoid short circuit .1376
Wiring Diagram and monitoring screen for message DWBPKB .1377
DWBPKY – Stick2 in solenoid hot short circuit .1378
Wiring Diagram and monitoring screen for message DWBPKY .1379
DWATKA – Bucket2 fill solenoid open circuit .1380
Wiring Diagram and monitoring screen for message DWATKA .1381
DWATKB – Bucket2 fill solenoid short circuit 1382
Wiring Diagram and monitoring screen for message DWATKB .1383
DWATKY – Bucket2 fill solenoid hot short circuit 1384
Wiring Diagram and monitoring screen for message DWATKY .1385
DWAXKA – Bucket2 dump solenoid open circuit .1386
Wiring Diagram and monitoring screen for message DWAXKA .1387
DWAXKB – Bucket2 dump solenoid short circuit 1388
Wiring Diagram and monitoring screen for message DWAXKB .1389
DWAXKY – Bucket2 dump solenoid hot short circuit 1390
Wiring Diagram and monitoring screen for message DWAXKY .1391
DWKFKA – Travel2 left backward sol. open circuit 1392
Wiring Diagram and monitoring screen for message DWKFKA .1393
DWKFKB – Travel2 left backward sol. short circuit .1394
Wiring Diagram and monitoring screen for message DWKFKB .1395
DWKFKY – Travel2 left backward sol. hot short circuit .1396
Wiring Diagram and monitoring screen for message DWKFKY .1397
DWKBKA – Travel2 left forward sol. open circuit .1398
Wiring Diagram and monitoring screen for message DWKBKA .1399
DWKBKB – Travel2 left forward sol. short circuit 1400
Wiring Diagram and monitoring screen for message DWKBKB .1401
DWKBKY – Travel2 left forward sol. hot short 1402
Wiring Diagram and monitoring screen for message DWKBKY .1403
D5ZWKB – Travel hour meter short circuit 1404
Wiring Diagram and monitoring screen for message D5ZWKB .1405
D1EUKB – Travel alarm relay short circuit .1406
Wiring Diagram and monitoring screen for message D1EUKB .1407
DBX9KQ – Model Selection Abnormality 1408
Wiring Diagram and monitoring screen for message DBX9KQ .1409
DBXZKQ – Lever Control Selection Abnormality 1410
Wiring Diagram and monitoring screen for message DBXZKQ .1411
DBXYKQ – Attachment selection abnormality .1412
Wiring Diagram – Attachment selection abnormality (DBXYKQ) 1413
D561MA – Lock lever sol. power cut abnorm (VALVE/S1) 1414
Monitoring screens and Wiring Diagram 1 for message D561MA 1415
Wiring Diagram 2 for message D561MA .1416
D563MA – Ladder up sensor sol cut abnorm (VLV/S1) .1417
Monitoring screens and Wiring Diagram 1 for message D563MA 1418
Wiring Diagram 2 for message D563MA .1419
D565MA – Service arm (up) sensor sol cut abnorm (VLV/S1) 1420
Wiring Diagram 1 and monitoring screens for message D565MA 1421
Wiring Diagram 2 for message D565MA .1422
DBX2KK – Solenoid Power Low Error (VALVE/S1 Con) 1423
Monitoring screen & Wiring Diagram 1 for message DBX2KK .1424
Wiring Diagram 2 for message DBX2KK – Safety circuit 1425
DBX0KQ – VALVE/S1 Con Selection Abnormality .1427
Wiring Diagram and monitoring screen for message DBX0KQ .1428
DWAQKA – Slew3 right solenoid open circuit 1429
Wiring Diagram and monitoring screen for message DWAQKA .1430
DWAQKB – Slew3 right solenoid short circuit .1431
Wiring Diagram and monitoring screen for message DWAQKB .1432
DWAQKY – Slew3 right solenoid hot short circuit .1433
Wiring Diagram and monitoring screen for message DWAQKY .1434
DWALKA – Slew3 left solenoid open circuit .1435
Wiring Diagram and monitoring screen for message DWALKA .1436
DWALKB – Slew3 left solenoid short circuit 1437
Wiring Diagram and monitoring screen for message DWALKB .1438
DWALKY – Slew3 left solenoid hot short circuit 1439
Wiring Diagram and monitoring screen for message DWALKY .1440
DWAUKA – Bucket3 fill solenoid open circuit .1441
Wiring Diagram and monitoring screen for message DWAUKA .1442
DWAUKB – Bucket3 fill solenoid short circuit 1443
Wiring Diagram and monitoring screen for message DWAUKB .1444
DWAUKY – Bucket3 fill solenoid hot short circuit 1445
Wiring Diagram and monitoring screen for message DWAUKY .1446
DWAYKA – Bucket3 dump solenoid open circuit .1447
Wiring Diagram and monitoring screen for message DWAYKA .1448
DWAYKB – Bucket3 dump solenoid short circuit 1449
Wiring Diagram and monitoring screen for message DWAYKB .1450
DWAYKY – Bucket3 dump solenoid hot short circuit 1451
Wiring Diagram and monitoring screen for message DWAYKY .1452
DWBGKA – Boom3 down solenoid open circuit .1453
Wiring Diagram and monitoring screen for message DWBGKA .1454
DWBGKB – Boom3 down solenoid short circuit 1455
Wiring Diagram and monitoring screen for message DWBGKB .1456
DWBGKY – Boom3 down solenoid hot short circuit 1457
Wiring Diagram and monitoring screen for message DWBGKY .1458
DWBDKA – Boom4 up solenoid open circuit .1459
Wiring Diagram and monitoring screen for message DWBDKA .1460
DWBDKB – Boom4 up solenoid short circuit 1461
Wiring Diagram and monitoring screen for message DWBDKB .1462
DWBDKY – Boom4 up solenoid hot short circuit 1463
Wiring Diagram and monitoring screen for message DWBDKY .1464
DWBHKA – Boom4 down solenoid open circuit .1465
Wiring Diagram and monitoring screen for message DWBHKA .1466
DWBHKB – Boom4 down solenoid short circuit 1467
Wiring Diagram and monitoring screen for message DWBHKB .1468
DWBHKY – Boom4 down solenoid hot short circuit 1469
Wiring Diagram and monitoring screen for message DWBHKY .1470
DWAVKA – Bucket4 fill solenoid open circuit .1471
Wiring Diagram and monitoring screen for message DWAVKA .1472
DWAVKB – Bucket4 fill solenoid short circuit 1473
Wiring Diagram and monitoring screen for message DWAVKB .1474
DWAVKY – Bucket4 fill solenoid hot short circuit 1475
Wiring Diagram and monitoring screen for message DWAVKY .1476
DWAZKA – Bucket4 dump solenoid open circuit .1477
Wiring Diagram and monitoring screen for message DWAZKA .1478
DWAZKB – Bucket4 dump solenoid short circuit 1479
Wiring Diagram and monitoring screen for message DWAZKB .1480
DWAZKY – Bucket4 dump solenoid hot short circuit 1481
Wiring Diagram and monitoring screen for message DWAZKY .1482
DWBMKA – Stick4 out solenoid open circuit .1483
Wiring Diagram and monitoring screen for message DWBMKA .1484
DWBMKB – Stick4 out solenoid short circuit 1485
Wiring Diagram and monitoring screen for message DWBMKB .1486
DWBMKY – Stick4 out solenoid hot short circuit 1487
Wiring Diagram and monitoring screen for message DWBMKY .1488
DWBRKA – Stick4 in solenoid open circuit 1489
Wiring Diagram and monitoring screen for message DWBRKA .1490
DWBRKB – Stick4 in solenoid short circuit .1491
Wiring Diagram and monitoring screen for message DWBRKB .1492
DWBRKY – Stick4 in solenoid hot short circuit .1493
Wiring Diagram and monitoring screen for message DWBRKY .1494
DWKRKA – Travel4 right backward sol. open circuit .1495
Wiring Diagram and monitoring screen for message DWKRKA .1496
DWKRKB – Travel4 right backward sol. short circuit 1497
Wiring Diagram and monitoring screen for message DWKRKB .1498
DWKRKY – Travel4 right backward sol. hot short 1499
Wiring Diagram and monitoring screen for message DWKRKY .1500
DWKMKA – Travel4 right forward sol. open circuit 1501
Wiring Diagram and monitoring screen for message DWKMKA .1502
DWKMKB – Travel4 right forward sol. short circuit .1503
Wiring Diagram and monitoring screen for message DWKMKB .1504
DWKMKY – Travel4 right forward sol. hot short .1505
Wiring Diagram and monitoring screen for message DWKMKY .1506
DXEDKA – Hydraulic slew brake epc sol. open circuit .1507
Wiring Diagram and monitoring screen for message DXEDKA .1508
DXEDKB – Hyd. slew brake epc sol. short circuit .1509
Wiring Diagram and monitoring screen for message DXEDKB .1510
DXEDKY – Hyd. slew brake epc sol. hot short circuit .1511
Wiring Diagram and monitoring screen for message DXEDKY .1512
DWKVKA – Boom4 float solenoid open circuit 1513
Wiring Diagram and monitoring screen for message DWKVKA .1514
DWKVKB – Boom4 float solenoid short circuit .1515
Wiring Diagram and monitoring screen for message DWKVKB .1516
DWKVKY – Boom4 float solenoid hot short circuit .1517
Wiring Diagram and monitoring screen for message DWKVKY .1518
DWKWKA – Stick1 float solenoid open circuit .1519
Wiring Diagram and monitoring screen for message DWKWKA .1520
DWKWKB – Stick1 float solenoid short circuit 1521
Wiring Diagram and monitoring screen for message DWKWKB .1522
DWKWKY – Stick1 float solenoid hot short circuit 1523
Wiring Diagram and monitoring screen for message DWKWKY .1524
DWKZKA – Stick4 float solenoid open circuit .1525
Wiring Diagram and monitoring screen for message DWKZKA .1526
DWKZKB – Stick4 float solenoid short circuit 1527
Wiring Diagram and monitoring screen for message DWKZKB .1528
DWKZKY – Stick4 float solenoid hot short circuit 1529
Wiring Diagram and monitoring screen for message DWKZKY .1530
DBY9KQ – Model Selection Abnormality 1531
Wiring Diagram and monitoring screen for message DBY9KQ .1532
DBYZKQ – Lever Control Selection Abnormality 1533
Wiring Diagram and monitoring screen for message DBYZKQ .1534
DBYYKQ – Attachment selection abnormality .1535
Wiring Diagram – Attachment selection abnormality (DBYYKQ) 1536
D562MA – Lock lever sol power cut abnorm (VALVE/S2) .1537
Wiring Diagram 1 and monitoring screen for message D562MA .1538
Wiring Diagram 2 for message D562MA .1539
D564MA – Ladder up sensor sol cut abnorm (VLV/S2) .1540
Monitoring screens and Wiring Diagram 1 for message D564MA 1541
Wiring Diagram 2 for message D564MA .1542
D566MA – Service arm sensor sol cut abnorm (VALV/S2) 1543
Wiring Diagram 1 and monitoring screens for message D566MA 1544
Wiring Diagram 2 for message D566MA .1545
DBY2KK – Solenoid Power Low Error (VALVE/S2 Con) 1546
Monitoring screen and Wiring Diagram 1 for message DBY2KK .1547
Wiring Diagram 2 for message DBY2KK .1548
DBY0KQ – VALVE/S2 Con Selection Abnormality .1550
Wiring Diagram and monitoring screen for message DBY0KQ .1551
DJH2KX – Hydraulic oil level sensor abnormality .1552
Wiring Diagram and monitoring screen for message DJH2KX .1553
DJE3KX – Remote engine oil level1 sens. abnormality .1554
Wiring Diagram and monitoring screen for message DJE3KX .1555
DH2GKX – Suction tank pressure sensor abnormality .1556
Wiring Diagram and monitoring screen for message DH2GKX .1557
DH2HKX – Oil cooler pressure sensor abnormality .1558
Wiring Diagram and monitoring screen for message DH2HKX .1559
DH2JKX – Preload valve return oil press abnormality .1560
Wiring Diagram and monitoring screen for message DH2JKX .1561
DHSUKX – X2 pressure sensor abnormality .1562
Wiring Diagram and monitoring screen for message DHSUKX .1563
DJF1KX – Fuel level sensor abnormality 1564
Wiring Diagram and monitoring screen for message DJF1KX .1565
DGE5MA – Ambient air temp sensor abnormality 1566
Wiring Diagram and monitoring screen for message DGE5MA .1567
DH2KKX – Return oil chamber press. sensor abnormal 1568
Wiring Diagram and monitoring screen for message DH2KKX .1569
DH2LKX – Leak oil chamber press. sensor abnormality .1570
Wiring Diagram and monitoring screen for message DH2LKX .1571
DJE5L4 – SLS sensor system abnormality 1572
Wiring Diagram and monitoring screen for message DJE5L4 .1573
DJE6L4 – CLS sensor system abnormality 1574
Wiring Diagram and monitoring screen for message DJE6L4 .1575
DBVLKA – Operating Lamp Open Circuit(KOMTRAX) .1576
Wiring Diagram for message DJE6L4 .1577
DBVLKB – Operating Lamp Short Circuit (KOMTRAX) .1578
Wiring Diagram for message DBVLKB .1579
DBV1KK – KOMTRAX Plus source voltage Error 1580
Wiring Diagram for message DBV1KK .1581
DBV5KB – 5V sensor1 power abnormality .1582
Wiring Diagram 1 and monitoring screens for message DBV5KB 1583
Wiring Diagram 2 for message DBV5KB .1584
DBV6KB – 24V Sensor Power Abnormality .1586
Wiring Diagram 1 and monitoring screens for message DBV6KB 1587
Wiring Diagram 2 for message DBV6KB .1588
DAFGMC – GPS Module Error .1590
Wiring Diagram for message DAFGMC .1591
D862KA – GPS Antenna Open Circuit .1592
DBVVKR – Ethernet 1 Disconnection .1593
DBVWKR – Ethernet 2 Disconnection .1594
DA2RKR – CAN1 Discon (Pump Con) .1596
CAN1 overview for message DA2RKR 1597
DBWRKR – CAN1 Discon (Valve/M Con) 1598
CAN1 overview for message DBWRKR 1599
DBXRKR – CAN1 Discon (Valve/S1 Con) .1600
CAN1 overview for message DBXRKR 1601
DBYRKR – CAN1 Discon (Valve/S2 Con) .1602
CAN1 overview for message DBYRKR 1603
DB2QKR – CAN2 Discon (Engine Con) .1604
CAN2 overview for message DB2QKR 1605
DA2QKR – CAN2 Discon (Pump Con) .1606
CAN2 overview for message DA2QKR 1607
DBWQKR – CAN2 Discon (Valve/M Con) 1608
CAN2 overview for message DBWQKR 1609
DBXQKR – CAN2 Discon (Valve/S1 Con) .1610
CAN2 overview for message DBXQKR 1611
DBYQKR – CAN2 Discon (Valve/S2 Con) .1612
CAN2 overview for message DBYQKR 1613
DBVQKR – CAN2 Discon (KOMTRAX Plus) .1614
CAN2 overview for message DBVQKR 1615
D19YKB – Emergency Lighting Ladder Relay Short Circuit 1616
Wiring Diagram and monitoring screen for message D19YKB .1617
DV00KB – Shutdown Buzzer Short Circuit 1618
Wiring Diagram and monitoring screen for message DV00KB .1619
7 Troubleshooting by Symptoms .1621
7.1 Symptoms of the engine and related electrical system 1622
SEL001 – Engine does not start (engine does not rotate) .1622
Wiring Diagram 1 (batteries) for symptom code SEL001 1624
Wiring Diagram 2 (20S030 & 20S105) for symptom code SEL001 1625
Wiring Diagram 3 (engine enable) for symptom code SEL001 1626
Wiring Diagram 4 (starter motors) for symptom code SEL001 .1627
SEL001a – Engine does not start (Pre-lube does not stop) 1628
SEL002 – Engine stops while in operation 1630
View onto the fuel system water separator (SEL002) 1631
SEL003 – Engine speed is hunting during boom-up movement 1632
SEL004 – Engine does not stop .1634
SEL005 – Engine lacks output (no power) .1636
Judgment Table for SEL005 .1637
SEL006 – Exhaust smoke is black .1638
Judgment Table for SEL006 .1639
SEL007 – Oil consumption is excessive .1640
Judgment Table for SEL007 .1641
SEL008 – Oil becomes contaminated quickly .1642
Judgment Table for SEL008 .1643
SEL009 – Fuel consumption is excessive 1644
Judgment Table for SEL009 .1645
SEL010 – Oil is in engine coolant .1646
Judgment Table for SEL010 .1647
SEL011 – Oil level rises 1648
Judgment Table for SEL011 .1649
SEL012 – Coolant temperature becomes too high (overheating) .1650
Judgment Table for SEL012 .1651
7.2 Symptoms of the Hydraulic System 1652
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function) 1652
SHY002 – Engine speed sharply drops or engine stalls too much .1654
SHY003 – No work equipment, travel or slew movement .1655
SHY004 – Work equipment has too much hydraulic drift 1656
SHY005 – Work equipment has big time lag 1657
SHY006 – Machine deviates during travel movement 1658
SHY007 – Hydraulic system has lack of power .1659
SHY008 – Machine does not slew 1660
Slew brake block (SHY008) .1661
SHY009 – Slew acceleration is poor 1662
SHY010 – Excessive overrun when stopping slew movement 1664
SHY011 – Floating system without function (FSA only) 1666
SHY012 – Abnormal noise coming from SRV or MRV 1667
SHY013 – Track tensioning system without function .1668
Track tensioning – overview (SHY013) 1669
SHY014 – Ladder does not move, or slow movement .1670
SHY015 – Refilling arm does not move, or slow movement 1672
SHY016 – The hydr. driven grease pump does not move .1674
SHY017 – Abnormal track chain movement during digging .1676
SHY018 – Slew parking brake without function 1677
SHY019 – Travel parking brake without function 1678
7.3 Symptoms of the Mechanical System .1680
SME001 – Abnormal noise is made .1680
Judgment Table for SME001 .1681
SME002 – Abnormal noise around the PTO / hydraulic pumps 1682
SME003 – Vibration is excessive (engine mountings) 1684
Judgment Table for SME003 .1685
SME004 – Vibration is excessive (engine torsion) 1686
SME005 – There is a big shock when stopping slew movement .1687
SME006 – There is a big abnormal noise when moving/stopping slew movement .1688
SME007 – Fan blades make abnormal noise .1690
SME008 – Abnormal noise coming from a travel gearbox 1692
SME009 – Abnormal noise coming from the work equipment (lack of grease) .1694
SME010 – Abnormal idler movement 1696
SME011 – Leak at the PTO shaft seal .1698
7.4 Symptoms of Additional Systems 1700
SAD001 – Air conditioner for the cabin does not work 1700
View onto the A/C unit (SAD001) .1701
SAD002 – Air conditioner compressor clutch is burnt .1702
View onto the A/C compressor and its mounting (SAD002) 1703
SAD003 – Air conditioning system defective (pipes and hoses full of moisture) .1704
View onto the A/C filling and service station .1705
50 Disassembly & Assembly .1707
TOC .1709
1 Introduction 1717
1.1 Foreword 1718
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 1719
1.3 Diagrams and illustrations in this manual .1719
1.4 Procedures for disassembling and assembling in this manual 1720
2 Safety 1721
2.1 Overview 1723
2.1.1 Method of using this manual .1723
2.2 General precautions .1725
2.2.1 General .1725
2.2.2 Personal protective clothing 1725
2.2.3 When using a hammer .1726
2.2.4 Proper tools 1726
2.2.5 Personnel .1726
2.2.6 Fire prevention .1727
2.2.7 Unauthorized modification .1727
2.3 Precautions for maintenance and repair 1728
2.3.1 General precautions .1728
2.3.2 Keep work place clean and tidy 1728
2.3.3 Precautions when welding 1729
2.3.4 Precaution with high pressure fluids 1729
2.3.4.1 Handling high pressure hoses and pipes 1729
2.3.5 Compressed air 1729
2.3.6 Waste materials .1730
3 Superstructure 1731
3.1 Superstructure 1732
3.2 Machine house .1734
3.2.1 Disconnection plate at the machine house 1736
3.2.1.1 Machine house hose ports – port allocations .1736
3.2.2 Machine house roof 1738
3.2.2.1 Disassembling of the machine house roof cover plates 1741
3.2.2.2 Assembling of the machine house roof cover plates .1746
3.2.3 Exhaust System 1750
3.2.3.1 Disassembling of the Exhaust System .1750
3.2.3.2 Assembling of the exhaust system 1753
3.2.4 air intake system .1756
3.2.4.1 Disassembling of the Air intake System 1756
3.2.4.2 Assembling of the air intake system .1759
3.2.5 Air duct 1762
3.2.5.1 Disassembling of the air duct system (if equipped) 1762
3.2.5.2 Assembling of the Air Duct (If equipped) 1763
3.2.6 Diesel engine .1764
3.2.6.1 DISASSEMBLING AND ASSEMBLING OF THE ALTERNATOR 1764
3.2.6.2 DISASSEMBLING AND ASSEMBLING OF THE STARTER MOTORS 1764
3.2.6.3 Disassembling of the Diesel engine 1765
3.2.6.4 Assembling of the Diesel engine .1773
3.2.7 Batteries .1780
3.2.7.1 Disassembling of the batteries 1780
3.2.7.2 Assembling of the batteries .1782
3.2.8 Flexible coupling .1783
3.2.8.1 Disassembling of the CentaFlex coupling assembly 1783
3.2.8.2 Assembling of the CentaFlex coupling assembly .1786
3.2.8.3 Replacing the rubber rollers of the CentaFlex coupling 1788
3.2.9 Radiator fan and fan drive assembly .1790
3.2.9.1 Disassembling of the radiator fan .1792
3.2.9.2 Assembling of the radiator fan 1794
3.2.9.3 Disassembling of the radiator fan motor .1796
3.2.9.4 Assembling of the radiator fan motor 1798
3.2.9.5 Disassembling of the Radiator assembly 1800
3.2.9.6 Assembling of the radiator assembly .1805
3.2.10 Main pump assemblies .1810
3.2.10.1 Disassembling and assembling of the auxiliary pumps 1811
3.2.10.2 Disassembling of the main pump assemblies 1812
3.2.10.3 Assembling of the main pump assemblies .1816
3.2.11 Universal PTO 1820
3.2.11.1 Disassembling of the universal PTO .1820
3.2.11.2 Assembling of the universal PTO 1823
3.3 Hydraulic System 1826
3.3.1 Hydraulic oil cooler assembly .1826
3.3.1.1 Disassembling of hydraulic cooler fan and motor .1827
3.3.1.2 Assembling of hydraulic cooler fan and motor 1830
3.3.1.3 Disassembling of the hydraulic oil radiators 1833
3.3.1.4 Assembling of the hydraulic oil coolers .1837
3.3.1.5 Disassembling of the hydraulic oil cooler assembly 1840
3.3.1.6 Assembling of the hydraulic oil cooler assembly .1845
3.3.2 Hydraulic oil tank 1850
3.3.2.1 Disassembling of the main shut-off valve 1852
3.3.2.2 Assembling of the main shut-off valve .1854
3.3.2.3 Disassembling of the hydraulic oil tank .1856
3.3.2.4 Assembling of the hydraulic oil tank 1861
3.3.3 Main control valve blocks .1868
3.3.3.1 Disassembling of the main control valve blocks 1868
3.3.3.2 Assembling of the main control valve blocks .1871
3.3.3.3 Disassembling of the MRV at the main control valve blocks .1874
3.3.3.4 Assembling of the MRV at the main control valve blocks 1875
3.3.3.5 Disassembling of SRV on main control valve block 1876
3.3.3.6 Assembling of SRV on main control valve blocks 1877
3.3.3.7 Disassembling of ACV-/SRV-block on main control valve blocks 1878
3.3.3.8 Assembling of ACV-/SRV-block on main control valve blocks .1880
3.3.4 Distributor Manifold 1882
3.3.4.1 Disassembling of SRV-valve blocks / restrictor blocks at the distributor manifold .1883
3.3.4.2 Assembling of SRV-valve blocks / restrictor blocks at the distributor manifold 1885
3.3.4.3 Disassembling of anti cavitation valves at the distributor manifold .1887
3.3.4.4 Assembling of anti cavitation valves at the distributor manifold 1889
3.3.4.5 Disassembling of the Diffuser block at the manifold (FSA) .1891
3.3.4.6 Assembling of the Diffuser block at the manifold 1893
3.3.4.7 Disassembling of the distributor manifold .1894
3.3.4.8 Assembling of the distributor manifold 1897
3.4 Slew system .1900
3.4.1 Slew gears 1900
3.4.1.1 Disassembling of the slew gear 1901
3.4.1.2 Assembling of the slew gear .1904
3.4.2 Slew motor 1908
3.4.2.1 Disassembling of the slew motor .1909
3.4.2.2 Assembling of the slew motor 1912
3.4.3 Slew parking brake 1914
3.4.3.1 Disassembling of the slew parking brake of type 2063 1915
3.4.3.2 Assembling of the slew parking brake of type 2063 .1918
3.4.3.3 Disassembling of the slew parking brake of type 632770 1921
3.4.3.4 Assembling of the slew parking brake of type 632770 .1924
3.4.4 slew service brake valve 1927
3.4.4.1 Disassembling of the slew service brake valve .1927
3.4.4.2 Assembling of the of the slew service brake valve .1929
3.4.5 Slew circle .1931
3.4.5.1 Disassembling of the slew circle 1931
3.4.5.2 Assembling of the slew circle .1935
3.4.6 Slew circle lubrication pinion (dummy wheel) 1940
3.4.6.1 Disassembling of the lubrication pinion assembly 1940
3.4.6.2 Assembling of the lubrication pinion assembly .1941
3.5 Lubrication pumps .1942
3.5.1 Disassembling of the lubrication pump .1942
3.5.2 Assembling of the lubricating pump 1943
3.6 Operator’s cab 1944
3.6.1 Disassembling of the operator’s cab .1945
3.6.2 Assembling of the operator’s cab 1949
3.6.3 Disassembling of the operator’s cab together with the cab support frame .1952
3.6.4 Assembling of the operator’s cab together with the cab support frame 1956
3.6.5 Cab-mounts 1960
3.6.5.1 Disassembling of the cab-mounts .1960
3.6.5.2 Assembling of the cab-mounts 1962
3.6.6 Front window 1964
3.6.6.1 Disassembling of the front window .1964
3.6.6.2 Assembling of the front window 1965
3.6.7 Operator’s seat .1966
3.6.7.1 Disassembling of the operator’s seat 1966
3.6.7.2 Assembling of the operator’s seat .1967
3.7 Cab base 1968
3.7.1 Disassembling of the cab support frame 1969
3.7.2 Assembling of the cab support frame .1971
3.7.3 Disassembling of the cab base .1973
3.7.4 Assembling of the cab base 1975
3.8 stairways and platforms .1977
3.8.1 Hydraulic access stairway .1977
3.8.1.1 Disassembling of the hydraulic access stairway 1977
3.8.1.2 Assembling of the hydraulic access stairway .1979
3.8.2 Disassembling of the access stairway cylinder .1981
3.8.3 Assembling of the access stairway cylinder 1983
3.8.4 Fuel tank step 1984
3.8.4.1 Disassembling of the fuel tank step .1984
3.8.4.2 Assembling of the fuel tank step 1986
3.8.5 step platforms 1987
3.8.5.1 Disassembling of the upper step platform at fuel tank .1987
3.8.5.2 Assembling of the upper step platform at fuel tank 1989
3.8.5.3 Disassembling of the lower step platform at machine house .1990
3.8.5.4 Assembling of the lower step platform at machine house 1991
3.8.6 Emergency escape ladders 1992
3.8.6.1 Disassembling of the emergency escape ladder assembly at the cab base .1992
3.8.6.2 Assembling of the emergency escape ladder assembly at the cab base 1994
3.8.6.3 Disassembling of the emergency escape ladder assembly at the machine house 1995
3.8.6.4 Assembling of the emergency escape ladder assembly at the machine house .1997
3.9 Counterweight .1998
3.9.1 Disassembling of the counterweight 1999
3.9.2 Assembling of the counterweight .2001
3.10 Fuel tank 2004
3.10.1 Disassembling of the fuel tank .2004
3.10.2 Assembling of the fuel tank 2008
3.11 Superstructure Lifting .2012
3.11.1 Disassemble the superstructure from the undercarriage 2012
3.11.2 Install the superstructure onto the undercarriage 2015
4 Undercarriage .2019
4.1 Undercarriage overview 2020
4.2 Travel system .2022
4.2.1 Crawler track .2022
4.2.1.1 Changing of the crawler track .2022
4.2.2 Sprocket 2029
4.2.2.1 Disassembling of the sprocket assembly 2029
4.2.2.2 Assembling of the sprocket assembly .2034
4.2.3 Guide wheel assembly 2037
4.2.3.1 Disassembling of the guide wheel assembly .2037
4.2.3.2 Assembling of the guide wheel assembly 2039
4.2.4 Track tensioning accumulators .2042
4.2.4.1 Disassembling of the low pressure accumulators 2042
4.2.4.2 Assembling of the low pressure accumulators .2044
4.2.4.3 Disassembling of the high pressure accumulators .2046
4.2.4.4 Assembling of the high pressure accumulators 2047
4.2.5 Track tension valve block .2048
4.2.5.1 Disassembling of the track tensioning valve block .2048
4.2.5.2 Assembling of the track tensioning valve block 2049
4.2.6 Track tensioning cylinders 2050
4.2.6.1 Disassembling of the track tensioning cylinders .2050
4.2.6.2 Assembling of the track tensioning cylinders 2052
4.2.7 Hydraulic hoses of the track tensioning system 2055
4.2.7.1 Precursory work .2055
4.2.7.2 Replace the hydraulic hoses inside the center body 2057
4.2.7.3 Replace the hydraulic hoses between center body and crawler frame .2057
4.2.7.4 Replace the hydraulic hoses inside the crawler frame 2059
4.2.7.5 Subsequent work .2059
4.2.8 Travel brake valve block (overspeed valve) 2060
4.2.8.1 Disassembling of the travel brake valve block .2060
4.2.8.2 Assembling of the travel brake valve block 2062
4.2.9 Travel motors .2064
4.2.9.1 Disassembling of the travel motors 2064
4.2.9.2 Assembling of the travel motors .2066
4.2.10 Travel parking brake .2068
4.2.10.1 Travel parking brake overview 2068
4.2.10.2 Disassembling of the travel parking brake of type 2063 .2073
4.2.10.3 Assembling of the travel parking brake of type 2063 2076
4.2.10.4 Disassembling of the travel parking brake of type 631053 .2079
4.2.10.5 Assembling of the travel parking brake of type 631053 2082
4.2.11 Travel gear box 2086
4.2.11.1 Disassembling of the travel gear box .2087
4.2.11.2 Assembling of the travel gear box 2089
4.2.12 Carrier roller .2092
4.2.12.1 Disassembling of the carrier roller assembly .2092
4.2.12.2 Assembling of the carrier roller assembly 2094
4.2.13 Track roller .2096
4.2.13.1 Disassembling of the track roller assembly .2096
4.2.13.2 Assembling of the track roller assembly 2098
4.3 Undercarriage center body .2100
4.3.1 Disassembling of the undercarriage center body and the crawler carriers .2100
4.3.2 Assembling of the undercarriage center body and the crawler carriers 2105
4.3.2.1 Install crawler carrier mounting bolts 2111
4.3.3 Rotary joint 2112
4.3.3.1 Disassembling of the rotary joint .2112
4.3.3.2 Assembling of the rotary joint 2116
5 Attachment 2121
5.1 Repair procedures .2122
5.1.1 Replacement of bushings at the attachment .2122
5.1.1.1 Disassembling of the bushings .2122
5.1.1.2 Installation of the bushings 2123
5.1.2 General installation instructions for attachment pins .2124
5.2 Backhoe Attachment (BHA) 2126
5.2.1 Overview 2126
5.2.2 Pin Sealing bucket – Steering Rod – bucket link rod .2128
5.2.3 Boom assembly .2130
5.2.3.1 Disassembling of the Boom .2130
5.2.3.2 Assembling of the boom 2132
5.2.3.3 Disassembling of the boom cylinders .2135
5.2.3.4 Assembling of the boom cylinders 2140
5.2.4 Stick assembly 2145
5.2.4.1 Disassembling of the Stick 2145
5.2.4.2 Assembling of the Stick .2150
5.2.4.3 Disassembling of the Stick Cylinders 2154
5.2.4.4 Assembling of the Stick cylinders .2158
5.2.5 Bucket and steering .2163
5.2.5.1 Disassembling of the bucket .2163
5.2.5.2 Assembling of the bucket 2167
5.2.5.3 Disassembling of the Bucket Cylinders .2170
5.2.5.4 Assembling of the Bucket Cylinders 2177
5.2.5.5 Disassembling of the bucket link rod 2184
5.2.5.6 Assembling of the bucket link rod .2187
5.2.5.7 Disassembling of the steering rods 2190
5.2.5.8 Assembling of the steering rods .2196
5.2.6 Hydraulic hoses at the backhoe attachment .2201
5.2.6.1 Replacing of the boom arc hoses .2201
5.2.6.2 Replacing of the lubrication hoses 2204
5.2.6.3 Replacing of the boom cylinder hoses 2205
5.2.6.4 Replacing of the stick cylinder hoses .2208
5.2.6.5 Replacing of the bucket cylinder hoses 2211
5.3 Front Shovel Attachment (FSA) .2214
5.3.1 Overview 2214
5.3.2 Using the Cylinder Mounting Device for Front shovel attachments (PN 967 000 40) .2216
5.3.2.1 Designated usage 2217
5.3.2.2 Non-designated usage 2217
5.3.3 Boom assembly .2218
5.3.3.1 Disassembling of the boom .2218
5.3.3.2 Assembling of the boom 2221
5.3.3.3 Disassembling of the boom cylinders .2224
5.3.3.4 Assembling of the boom cylinders 2229
5.3.4 Stick assembly 2234
5.3.4.1 Disassembling of the stick 2234
5.3.4.2 Assembling of the stick .2239
5.3.4.3 Disassembling of the stick cylinders 2244
5.3.4.4 Assembling of the stick cylinders .2248
5.3.5 Bull Clam bucket 2252
5.3.5.1 Disassembling of the bull clam bucket .2252
5.3.5.2 Assembling of the bull clam bucket 2256
5.3.5.3 Disassembling of the bucket cylinders .2260
5.3.5.4 Assembling of the bucket cylinders 2266
5.3.5.5 Disassembling of the clam cylinders .2272
5.3.5.6 Assembling of the clam cylinders 2277
5.3.6 Hydraulic hoses at the Faceshovel attachment 2283
5.3.6.1 Replacing of the boom arc hoses .2283
5.3.6.2 Replacing of the lubrication hoses 2286
5.3.6.3 Replacing of the boom cylinder hoses 2287
5.3.6.4 Replacing of the stick arc hoses 2290
5.3.6.5 Replacing of the stick cylinder hoses .2293
5.3.6.6 Replacing of the bucket cylinder hoses 2296
5.3.6.7 Replacing of the clam cylinder hoses 2298
5.4 Metering valves (grease injectors) at the attachment 2304
5.4.1 Disassembling of the metering valves (grease injectors) .2304
5.4.2 Assembling of the metering valves (grease injectors) 2306
5.5 Ground engaging tools (GET) .2307
5.5.1 Disassembling and assembling of the GET .2307
5.6 Cylinder bypass test 2309
6 Service Information .2311
6.1 Fluids and lubricants .2312
6.2 Lifting Gears .2312
6.3 Safety hints for sling accessory 2314
6.4 Weight tables .2315
6.4.1 Superstructure 2315
6.4.2 Undercarriage .2317
6.4.3 Backhoe attachment (BHA) 2318
6.4.4 Face shovel attachment (FSA) 2319
6.5 Torque charts according to KOMATSU company standard .2320
6.5.1 Metric standard thread 2320
6.5.2 Metric fine thread 2321
6.5.3 Cummins motor torques – metric 2322
6.5.4 Cummins motor torques – U.S. customary 2322
6.5.5 SAE-flange connections 2323
6.6 Blind plugs .2324
6.6.1 Dummy plates for SAE–flanges 2324
6.6.2 Classification of threads to the nominal width 2326
6.6.3 Plugs and fittings according to DIN 2353 2327
6.7 Conversion table 2328
6.7.1 Method of using the conversation table 2328
6.7.2 Millimeter – inch & kilogram – pound 2329
6.7.3 Liter – U.S. gallon & liter – U.K. gallon .2330
6.7.4 Nm- ft.lb .2331
6.7.5 Bar – PSI – kPa – MPa .2332
6.7.6 Temperature .2333
6.8 Tools .2334
6.8.1 Standard tool case 2334
6.8.2 Used special tools (Overview) .2336
6.9 Work instructions .2339
6.9.1 Bleeding the track tensioning system 2339
6.9.2 Hints for hydraulic hose installation .2341
6.9.3 Remove / install the crawler carrier 2344
6.9.4 Repair procedure for the radiator assembly 2345
7 Parts & Service News 2347
7.1 List of relevant PARTS AND SERVICE NEWS .2348

DESCRIPTION:

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267 – PDF DOWNLOAD

SERIAL NUMBER

08267
08271
08273

BEFORE READING THIS MANUAL:
This manual gives details of the methods of inspection, maintenance and troubleshooting for this machine that
must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental
safety rules for the inspection, maintenance and troubleshooting of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
inspection, maintenance or troubleshooting. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that may involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety
precautions. If you carry out any inspection, maintenance and troubleshooting under conditions that are not
described in this manual, understand that it is your responsibility to take the necessary precautions to ensure
safety. In no event should you or others engage in prohibited uses or actions described in this manual.
Improper inspection, maintenance and troubleshooting of the machine can be hazardous and could result in
serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
This manual uses the international units (SI) for units of measurement. For reference, units that have been used
in the past are given in ( ).
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the
latest available information concerning your machine or with questions regarding information contained in this
manual.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which
it has been shipped. If the machine has been purchased in another country, it may lack certain safety devices
and specifications that are necessary for use in your country. If there is any question about whether your
product complies with the applicable standards and regulations of your country, consult Komatsu or your
Komatsu distributor before operating the machine.

G.B 30/12/24

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267 PDF

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267 – PDF DOWNLOAD

Description

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08267 – PDF DOWNLOAD

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