Komatsu PC4000-11 T4 Hydraulic Mining Shovel Shop Manual PDF

Description

Komatsu PC4000-11 T4 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC4000-11 T4 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD 

Language : English
Pages : 2426
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC4000-11 T4 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD 

BEFORE READING THIS MANUAL:

• This manual gives details of the methods of inspection, maintenance and troubleshooting for this excavator
  that must be obeyed in order to use the excavator safely. Most accidents are caused by the failure to follow
  fundamental safety rules for the inspection, maintenance and troubleshooting of excavators.
• Read, understand and follow all precautions and warnings in this manual and on the excavator 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 excavator is used.
  Therefore, the safety messages in this manual and on the excavator 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 excavator can be hazardous and could result in
  serious injury or death.
• If you sell the excavator, be sure to give this manual to the new owner together with the excavator.
• 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 excavator 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 excavator or with questions regarding information contained in this manual.
• Komatsu delivers excavators that comply with all applicable regulations and standards of the country to which
  it has been shipped. If the excavator 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 excavator.

TABLE OF CONTENTS:

Komatsu PC4000-11 T4 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD 

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
TOC 11
2 1 SAFETY INFORMATION 13
2 2 OVERVIEW 14
2 2 1 NORMAL OPERATIONS 14
2 2 2 REGULAR MAINTENANCE 14
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 14
2 2 4 ADDITIONAL SAFETY PRECAUTIONS 14
2 3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 15
2 3 1 SOUND 15
2 3 2 VIBRATION 15
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 16
2 4 1 UNDERSTANDING THE MACHINE 16
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 16
2 4 2 1 ENSURING SAFE OPERATION 16
2 4 3 PREPARATIONS FOR SAFE OPERATION 16
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 16
2 4 3 2 INSPECTING THE MACHINE 16
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 17
2 4 3 4 KEEP MACHINE CLEAN 17
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 17
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 18
2 4 3 7 IF A PROBLEM IS FOUND 18
2 4 4 FIRE PREVENTION 18
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 18
2 4 4 2 ACTION IF FIRE OCCURS ON PC3000 19
2 4 4 3 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000 20
2 4 4 4 EMERGENCY EXIT FROM OPERATOR’S CAB 20
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 21
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 21
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 21
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 21
2 4 5 4 WORKING IN HIGH PLACES 21
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 22
2 4 5 6 LEAVING THE MACHINE 22
2 4 6 BURN PREVENTION 22
2 4 6 1 Hot coolant 22
2 4 6 2 Hot oil 23
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 23
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 23
2 4 9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 24
2 4 9 1 UNAUTHORIZED MODIFICATION 24
2 4 9 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 24
2 4 10 ELECTROMAGNETIC COMPATIBILITY (EMC) 24
2 4 11 PRECAUTIONS AT JOBSITE 25
2 4 11 1 VISIBILITY FROM OPERATOR’S SEAT 26
2 4 11 2 CAMERA SYSTEM WITH MONITORS 26
2 4 11 3 ENSURE GOOD VISIBILITY 26
2 4 11 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 26
2 4 11 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 27
2 4 11 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 27
2 4 11 7 Lightning Strikes 28
2 4 11 8 WORKING ON LOOSE GROUND 28
2 4 11 9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 29
2 4 11 10 VENTILATION OF ENCLOSED AREAS 30
2 4 12 STARTING motor 31
2 4 12 1 WARNING TAG 31
2 4 12 2 CHECKS BEFORE STARTING motor 31
2 4 12 3 PRECAUTION WHEN STARTING motor 31
2 4 12 4 PRECAUTION IN COLD AREAS 32
2 4 13 OPERATION 32
2 4 13 1 CHECKS BEFORE OPERATION 32
2 4 13 2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 33
2 4 13 3 PRECAUTIONS WHEN traveling 34
2 4 13 4 TRAVELING ON SLOPES 35
2 4 13 5 OPERATIONS ON SLOPES 36
2 4 13 6 PROHIBITED OPERATIONS 36
2 4 13 7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 37
2 4 13 8 PARKING THE MACHINE 37
2 4 13 9 TRANSPORTATION 37
2 5 PRECAUTION FOR MAINTENANCE 38
2 5 1 GENERAL PRECAUTIONS 38
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 39
2 5 1 2 STOP motor FOR MAINTENANCE 40
2 5 1 3 WARNING TAG 41
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 42
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 42
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 43
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 43
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 44
2 5 1 9 NOISE 44
2 5 1 10 WHEN USING A HAMMER 44
2 5 1 11 PROPER TOOLS 45
2 5 1 12 ACCUMULATOR 45
2 5 1 13 PERSONNEL 45
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 46
2 5 2 1 PRECAUTION WHEN WELDING 46
2 5 2 2 BATTERY HANDLING 46
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 47
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 48
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 49
2 5 3 3 REPLACEMENT OF HOSE LINES 49
2 5 3 4 INSPECTION OF HOSE LINES 49
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 50
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 50
2 5 3 7 AIR CONDITIONING MAINTENANCE 50
2 5 3 8 COMPRESSED AIR 51
2 5 3 9 WASTE MATERIALS 51
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 52
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 52
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 52
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 52
2 7 SPECIAL SAFETY EQUIPMENT 53
2 7 1 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB 54
2 7 2 OBJECT HANDLING 54
2 7 3 LIGHTING 54
2 7 4 WARNING BEACON 54
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 54
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 54
2 7 5 2 INSTRUCTIONS FOR USE 56
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 58
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 58
2 7 5 5 INSTRUCTIONS FOR USE 60
01 Specification 61
PC4000-11 63
10 Structure & Function 87
TOC 89
1 Introduction 101
1 1 Foreword 102
1 2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 103
1 3 Explanation of abbreviations 104
1 4 Diagrams and illustrations in this manual 105
2 Specifications 107
2 1 Lifting Gears 108
2 2 Safety hints for sling accessory 110
2 3 Standard Tightening Torque Chart 111
2 4 Conversion Table 112
2 5 Blind plugs 118
2 6 Classification of threads to the nominal width 120
2 7 Plugs and fittings according to ISO 8434-1 / DIN 2353 121
3 Main assembly groups 123
3 1 General layout 124
3 2 Superstructure 126
3 2 1 Side view 126
3 2 2 Top view 128
3 3 Machine house 130
3 4 Hydraulic oil tank 132
3 5 Hydraulic oil cooler 134
3 6 Fuel tank 136
3 7 Cab base 138
3 8 Operator’s cab 140
3 9 Control blocks 142
3 10 Slew gear 144
3 10 1 Slew gear of type 2063 144
3 10 2 Slew gear of type 632770 146
3 11 Undercarriage 148
3 12 Slew ring 150
3 13 Attachment 152
3 13 1 Front Shovel Attachment (FSA) 152
3 13 2 Backhoe Attachment (BHA) 154
3 14 Counterweight 156
3 15 Safety circuit (pilot control circuit) 158
3 15 1 Wiring Diagram of 20S105 and 20S105a 160
4 Drive 161
4 1 Prime drive assembly 162
4 2 Engine and PTO mounts 164
4 2 1 Engine Mounts 164
4 2 2 Torque Support 165
4 3 Flexible coupling 166
4 3 1 Information for maintenance 168
4 3 2 Coupling elements 169
4 3 3 Separation and assembly of the coupling inner and outer part 170
4 3 4 Operation troubles, causes, and rectification 171
4 4 Fan drive and radiator assembly 172
4 4 1 Radiator fan drive 174
4 4 2 Fan pump 176
4 4 3 Radiator fan drive speed adjustment 178
4 5 Fuel cooling (T4 equipment) 180
4 6 Pump distributor gearbox (PTO) 182
4 6 1 Pump spline lubrication 184
4 6 1 1 Oil level in the main pump drive shaft housing 185
4 6 2 PTO lubrication and cooling 186
4 6 2 1 Checks and adjustments 188
4 7 Hydraulic pumps – location, drive speed and flow rates 190
4 7 1 Pump data 192
4 8 Air filter 194
5 Hydraulic oil tank 197
5 1 General layout 198
5 2 Hydraulic oil tank, location of the electric equipment 200
5 3 Suction oil tank with strainers 202
5 4 Return oil collector pipe with strainer 204
5 5 Back pressure valve 206
5 6 Transfer pump 208
5 7 Return and leak oil filter 210
5 8 Breather filter 212
6 Hydraulic oil cooling 215
6 1 Overall view of the hydraulic oil cooling 216
6 2 Function of the hydraulic oil cooling circuit 218
6 3 Adjustment of the back pressure valve 220
6 4 Two stage cooler fan RPM control 222
6 4 1 Pressure reducing valve 224
6 4 2 Solenoid valves 226
6 4 3 Fan pump 228
6 5 Checks and Adjustments of the cooler fan drive speeds 230
6 5 1 Function Check of Fan Speed Control 234
7 Controlling 235
7 1 General layout 236
7 2 Control and filter panel 238
7 3 Valve cartridge block 240
7 4 Pilot pressure supply and adjustments 242
7 4 1 Pilot pressure control (PPC) circuit 242
7 4 2 Checks and adjustment of pilot pressure 246
7 4 3 Remote control valves arrangement 248
7 5 Function of the electro-hydraulic control system 250
7 5 1 Electronic hand lever (joystick) 254
7 5 1 1 Voltage supply of hand lever 20S020 255
7 5 1 2 Direction signal course from hand lever to controllers 256
7 5 1 3 Double ratiometric* output diagram 257
7 6 Foot pedal control 258
7 6 1 Voltage supply of Foot lever (20S021a) 260
7 6 2 Direction signal course from foot pedal to controllers 261
7 6 3 Double ratiometric* output diagram for 2 direction pedal 262
7 6 4 Single ratiometric* output diagram for 1 direction pedal 262
7 7 Hand lever & foot pedal monitoring 263
7 7 1 Lever monitoring screens (example) 264
7 7 2 Valve monitoring screen (example) 266
7 8 Valve solenoid adjustment 268
7 8 1 Overview sol min/max current & adjustment range 269
7 9 ACCEL & DECEL time adjustment 270
7 9 1 Accel & Decel times 270
8 Components 273
8 1 Main control blocks and high pressure strainers (FSA) 274
8 2 Main control blocks and high pressure strainers (BHA) 276
8 3 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) 278
8 4 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) 280
8 5 Single control blocks (floating) for stick and boom (FSA) 282
8 6 Restrictor block with secondary relief valve 284
8 7 Anti-cavitation valve (ACV) block 286
8 8 Remote control valves 288
8 9 4/3 Directional solenoid valves 290
8 10 Proportional solenoid valves 292
8 11 High pressure Strainer 294
8 12 Control blocks and valves 296
8 12 1 Spool types 302
8 12 2 MRV, SRV and ACV 304
8 12 3 Load holding valve 306
8 13 Travel brake valve 310
8 14 Pressure reducing valve 312
8 15 4/2 Directional valves 314
8 16 Pressure double stage valve 316
8 17 Hydraulic cylinder with NOK-3 sealing 318
8 17 1 Cylinder data markings 321
9 Main hydraulic pumps and pump regulation 323
9 1 General 324
9 1 1 Pump locations and pump data 326
9 2 Main pumps 328
9 2 1 Hydraulic pump type HPV375+375 328
9 2 1 1 Main pump sectional drawings 330
9 2 2 Servo valve 332
9 2 2 1 VC valve  servo piston 333
9 2 2 2 EPC valve 338
9 3 Electronic pump regulation system 340
9 3 1 Cut-off function 342
9 3 2 Slew control 343
9 3 2 1 Function of slew speed switch 20S154 343
9 3 3 Temperature control 344
9 3 3 1 Hydraulic oil temperature charts 344
9 3 4 Energy efficiency (economy mode) 345
9 4 Pump controller (14K305) 346
9 5 Monitoring, error indication, adjustment 348
9 5 1 Monitoring items of the pump controller 348
9 5 2 Error indication of the pump controller 351
9 5 3 Adjustable parameters of the pump controller 352
9 5 3 1 Description of the Primary P-Factor 354
9 5 4 Pump sol ’min’ current values according to pump type plate 355
9 5 5 Pump sol ’max’ current values according to pump type plate 356
9 6 Checks and adjustments 358
9 6 1 Engine power check 358
9 6 2 Cut-off function check 360
9 6 2 1 Cut-off for clam close (FSA only) 361
9 7 Engine speed sensor (pick-up) 362
9 7 1 General 363
9 7 2 Engine speed sensor (pick-up) adjustment 363
9 7 3 In case of problems – when correct speed sensor adjustment is guaranteed 364
10 Operating hydraulics 365
10 1 General 366
10 1 1 Floating system (FSA only) 368
10 2 Hydraulics for the attachment cylinders 372
10 2 1 Electric / hydraulic flowchart “Boom UP” (FSA) 372
10 2 2 Electric / hydraulic flowchart “boom up” (BHA) 374
10 2 3 Electric / hydraulic flowchart “boom down” (FSA) 376
10 2 4 Electric / hydraulic flowchart “Boom down” (BHA) 378
10 2 5 Electric / hydraulic flowchart “Stick out” (FSA) 380
10 2 6 Electric / hydraulic flowchart “Stick out” (BHA) 382
10 2 7 Electric / hydraulic flowchart “Stick in” (FSA) 384
10 2 8 Electric / hydraulic flowchart “Stick in” (BHA) 386
10 2 9 Electric / hydraulic flowchart “Bucket fill” (FSA) 388
10 2 10 Electric / hydraulic flowchart “Bucket fill” (BHA) 390
10 2 11 Electric / hydraulic flowchart “Bucket dump” (FSA) 392
10 2 12 Electric / hydraulic flowchart “Bucket dump” (BHA) 394
10 2 13 Electric / hydraulic flowchart “Clam open” (FSA) 396
10 2 14 Electric / hydraulic flowchart “Clam close” (FSA) 398
10 2 15 Checks & adjustments of the main relief valve (MRV) 400
10 2 16 Checks and adjustments of the secondary relief valves (SRV) 402
10 2 16 1 Boom cylinders, piston side (BHA & FSA), boom up 402
10 2 16 2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down 406
10 2 16 3 Stick cylinders, piston side (FSA), stick out 410
10 2 16 4 Stick cylinders, piston side (BHA), stick in 414
10 2 16 5 Stick cylinders, piston rod side (FSA), stick in 418
10 2 16 6 Stick cylinders, piston rod side (BHA), stick out 422
10 2 16 7 Bucket cylinders, piston side (FSA), bucket fill 426
10 2 16 8 Bucket cylinders, piston side (BHA), bucket fill 430
10 2 16 9 Bucket cylinders, piston rod side (FSA), bucket dump 434
10 2 16 10 Bucket cylinders, piston rod side (BHA), bucket dump 438
10 2 16 11 Clam cylinders, piston rod side (FSA), clam open 442
10 2 16 12 Clam cylinders, piston side (FSA), clam close 446
10 2 17 Checks and adjustments of the lowering speed 450
10 2 17 1 Checks and adjustments of the lowering speed – boom (FSA) 450
10 2 17 2 Checks and adjustments of the lowering speed – boom (BHA) 456
10 2 17 3 Checks and adjustments of the lowering speed – stick (FSA) 458
10 2 17 4 Checks and adjustments of the lowering speed – stick (BHA) 464
10 2 17 5 Checks and adjustments of the lowering speed – bucket (FSA) 466
10 2 17 6 Checks and adjustments of the lowering speed – bucket (BHA) 468
10 2 17 7 Checks and adjustments of the lowering speed – clam (FSA) 470
10 3 Hydraulics for the slew circuit 472
10 3 1 Slew circuit 472
10 3 2 Slew motor 476
10 3 3 Slew gearbox of type 2063 478
10 3 4 Slew gearbox of type 632770 480
10 3 5 Slew parking brake of type 2063 482
10 3 6 Slew parking brake of type 632770 484
10 3 7 Slew brake valve 486
10 3 8 Electric / hydraulic flowchart “Slew left” 490
10 3 9 Electric / hydraulic flowchart “Slew right” 492
10 3 10 Checks and adjustments for the slew circuit 494
10 3 10 1 Checks & adjustments, slew speed 494
10 3 10 2 Checks & adjustments, double stage valve 496
10 3 10 3 Checks of the brake pilot pressure 499
10 3 11 Function check for hydraulic slew brake 500
10 3 12 Slew parking brake release function check 502
10 4 Hydraulics for the travel system 504
10 4 1 Travel circuit 504
10 4 2 Travel motor 506
10 4 3 Rotary joint 508
10 4 4 Travel gearbox 510
10 4 4 1 Travel gearbox of type 2063 510
10 4 4 2 Travel gearbox of type 631053 512
10 4 5 Travel parking brake 514
10 4 5 1 Travel parking brake of type 631053 514
10 4 5 2 Travel parking brake of type 2063 515
10 5 Travel brake valve 516
10 5 1 Electric / hydraulic flowchart “travel forward” 518
10 5 2 Electric / hydraulic flowchart “travel backwards” 520
10 5 3 Checks and adjustments 522
10 5 3 1 Checks and adjustments for the travel circuit 522
10 5 3 2 Function check for the travel parking brake 526
11 Hydraulic track tensioning system 529
11 1 General 530
11 2 Functional description 532
11 3 Double stage valve 534
11 4 Tensioning cylinder 536
11 5 Adjustments / checks 538
12 Access ladder, hydraulically operated 541
12 1 General 542
12 2 Function of the hydraulically operated access ladder 544
12 3 Adjustments / checks 550
13 Central refilling system (Service arm) 553
13 1 General 554
13 2 Function 556
14 Hints for reading the Hydraulic Diagram 559
14 1 General 560
14 2 Hydraulic symbols 562
14 2 1 Lines, unions 563
14 2 2 Components, valves 565
14 2 3 Sensors 565
14 2 4 Valves, valve components 566
14 2 5 Pump, motor, cylinder 570
15 Hints for reading the electric Wiring Diagram 575
15 1 General 576
15 2 Reference code of the electrical components 577
15 2 1 Area code 577
15 2 2 Component identifying letter 578
15 3 Graphical symbols 579
15 4 Concept of the Wiring Diagram 584
15 4 1 Cover page of the Komatsu W/D 584
15 4 2 Example 1 from the schematics in the W/D 586
15 4 3 Example 2 from the schematics in the W/D 588
15 4 4 Table of contents in the W/D (page 1 of 2) 590
15 4 5 Location list 592
15 4 6 Cross reference list for electr components in the W/D 594
15 4 7 Cross reference list for terminals in the W/D 596
15 4 8 Cross reference list for connectors in the W/D 598
15 4 9 Cross reference list for terminal boards in the W/D 600
15 4 10 Connection table 602
15 5 Cable and connector marking 604
15 6 Cable color identification 606
16 Monitoring & Control System 607
16 1 General 608
16 1 1 Monitoring & control system – overview 608
16 1 2 Global layout PC4000-11 T4 609
16 1 3 Controller system overview PC4000-11 T4 610
16 1 4 Interface connection 612
16 1 5 General description 613
16 2 Machine monitor – Operator level 614
16 2 1 Main gauge screens 616
16 2 2 Operator menu / tabs / functions of keys F1 F6 620
16 2 2 1 Operator menu: ECO Guidance – Operation Records 622
16 2 2 2 Operator menu: ECO Guidance-Average Fuel Consumption Logs 624
16 2 2 3 Operator menu: Machine Setting 626
16 2 2 4 Operator menu: Aftertreatment cleaning 628
16 2 2 5 Operator menu: SCR Information 634
16 2 2 6 Operator menu: Maintenance 638
16 2 2 7 Reset of ’remaining time’ till next maintenance interval 640
16 2 2 8 Usage limitation 641
16 2 2 9 Operator menu: Monitor Setting – Screen Adjustment 643
16 2 2 10 Operator menu: Monitor Setting – Clock Adjustment – Calender 644
16 2 2 11 Operator menu: Monitor Setting – Clock Adjustment – Time 645
16 2 2 12 Operator menu: Monitor Setting – Clock Adjustment – 12h/24h Mode 646
16 2 2 13 Operator menu: Monitor Setting – Clock Adjustment – Daylight Saving Time 647
16 2 2 14 Operator menu: Monitor Setting – Language 648
16 2 2 15 Operator menu: Message screen 649
16 3 Error and status indication on the operator level 650
16 3 1 Prompts (status indications) 650
16 3 2 Cautions 651
16 3 3 Warning icons for Tier 4 equipment 652
16 3 4 Emergency shutdown screen 654
16 3 5 Fault levels for error messages 656
16 3 6 Action code level L01 657
16 3 7 Action code level L02 658
16 3 8 Action code level L03 659
16 3 9 Action code level L04 660
16 3 10 Error list 661
16 4 Table of failure codes 662
16 4 1 Failure codes without monitor indication 675
16 4 2 Additional text information for action codes 675
16 5 Table of C-codes – Diesel engine Tier4 676
16 6 Flow charts of machine monitor screens 694
16 6 1 Flow chart Operator Level 694
16 6 2 Flow chart Service Level 695
16 7 Machine monitor 696
16 7 1 Entering the Service Level 696
16 7 2 Key symbols (F1 F6) on the Service Level 698
16 7 3 Service Menu selection screens 699
16 8 Service Menu – item 01 Monitoring / Custom 701
16 8 1 Monitoring list for: ENG controller 701
16 8 2 Monitoring list for: PUMP controller 703
16 8 3 Monitoring list for: VALVE0 controller 706
16 8 4 Monitoring list for: VALVE1 controller 709
16 8 5 Monitoring list for: VALVE2 controller 712
16 8 6 Monitoring list for: MON (monitor) 714
16 8 7 Monitoring list for: KOM PLS (K+ controller) 716
16 8 8 How to perform the monitoring function 718
16 9 Service Menu – item 02 PM Clinic 720
16 9 1 PM Clinic (General) 720
16 9 2 PM Clinic (Power Check) 721
16 9 3 Functions of PM CLINIC (POWER CHECK) 722
16 10 Service Menu – item 03 Memory Clear 723
16 11 Service Menu – item 04 Abnormality record 724
16 11 1 Reset error messages 725
16 12 Service Menu – item 05 Maintenance record 726
16 13 Service Menu – item 06 Maintenance Mode Setting 727
16 14 Service Menu – item 07 Snap Shot 728
16 15 Service Menu – item 08 Phone Number Entry 729
16 16 Service Menu – item 09 Default 730
16 17 Service Menu – item 10 Unit 732
16 18 Service Menu – item 11 Adjustment 733
16 18 1 Adjustments for: PUMP controller 733
16 18 2 Pump sol ’min’ current values according to pump type plate 736
16 18 3 Pump sol ’max’ current values according to pump type plate 737
16 18 4 Adjustments for: VALVE0 controller 738
16 18 5 Accel & Decel times 745
16 18 6 Adjustments for: VALVE2 controller 746
16 18 7 Adjustments for: MON (Monitor) 747
16 18 7 1 Using the Idling Stop Timer 748
16 19 Service Menu – item 12 Machine Configuration 750
16 19 1 Details of Machine Configuration for PC4000-11 T4 751
16 19 2 Changing lever control from EURO to KMG 752
16 19 2 1 Changing lever control from KMG to EURO 752
16 19 3 Changing attachment type from FSA to BHA 754
16 19 3 1 Changing attachment type from BHA to FSA 754
16 19 4 In case of problems during changing procedure for lever control or attachment type 755
16 19 5 Hydraulic Oil & PTO Gear Oil Definition Tables 756
16 19 5 1 Hydraulic oil temperature charts 756
16 19 5 2 PTO gear oil temperature charts 756
16 20 Service Menu – item 13 KOMTRAX Settings 757
16 21 Service Menu – item 14 Service Message 758
16 22 Automatic engine speed control 759
16 22 1 Auto Deceleration mode 759
16 22 2 Auto Low Idle mode 759
16 22 3 Idling Stop Timer 759
16 23 KOMTRAX Plus controller (UM600) 760
16 24 CR720 controller 764
16 24 1 Location of CR720 controllers 764
16 25 Controller replacement procedure 766
16 25 1 Sequence of the controller replacement procedure 766
16 25 2 After controller replacement 767
16 25 3 Controller location 768
17 Lubrication system 769
17 1 General overview (SLS & CLS ) 770
17 1 1 General description 771
17 2 Basic function of the lubrication systems 772
17 3 Lubrication systems (CLS 1 & SLS) 774
17 3 1 Lubrication pump station 774
17 3 2 General Information on CLS 1 776
17 3 3 General information on the SLS 776
17 3 4 Manual lube activation 776
17 4 Lubrication cycle 777
17 4 1 Operation and control 777
17 4 2 Lubrication cycle – processing 778
17 4 3 Time segments & switch points of a lubrication cycle 779
17 4 4 Lubrication modes 780
17 4 4 1 Automatic lubrication mode 780
17 4 4 2 Manual lubrication mode 780
17 4 4 3 REDUCED PAUSE TIME FOR SERVICE 780
17 5 Hydraulically driven lube pump 782
17 5 1 Adjustment of lube pump speed 784
17 5 1 1 Stroke speed adjustment 785
17 5 1 2 Working pressure 785
17 6 Lubricant injectors 786
17 6 1 Tightening torques for fittings at grease injectors 787
17 6 2 Description 787
17 6 3 Adjustment of the lubricant output 788
17 6 4 Operation principle of lubricant injectors 790
17 6 4 1 Function description 791
17 6 5 Connection of one or more injectors 792
17 7 Vent Valve and grease outlet filter 794
17 7 1 Vent valve description 795
17 8 End-line switch 796
17 8 1 Description 797
17 8 2 CLS 1 end-line switch adjustment 798
17 8 3 SLS end-line switch adjustment 800
17 9 Lubricant level sensors 802
17 9 1 Description 803
17 9 1 1 Checks 803
17 10 Commissioning 804
17 10 1 Commissioning of the CLS 1 lubrication system 804
17 10 2 Fine adjustment 805
17 10 3 Commissioning of the SLS lubrication system 806
18 Deep temperature equipment (option) 809
18 1 General information 810
18 1 1 Introduction 810
18 1 2 Deep temperature components overview 810
18 1 3 Power supply preconditions for preheating 811
18 1 4 Power requirements for preheating systems 812
18 2 Preheating procedure 813
18 2 1 Global flow chart of the preheating procedure 813
18 2 2 Starting the preheating procedure 814
18 2 3 Preheating of operator’s cab and Diesel engine [coolant system] 815
18 2 4 Preheating of lubricants and superstructure (Diesel) [electric system] 816
18 3 Constant heating of travel motors (TTT equipment below-40°C only) 817
18 4 Component location 818
18 4 1 Electric heating elements for hydraulic & batteries [electric machine] 818
18 4 2 Electric heating elements for hydraulics [Diesel machine] 820
18 4 3 Electric heating elements for engines & batteries [Diesel machine] 822
18 5 Components of TT equipment 824
18 5 1 Preheating components on a Diesel machine 824
18 5 2 Preheating components on an electric machine 825
18 5 3 Wiring Diagrams for preheating systems (examples) 826
18 5 3 1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 826
18 5 3 2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 827
18 5 3 3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 828
18 5 3 4 Wiring diagram “Suction Oil Manifold Preheating” 829
18 5 3 5 Wiring diagram “PTO Preheating” 830
18 5 3 6 Wiring diagram “Battery heater pads” 831
40 Troubleshooting 833
TOC 835
1 Introduction 861
1 1 Overview 862
1 1 1 General advice when using troubleshooting charts 862
1 2 General Precautions 863
2 General Information for Troubleshooting 865
2 1 Preparations For Work 866
2 2 Precautions During Work 866
2 3 Precautions When Carrying Out Any Operation 867
2 3 1 Precautions when carrying out removal work 867
2 3 2 Precautions when carrying out installation work 867
2 3 3 Precautions when completing the operation 868
2 4 Fundamental Requirements for Trouble shooting 869
2 4 1 Technical documentation 869
2 4 2 Tools 869
2 4 2 1 Reference Guide for Deutsch Removal Tools 872
2 4 3 Personnel 873
2 5 Points To Remember When Trouble- shooting 873
2 6 Sequence Of Events In Troubleshooting 875
2 7 Checks Before Troubleshooting 876
2 8 Handling Of Electric Equipment And Hydraulic Components 877
2 8 1 Points to remember when handling electric equipment 877
2 8 2 Points To Remember When Handling Hydraulic Equipment 879
2 9 General working procedures 882
2 9 1 Air Bleeding of Various Hydraulic Parts 882
2 9 2 Air bleeding from the hydraulic pumps 882
2 9 3 Air bleeding from hydraulic cylinders 882
2 10 Cylinder bypass test 883
2 11 Basics about “How to crimp” (with strain relief) 884
2 11 1 Crimp tool & repair kit 884
2 11 2 General 885
2 11 3 Select the required connector components 885
2 11 4 Stripping a wire 886
2 11 5 Crimping 887
2 11 6 Connector assembly after crimping 888
2 12 Cable Shielding 889
3 Mounting Locations and Connector Types 891
3 1 Side view onto the superstructure 892
3 2 Top view onto the superstructure 894
3 3 Location of engine electrical parts 896
3 3 1 Engine side view 896
3 3 2 Engine top view 897
3 3 3 Location of engine remote oil tank sensors 899
3 4 Location of hydraulic components (1) 900
3 4 1 Location of hydraulic components (2) 902
3 4 2 Location of hydraulic components (3) 904
3 5 View onto the SLS or CLS grease barrel and the lubrication cycle components 906
3 6 Batteries, battery main switches & safety switch for maintenance 908
3 7 Hydraulic oil tank & suction oil tank – Location of electrical components 910
3 8 Hydraulically operated access ladder 912
3 9 Service arm 914
3 10 Connector Types Overview 916
4 Standard Value Table for Electrical Components 921
5 Tables for Testing and Troubleshooting 935
5 1 Test Value Tables for Transducers 936
5 1 1 Pump press transducers 936
5 1 2 Hydraulic oil pressure transducers 937
5 1 3 Miscellaneous Pressure Transducers 938
5 1 4 Temperature Transducers 939
5 2 Hydraulic oil temperature charts 940
5 3 PTO gear oil temperature charts 940
5 4 Table of failure codes 941
5 5 Table of C-codes – Diesel engine Tier4 954
5 6 Tables of Symptom Codes 971
5 6 1 Symptoms of the engine and Related electrical systems 971
5 6 2 Symptoms of the Hydraulic System 971
5 6 3 Symptoms of the Mechanical System 972
5 6 4 Symptoms of Additional Systems 972
5 7 Cable colour identification 973
6 Troubleshooting by Trouble Code 975
B@HANS – Hyd Oil Overheat 976
Hydraulic diagram and location of 57K506a/b-1 for message B@HANS 978
6A1BMA – Trouble Shut-Off (gate) valve not open error 979
View onto the gap of proximity switch 40B031 980
Wiring Diagram (40B031) for message 6A1BMA 981
AA10NX – Air Cleaner1 Clogging 982
View onto the engine air cleaner (AA10NX) 983
AB00KE – Charge Voltage Low 986
Wiring Diagram (alternator) for message AB00KE 987
K@3A00 – Fire In System 988
Configuration information for Fire Suppression System Machinery House 989
Monitoring information for Fire Suppression System Machinery House 989
Wiring Diagram (20K351) for message K@3A00 990
Wiring Diagram (controller input of fire suppression system MH) for K@3A00 991
B@F0MA – CLS1 Lubrication System Error 992
B@CPMA – SLS Lubrication System Error 993
B@F0N9 – CLS1 pressure increase time too long 994
B@CPN9 – SLS pressure increase time too long 994
Allocation of vent valves and end-of-line switches 995
Vent valve (62Q507a & 62Q509a) 996
Wiring Diagram – lube pump solenoid & vent valve (CLS1 & SLS) 997
B@F0N0 – CLS1 pressure decrease time too long 998
B@CPN0 – SLS pressure decrease time too long 998
Vent valve (62Q507a & 62Q509a) 999
B@F0ZK – CLS1 grease level too low 1000
B@CPZK – SLS grease level too low 1000
Wiring Diagram – grease level sensors (CLS1) 1002
Wiring Diagram – grease level sensors (SLS) 1003
B@HAZK – Hydraulic oil level too low 1004
Hydraulic oil level in defined machine position 1005
Wiring Diagram – hydraulic oil level sensor 40B004 1006
B@CBNS – PTO1 Gear Oil Temp High 1007
View onto the universal pump distributor gearbox (PTO) 1009
B@CBZG – PTO1 Gear Lubrication Error 1011
Monitoring PTO lube oil pressure 1012
Shutdown adjustment for PTO lube oil pressure 1012
B@H2NX – Breather Filter Clogging 1013
Location of 40B024 and hydraulic oil level definitions 1014
B@M9NX – PTO1 Gear Oil Filter Clogging 1015
View onto the PTO1 gear oil filter with pressure sensor 57B027-1 1016
B@HBNX – Return Oil Filter Clogging 1017
B@L4NX – Leak Oil Filter Clogging 1018
B@L5N9 – Pilot Press X2 Too Low 1019
Valve cartridge block, location of components 1020
B@L5N0 – Pilot Press X2 Too High 1021
Valve cartridge block, location of components 1022
B@BKPQ – Eng Remote Oil Tank1 Empty 1023
B@HANX – Screen At Hyd Cooler Entry Clogging 1024
Hydraulic oil tank & return oil collector pipe with strainer, location of components 1025
AB30MA – Starter Circuit Abnormality 1027
Wiring Diagram for AB30MA 1028
989HMA – Emergency stop line abnormality 1029
Wiring Diagram – emergency line for 989HMA 1030
Monitoring screens for message 989HMA 1031
DGT3MA – PTO1 oil temperature sensor abnormality 1033
Wiring Diagram and location of 57B049-1 1034
DGH2MA – Hydraulic oil temp sensor abnormality 1035
Wiring Diagram and monitoring selection for 59B015 1036
DHQ7MA – PTO1 lube pressure sensor abnormality 1037
Wiring Diagram and monitoring selection for 57B017-1 1038
D1E7KB – Starter cut relay short circuit 1039
Wiring Diagram – Starter cut relay for message D1E7KB 1040
D1E7KY – Starter cut relay hot short circuit 1041
Wiring Diagram – Starter cut relay for message D1E7KY 1042
DHPEMA – Pump-1/2 pressure sensor abnormality 1043
DHPGMA – Pump-3/4 pressure sensor abnormality 1043
DHPJMA – Pump-5/6 pressure sensor abnormality 1043
DHPLMA – Pump-7/8 pressure sensor abnormality 1043
Wiring Diagram – PWR and GND supply for pump pressure transducers 1045
DLE2MA – Engine speed sensor abnormality 1047
Wiring Diagram – 52B064 for message DLE2MA 1048
DA27KP – 24V sensor power abnormality 1049
Wiring Diagram – 24V sensor power supply for DA27KP 1050
DA26KP – 5V sensor2 power abnormality 1051
Wiring Diagram – 5V sensor power supply for DA26KP 1052
DA22KK – Solenoid Power Low Error(Pump Con) 1053
DA22MA – Solenoid Power Circuit Abnormality 1054
Wiring Diagram 1 – emergency stop line for DA22MA 1055
Wiring Diagram 2 for DA22MA 1056
DXAAKA – Pump1 Solenoid open circuit 1057
DXABKA – Pump2 Solenoid open circuit 1057
DXACKA – Pump3 Solenoid open circuit 1057
DXADKA – Pump4 Solenoid open circuit 1057
DXAEKA – Pump5 Solenoid open circuit 1057
DXAFKA – Pump6 Solenoid open circuit 1057
DXAGKA – Pump7 Solenoid open circuit 1057
DXAHKA – Pump8 Solenoid open circuit 1057
Wiring Diagram – EPC valve control 1059
DXAAKB – Pump1 Solenoid short circuit 1060
DXABKB – Pump2 Solenoid short circuit 1060
DXACKB – Pump3 Solenoid short circuit 1060
DXADKB – Pump4 Solenoid short circuit 1060
DXAEKB – Pump5 Solenoid short circuit 1060
DXAFKB – Pump6 Solenoid short circuit 1060
DXAGKB – Pump7 Solenoid short circuit 1060
DXAHKB – Pump8 Solenoid short circuit 1060
Wiring Diagram – EPC valve control 1062
DWA5KA – CLS pump solenoid open circuit 1063
DWA8KA – SLS pump solenoid open circuit 1063
Wiring Diagram – CLS/SLS pump solenoid control 1064
DWA5KB – CLS pump solenoid short circuit 1065
DWA8KB – SLS pump solenoid short circuit 1065
Wiring Diagram – CLS/SLS pump solenoid control 1066
DWA5KY – CLS pump solenoid hot short circuit 1067
DWA8KY – SLS pump solenoid hot short circuit 1067
Wiring Diagram – CLS/SLS pump solenoid / hot short circuit 1068
DWA7KA – CLS line release solenoid open circuit 1069
DWA9KA – SLS lube line release sol open circuit 1069
Wiring Diagram – CLS/SLS lube line release solenoid control 1070
DWA7KB – CLS line release solenoid short circuit 1071
DWA9KB – SLS lube line release solenoid short circuit 1071
Wiring Diagram – CLS/SLS lube line release solenoid control 1072
DWA7KY – CLS line release sol hot short circuit 1073
DWA9KY – SLS lube line release sol hot short circuit 1073
Wiring Diagram – CLS/SLS lube line release solenoid / hot short circuit 1074
DWAAKA – PTO lube preload solenoid open circuit 1075
Wiring Diagram and monitoring screen for message DWAAKA 1076
DWAAKB – PTO lube preload solenoid short circuit 1077
Wiring Diagram and monitoring screen for message DWAAKB 1078
DWAAKY – PTO lube preload sol hot short circuit 1079
Wiring Diagram for message DWAAKY 1080
D166KB – Oil cooler fan sol(Min)relay short circuit 1081
Wiring Diagram – relay 11K068 for 57K506a (D166KB) 1082
D167KB – Oil cooler fan sol(Mid)relay short circuit 1083
Wiring Diagram – relay 11K069 for 57K506b (D167KB) 1084
D168KB – Oil cooler preload sol relay short circuit 1085
Wiring Diagram – Relay 11K070 (D168KB) 1086
D1E9KB – Wiper fast relay short circuit 1087
D1ETKB – Wiper slow relay short circuit 1087
D1EBKB – Wiper stop relay short circuit 1087
Wiring Diagram – wiper motor control 1088
D162KB – Horn relay short circuit 1089
Wiring Diagram – signal horn control 1090
D1F0KB – Engine1/motor1 shutdown relay short circuit 1091
Wiring Diagram 1 – engine1 shutdown relay 11K064-1 1092
D1F0KY – Engine1/motor1 shutdown relay hot short 1093
Wiring Diagram for D1F0KY 1094
D110KA – Battery relay open circuit 1095
Wiring Diagram – battery relay 11Q044d 1096
D110KB – Battery relay short circuit 1097
Wiring Diagram – Battery relay 11Q044d 1098
DA29KQ – Model Selection Abnormality 1099
Monitoring screen for machine selection 1099
Wiring Diagram – machine selection abnormality (DA29KQ) 1100
DA2YKQ – Motor/Engine Selection Abnormality 1101
Monitoring screen for motor/engine selection 1101
Wiring Diagram – motor/engine selection abnormality (DA2YKQ) 1102
DA20KQ – Pump Con Selection Abnormality 1103
Monitoring screen for PUMP controller selection 1103
DDABMC – Lock lever switch abnormality 1105
Wiring Diagram – lock lever switch 20S105 (DDABMC) 1106
DKURMA – R lever right-left potentio abnormality 1107
Wiring Diagram – right lever right-left potentiometer input (DKURMA) 1108
DKUSMA – R lever right-left redu pot abnorm(VALVE/M) 1109
Wiring Diagram – right lever redundant right-left potentiometer input (DKUSMA) 1110
DKUQL8 – R lever right-left potentio error 1111
Wiring Diagram – right lever main + redundant right-left signal voltage (DKUQL8) 1112
DKUQL4 – R lever right-left sig mismatch(VALVE/M) 1113
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1 1115
DKUNMA – R lever front-back potentio abnormality 1117
Wiring Diagram – right lever front-back potentiometer input (DKUNMA) 1118
DKUPMA – R lever front-back redu pot abnorm(VALVE/M) 1119
Wiring Diagram – right lever redundant front-back potentiometer input (DKUPMA) 1120
DKUML8 – R lever front-back potentio error 1121
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8) 1122
DKUML4 – R lever front-back sig mismatch(VALVE/M) 1123
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1 1125
DKUXMA – Left lever right-left potentio abnormality 1127
Wiring Diagram – left lever right-left potentiometer input (DKUXMA) 1128
DKUYMA – L lever right-left redu pot abnorm(VALVE/M) 1129
Wiring Diagram – left lever redundant right-left potentiometer input (DKUYMA) 1130
DKUWL8 – L lever right-left potentio error 1131
Wiring Diagram – left lever main + redundant right-left signal voltage (DKUWL8) 1132
DKUWL4 – L lever right-left sig mismatch(VALVE/M) 1133
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1 1135
DKUUMA – L lever front-back potentio abnormality 1137
Wiring Diagram – left lever front-back potentiometer input (DKUUMA) 1138
DKUVMA – L lever front-back redu pot abnorm(VALVE/M) 1139
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/M) for DKUVMA 1140
DKUTL8 – L lever front-back potentio error 1141
Wiring Diagram – L lever front-back potentio error (DKUTL8) 1142
DKUTL4 – L lever front-back sig mismatch(VALVE/M) 1143
Wiring Diagram – L lever front-back sig mismatch(VALVE/M) for DKUTL4 1145
DKW1MA – R pedal potentio abnormality 1147
Wiring Diagram – R pedal potentio abnormality (DKW1MA) 1148
DKW2MA – R pedal redundant pot abnormality(VALVE/M) 1149
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA 1150
DKW0L8 – R pedal potentio error 1151
Wiring Diagram – R pedal potentio error (DKW0L8) 1152
DKW0L4 – R pedal signal mismatch(VALVE/M Con) 1153
Wiring Diagram – R pedal signal mismatch(VALVE/M Con) for DKW0L4 1155
DKW4MA – L pedal potentio abnormality 1157
Wiring Diagram – L pedal potentio abnormality (DKW4MA) 1158
DKW5MA – L pedal redundant pot abnormality(VALVE/M) 1159
Wiring Diagram – L pedal redundant pot abnormality(VALVE/M) for DKW5MA 1160
DKW3L8 – L pedal potentio error 1161
Wiring Diagram – L pedal potentio error (DKW3L8) 1162
DKW3L4 – L pedal signal mismatch(VALVE/M Con) 1163
Wiring Diagram – L pedal signal mismatch(VALVE/M Con) for DKW3L4 1165
DKW7MA – Clam open potentio abnormality 1167
Wiring Diagram – Clam open potentio abnormality (DKW7MA) 1168
DKW8MA – Clam open redu pot abnormality(VALVE/M) 1169
Wiring Diagram – Clam open redu pot abnormality(VALVE/M) for DKW8MA 1170
DKW6L8 – Clam open potentio error 1171
Wiring Diagram – Clam open potentio error (DKW6L8) 1172
DKW6L4 – Clam open signal mismatch(VALVE/M Con) 1173
Wiring Diagram – Clam open signal mismatch(VALVE/M Con) for DKW6L4 1175
DKWAMA – Clam close potentio abnormality 1177
Wiring Diagram – Clam close potentio abnormality (DKWAMA) 1178
DKWBMA – Clam close redundant pot abnorm(VALVE/M) 1179
Wiring Diagram – Clam close redundant pot abnorm(VALVE/M) for DKWBMA 1180
DKW9L8 – Clam close potentio error 1181
Wiring Diagram – Clam close potentio error (DKW9L8) 1182
DKW9L4 – Clam close signal mismatch(VALVE/M Con) 1183
Wiring Diagram – Clam close signal mismatch(VALVE/M Con) for DKW9L4 1185
DKWDMA – Hydraulic slew brake potentio abnormality 1187
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA) 1188
DKWEMA – Hyd slew brake redu pot abnorm(VALVE/M) 1189
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/M) for DKWEMA 1190
DKWCL8 – Hydraulic slew brake potentio error 1191
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8) 1192
DKWCL4 – Hyd slew brake sig mismatch(VALVE/M) 1193
Wiring Diagram – Hyd slew brake sig mismatch(VALVE/M) for DKWCL4 1195
DWNPKA – Service arm up solenoid open circuit 1197
Wiring Diagram and monitoring screen for message DWNPKA 1198
DWNPKB – Service arm up solenoid short circuit 1199
Wiring Diagram and monitoring screen for message DWNPKB 1200
DWNPKY – Service arm up solenoid hot short circuit 1201
Wiring Diagram and monitoring screen for message DWNPKY 1202
DWNQKA – Service arm down solenoid open circuit 1203
Wiring Diagram and monitoring screen for message DWNQKA 1204
DWNQKB – Service arm down solenoid short circuit 1205
Wiring Diagram and monitoring screen for message DWNQKB 1206
DWNQKY – Service arm down solenoid hot short circuit 1207
Wiring Diagram and monitoring screen for message DWNQKY 1208
DW4BKA – Travel parking brake solenoid open circuit 1209
Wiring Diagram and monitoring screen for message DW4BKA 1210
DW4BKB – Travel parking brake sol short circuit 1211
Wiring Diagram and monitoring screen for message DW4BKB 1212
DW4BKY – Travel parking brake sol hot short circuit 1213
Wiring Diagram and monitoring screen for message DW4BKY 1214
DW45KA – Slew parking brake solenoid open circuit 1215
Wiring Diagram and monitoring screen for message DW45KA 1216
DW45KB – Slew parking brake solenoid short circuit 1217
Wiring Diagram and monitoring screen for message DW45KB 1218
DW45KY – Slew parking brake sol hot short circuit 1219
Wiring Diagram and monitoring screen for message DW45KY 1220
DXN0KA – Slew1 epc solenoid open circuit 1221
DXN1KA – Bucket/Boom1 epc solenoid open circuit (FSA) 1221
DXN2KA – Boom1 epc solenoid open circuit (BHA) 1221
DXN3KA – Stick1 epc solenoid open circuit 1221
DXN4KA – Boom2 epc solenoid open circuit 1221
DXN5KA – Clam2 epc solenoid open circuit (FSA) 1221
DXN6KA – Stick2 epc solenoid open circuit (BHA) 1221
DXN7KA – Stick/Bucket2 epc solenoid open circuit (FSA) 1221
DXN8KA – Bucket2 epc solenoid open circuit (BHA) 1221
DXN9KA – Travel2 left epc solenoid open circuit 1221
DXNAKA – Slew3 epc solenoid open circuit 1221
DXNBKA – Bucket3 epc solenoid open circuit 1221
DXNCKA – Boom3 epc solenoid open circuit 1221
DXNDKA – Boom4 epc solenoid open circuit 1221
DXNEKA – Bucket4 epc solenoid open circuit 1221
DXNFKA – Stick4 epc solenoid open circuit 1221
DXNGKA – Travel4 right epc solenoid open circuit 1221
Details of the above 6-digit failure codes (FSA & BHA) 1222
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 1223
Wiring Diagram for EPC 61K624 – 61K625 1224
Wiring Diagram for EPC 61K626 – 61K627 1225
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 1226
Wiring Diagram for EPC 61K632 – 61K633 1227
Wiring Diagram for EPC 61K634 – 61K635 1228
Monitoring screens as an example 1229
DXN0KB – Slew1 epc solenoid short circuit 1231
DXN1KB – Bucket/Boom1 epc solenoid short circuit (FSA) 1231
DXN2KB – Boom1 epc solenoid short circuit (BHA) 1231
DXN3KB – Stick1 epc solenoid short circuit 1231
DXN4KB – Boom2 epc solenoid short circuit 1231
DXN5KB – Clam2 epc solenoid short circuit FSA) 1231
DXN6KB – Stick2 epc solenoid short circuit (BHA) 1231
DXN7KB – Stick/Bucket2 epc solenoid short circuit (FSA) 1231
DXN8KB – Bucket2 epc solenoid short circuit (BHA) 1231
DXN9KB – Travel2 left epc solenoid short circuit 1231
DXNAKB – Slew3 epc solenoid short circuit 1231
DXNBKB – Bucket3 epc solenoid short circuit 1231
DXNCKB – Boom3 epc solenoid short circuit 1231
DXNDKB – Boom4 epc solenoid short circuit 1231
DXNEKB – Bucket4 epc solenoid short circuit 1231
DXNFKB – Stick4 epc solenoid short circuit 1231
DXNGKB – Travel4 right epc solenoid short circuit 1231
Details of the above 6-digit failure codes (FSA & BHA) 1232
DXN0KY – Slew1 epc solenoid hot short circuit 1233
DXN1KY – Bucket/Boom1 epc sol hot short circuit (FSA) 1233
DXN2KY – Boom1 epc solenoid hot short circuit (BHA) 1233
DXN3KY – Stick1 epc solenoid hot short circuit 1233
DXN4KY – Boom2 epc solenoid hot short circuit 1233
DXN5KY – Clam2 epc solenoid hot short circuit (FSA) 1233
DXN6KY – Stick2 epc solenoid hot short circuit (BHA) 1233
DXN7KY – Stick/Bucket2 epc sol hot short circuit (FSA) 1233
DXN8KY – Bucket2 epc solenoid hot short circuit (BHA) 1233
DXN9KY – Travel2 left epc sol hot short circuit 1233
DXNAKY – Slew3 epc solenoid hot short circuit 1233
DXNBKY – Bucket3 epc solenoid hot short circuit 1233
DXNCKY – Boom3 epc solenoid hot short circuit 1233
DXNDKY – Boom4 epc solenoid hot short circuit 1233
DXNEKY – Bucket4 epc solenoid hot short circuit 1233
DXNFKY – Stick4 epc solenoid hot short circuit 1233
DXNGKY – Travel4 right epc sol hot short circuit 1233
Details of the above 6-digit failure codes (FSA & BHA) 1234
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 1235
Wiring Diagram for EPC 61K624 – 61K625 1236
Wiring Diagram for EPC 61K626 – 61K627 1237
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 1238
Wiring Diagram for EPC 61K632 – 61K633 1239
Wiring Diagram for EPC 61K634 – 61K635 1240
DWACKA – Service arm check valve sol open circuit 1241
Wiring Diagram and monitoring screen for message DWACKA 1242
DWACKB – Service arm check valve sol short circuit 1243
Wiring Diagram and monitoring screen for message DWACKB 1244
DWACKY – Service arm check valveSol hotShortCircuit 1245
Wiring Diagram and monitoring screen for message DWACKY 1246
DWADKA – Ladder speed control solenoid open circuit 1247
Wiring Diagram and monitoring screen for message DWADKA 1248
DWADKB – Ladder speed control sol short circuit 1249
Wiring Diagram and monitoring screen for message DWADKB 1250
DWADKY – Ladder speed control sol hot short circuit 1251
Wiring Diagram – Ladder speed control sol hot short circuit (DWADKY) 1252
DBW5MA – 5V sensor1 power abnormality 1253
DBW6MA – 5V sensor2 power abnormality 1253
Wiring Diagram – 5V power supply and GND output at VALVE0 1257
DBW9KQ – Model Selection Abnormality 1259
Monitoring screen for machine selection 1259
Wiring Diagram – model selection abnormality (DBW9KQ) 1260
DBWZKQ – Lever control selection abnormality 1261
Monitoring screen & Wiring Diagram – Lever control selection abnormality (DBWZKQ) 1262
DBWYKQ – Attachment selection abnormality 1263
Monitoring screen & Wiring Diagram – Attachment selection abnormality (DBWYKQ) 1264
DBW2KK – Solenoid Power Low Error(VALVE/M Con) 1265
Wiring Diagram 1 for message DBW2KK 1267
Wiring Diagram 2 for message DBW2KK 1268
DBW0KQ – VALVE/M Con Selection Abnormality 1269
Monitoring screen and Wiring Diagram for message DBW0KQ 1270
DDDWMC – Ladder operation switch abnormality 1271
Wiring Diagram and monitoring screen for message DDDWMC 1272
DKWHMA – R lever right-left redu pot abnorm(VLV/S1) 1273
Wiring Diagram – right lever redundant right-left potentiometer input (DKWHMA) 1274
DKWFL4 – R lever right-left sig mismatch(VALVE/S1) 1275
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1 1277
DKWLMA – R lever front-back redu pot abnorm(VLV/S1) 1279
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA) 1280
DKWJL4 – R lever front-back sig mismatch(VALVE/S1) 1281
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1 1283
DKWPMA – L lever right-left redu pot abnorm(VLV/S1) 1285
Wiring Diagram – left lever redundant right-left potentiometer input (DKWPMA) 1286
DKWML4 – L lever right-left sig mismatch(VALVE/S1) 1287
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1 1289
DKWSMA – L lever front-back redu pot abnorm(VLV/S1) 1291
Wiring Diagram – L lever front-back redu pot abnorm(VLV/S1) for DKWSMA 1292
DKWQL4 – L lever front-back sig mismatch(VALVE/S1) 1293
Wiring Diagram – L lever front-back sig mismatch(VALVE/S1) for DKWQL4 1295
DKWVMA – R pedal red pot abnormality(VALVE/S1) 1297
Wiring Diagram – R pedal red pot abnormality(VALVE/S1) for DKWVMA 1298
DKWTL4 – R pedal signal mismatch(VALVE/S1 Con) 1299
Wiring Diagram – R pedal signal mismatch(VALVE/S1 Con) for DKWTL4 1301
DKWYMA – L pedal red pot abnormality(VALVE/S1) 1303
Wiring Diagram – L pedal red pot abnormality(VALVE/S1) for DKWYMA 1304
DKWWL4 – L pedal signal mismatch(VALVE/S1 Con) 1305
Wiring Diagram – L pedal signal mismatch(VALVE/S1 Con) for DKWWL4 1307
DKX2MA – Clam open redu pot abnormality(VALVE/S1) 1309
Wiring Diagram – Clam open redu pot abnormality(VALVE/S1) for DKX2MA 1310
DKX0L4 – Clam open signal mismatch(VALVE/S1 Con) 1311
Wiring Diagram – Clam open signal mismatch(VALVE/S1 Con) for DKX0L4 1313
DKX5MA – Clam close redu pot abnormality(VALVE/S1) 1315
Wiring Diagram – Clam close redu pot abnormality(VALVE/S1) for DKX5MA 1316
DKX3L4 – Clam close signal mismatch(VALVE/S1 Con) 1317
Wiring Diagram – Clam close signal mismatch(VALVE/S1 Con) for DKX3L4 1319
DKX8MA – Hyd slew brake redu pot abnorm(VALVE/S1) 1321
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/S1) for DKX8MA 1322
DKX6L4 – Hyd slew brake signal mismatch(VALVE/S1) 1323
Wiring Diagram – Hyd slew brake signal mismatch(VALVE/S1) for DKX6L4 1325
DWNRKA – Ladder up solenoid open circuit 1327
Wiring Diagram and monitoring screen for message DWNRKA 1328
DWNRKB – Ladder up solenoid short circuit 1329
Wiring Diagram and monitoring screen for message DWNRKB 1330
DWNRKY – Ladder up solenoid hot short circuit 1331
Wiring Diagram – Ladder up solenoid hot short circuit (DWNRKY) 1332
DW7RKA – Hydraulic slew brake solenoid open circuit 1333
Wiring Diagram and monitoring screen for message DW7RKA 1334
DW7RKB – Hydraulic slew brake sol short circuit 1335
Wiring Diagram and monitoring screen for message DW7RKB 1336
DW7RKY – Hyd slew brake sol hot short circuit 1337
Wiring Diagram – Hyd slew brake sol hot short circuit (DW7RKY) 1338
DWANKA – Slew1 right solenoid open circuit 1339
Wiring Diagram and monitoring screen for message DWANKA 1340
DWANKB – Slew1 right solenoid short circuit 1341
Wiring Diagram and monitoring screen for message DWANKB 1342
DWANKY – Slew1 right solenoid hot short circuit 1343
Wiring Diagram and monitoring screen for message DWANKY 1344
DWAJKA – Slew1 left solenoid open circuit 1345
Wiring Diagram and monitoring screen for message DWAJKA 1346
DWAJKB – Slew1 left solenoid short circuit 1347
Wiring Diagram and monitoring screen for message DWAJKB 1348
DWAJKY – Slew1 left solenoid hot short circuit 1349
Wiring Diagram and monitoring screen for message DWAJKY 1350
DWASKA – Bucket1 fill solenoid open circuit 1351
Wiring Diagram and monitoring screen for message DWASKA 1352
DWASKB – Bucket1 fill solenoid short circuit 1353
Wiring Diagram and monitoring screen for message DWASKB 1354
DWASKY – Bucket1 fill solenoid hot short circuit 1355
Wiring Diagram and monitoring screen for message DWASKY 1356
DWBEKA – Boom1 down solenoid open circuit 1357
Wiring Diagram and monitoring screen for message DWBEKA 1358
DWBEKB – Boom1 down solenoid short circuit 1359
Wiring Diagram and monitoring screen for message DWBEKB 1360
DWBEKY – Boom1 down solenoid hot short circuit 1361
Wiring Diagram and monitoring screen for message DWBEKY 1362
DWBAKA – Boom1 up solenoid open circuit 1363
Wiring Diagram and monitoring screen for message DWBAKA 1364
DWBAKB – Boom1 up solenoid short circuit 1365
Wiring Diagram and monitoring screen for message DWBAKB 1366
DWBAKY – Boom1 up solenoid hot short circuit 1367
Wiring Diagram and monitoring screen for message DWBAKY 1368
DWBJKA – Stick1 out solenoid open circuit 1369
Wiring Diagram and monitoring screen for message DWBJKA 1370
DWBJKB – Stick1 out solenoid short circuit 1371
Wiring Diagram and monitoring screen for message DWBJKB 1372
DWBJKY – Stick1 out solenoid hot short circuit 1373
Wiring Diagram and monitoring screen for message DWBJKY 1374
DWBNKA – Stick1 in solenoid open circuit 1375
Wiring Diagram and monitoring screen for message DWBNKA 1376
DWBNKB – Stick1 in solenoid short circuit 1377
Wiring Diagram and monitoring screen for message DWBNKB 1378
DWBNKY – Stick1 in solenoid hot short circuit 1379
Wiring Diagram and monitoring screen for message DWBNKY 1380
DWBBKA – Boom2 up solenoid open circuit 1381
Wiring Diagram and monitoring screen for message DWBBKA 1382
DWBBKB – Boom2 up solenoid short circuit 1383
Wiring Diagram and monitoring screen for message DWBBKB 1384
DWBBKY – Boom2 up solenoid hot short circuit 1385
Wiring Diagram and monitoring screen for message DWBBKY 1386
DWBFKA – Boom2 down solenoid open circuit 1387
Wiring Diagram and monitoring screen for message DWBFKA 1388
DWBFKB – Boom2 down solenoid short circuit 1389
Wiring Diagram and monitoring screen for message DWBFKB 1390
DWBFKY – Boom2 down solenoid hot short circuit 1391
Wiring Diagram and monitoring screen for message DWBFKY 1392
DWBXKA – Clam2 close solenoid open circuit 1393
Wiring Diagram and monitoring screen for message DWBXKA 1394
DWBXKB – Clam2 close solenoid short circuit 1395
Wiring Diagram and monitoring screen for message DWBXKB 1396
DWBXKY – Clam2 close solenoid hot short circuit 1397
Wiring Diagram and monitoring screen for message DWBXKY 1398
DWBKKA – Stick2 out solenoid open circuit 1399
Wiring Diagram and monitoring screen for message DWBKKA (FSA only) 1400
DWBKKB – Stick2 out solenoid short circuit 1401
Wiring Diagram and monitoring screen for message DWBKKB 1402
DWBKKY – Stick2 out solenoid hot short circuit 1403
Wiring Diagram and monitoring screen for message DWBKKY 1404
DWBTKA – Clam2 open solenoid open circuit 1405
Wiring Diagram and monitoring screen for message DWBTKA 1406
DWBTKB – Clam2 open solenoid short circuit 1407
Wiring Diagram and monitoring screen for message DWBTKB 1408
DWBTKY – Clam2 open solenoid hot short circuit 1409
Wiring Diagram and monitoring screen for message DWBTKY 1410
DWBPKA – Stick2 in solenoid open circuit 1411
Wiring Diagram and monitoring screen for message DWBPKA 1412
DWBPKB – Stick2 in solenoid short circuit 1413
Wiring Diagram and monitoring screen for message DWBPKB 1414
DWBPKY – Stick2 in solenoid hot short circuit 1415
Wiring Diagram and monitoring screen for message DWBPKY 1416
DWATKA – Bucket2 fill solenoid open circuit 1417
Wiring Diagram and monitoring screen for message DWATKA 1418
DWATKB – Bucket2 fill solenoid short circuit 1419
Wiring Diagram and monitoring screen for message DWATKB 1420
DWATKY – Bucket2 fill solenoid hot short circuit 1421
Wiring Diagram and monitoring screen for message DWATKY 1422
DWAXKA – Bucket2 dump solenoid open circuit 1423
Wiring Diagram and monitoring screen for message DWAXKA 1424
DWAXKB – Bucket2 dump solenoid short circuit 1425
Wiring Diagram and monitoring screen for message DWAXKB 1426
DWAXKY – Bucket2 dump solenoid hot short circuit 1427
Wiring Diagram and monitoring screen for message DWAXKY 1428
DWKFKA – Travel2 left backward sol open circuit 1429
Wiring Diagram and monitoring screen for message DWKFKA 1430
DWKFKB – Travel2 left backward sol short circuit 1431
Wiring Diagram and monitoring screen for message DWKFKB 1432
DWKFKY – Travel2 left backward sol hot short circuit 1433
Wiring Diagram and monitoring screen for message DWKFKY 1434
DWKBKA – Travel2 left forward sol open circuit 1435
Wiring Diagram and monitoring screen for message DWKBKA 1436
DWKBKB – Travel2 left forward sol short circuit 1437
Wiring Diagram and monitoring screen for message DWKBKB 1438
DWKBKY – Travel2 left forward sol hot short 1439
Wiring Diagram and monitoring screen for message DWKBKY 1440
D5ZWKB – Travel hour meter short circuit 1441
Wiring Diagram and monitoring screen for message D5ZWKB 1442
D1EUKB – Travel alarm relay short circuit 1443
Wiring Diagram and monitoring screen for message D1EUKB 1444
DBX9KQ – Model Selection Abnormality 1445
Wiring Diagram and monitoring screen for message DBX9KQ 1446
DBXZKQ – Lever Control Selection Abnormality 1447
Wiring Diagram and monitoring screen for message DBXZKQ 1448
DBXYKQ – Attachment selection abnormality 1449
Wiring Diagram – Attachment selection abnormality (DBXYKQ) 1450
D561MA – Lock lever sol power cut abnorm(VALVE/S1) 1451
Monitoring screens and Wiring Diagram 1 for message D561MA 1452
Wiring Diagram 2 for message D561MA 1453
D563MA – Ladder up sensor sol cut abnorm(VLV/S1) 1454
Monitoring screens and Wiring Diagram 1 for message D563MA 1455
Wiring Diagram 2 for message D563MA 1456
D565MA – Service arm (up) sensor sol cut abnorm(VLV/S1) 1457
Wiring Diagram 1 and monitoring screens for message D565MA 1458
Wiring Diagram 2 for message D565MA 1459
DBX2KK – Solenoid Power Low Error(VALVE/S1 Con) 1460
Monitoring screen and Wiring Diagram 1 for message DBX2KK 1461
Wiring Diagram 2 for message DBX2KK – Safety circuit 1462
DBX0KQ – VALVE/S1 Con Selection Abnormality 1463
Wiring Diagram and monitoring screen for message DBX0KQ 1464
DWAQKA – Slew3 right solenoid open circuit 1465
Wiring Diagram and monitoring screen for message DWAQKA 1466
DWAQKB – Slew3 right solenoid short circuit 1467
Wiring Diagram and monitoring screen for message DWAQKB 1468
DWAQKY – Slew3 right solenoid hot short circuit 1469
Wiring Diagram and monitoring screen for message DWAQKY 1470
DWALKA – Slew3 left solenoid open circuit 1471
Wiring Diagram and monitoring screen for message DWALKA 1472
DWALKB – Slew3 left solenoid short circuit 1473
Wiring Diagram and monitoring screen for message DWALKB 1474
DWALKY – Slew3 left solenoid hot short circuit 1475
Wiring Diagram and monitoring screen for message DWALKY 1476
DWAUKA – Bucket3 fill solenoid open circuit 1477
Wiring Diagram and monitoring screen for message DWAUKA 1478
DWAUKB – Bucket3 fill solenoid short circuit 1479
Wiring Diagram and monitoring screen for message DWAUKB 1480
DWAUKY – Bucket3 fill solenoid hot short circuit 1481
Wiring Diagram and monitoring screen for message DWAUKY 1482
DWAYKA – Bucket3 dump solenoid open circuit 1483
Wiring Diagram and monitoring screen for message DWAYKA 1484
DWAYKB – Bucket3 dump solenoid short circuit 1485
Wiring Diagram and monitoring screen for message DWAYKB 1486
DWAYKY – Bucket3 dump solenoid hot short circuit 1487
Wiring Diagram and monitoring screen for message DWAYKY 1488
DWBGKA – Boom3 down solenoid open circuit 1489
Wiring Diagram and monitoring screen for message DWBGKA 1490
DWBGKB – Boom3 down solenoid short circuit 1491
Wiring Diagram and monitoring screen for message DWBGKB 1492
DWBGKY – Boom3 down solenoid hot short circuit 1493
Wiring Diagram and monitoring screen for message DWBGKY 1494
DWBDKA – Boom4 up solenoid open circuit 1495
Wiring Diagram and monitoring screen for message DWBDKA 1496
DWBDKB – Boom4 up solenoid short circuit 1497
Wiring Diagram and monitoring screen for message DWBDKB 1498
DWBDKY – Boom4 up solenoid hot short circuit 1499
Wiring Diagram and monitoring screen for message DWBDKY 1500
DWBHKA – Boom4 down solenoid open circuit 1501
Wiring Diagram and monitoring screen for message DWBHKA 1502
DWBHKB – Boom4 down solenoid short circuit 1503
Wiring Diagram and monitoring screen for message DWBHKB 1504
DWBHKY – Boom4 down solenoid hot short circuit 1505
Wiring Diagram and monitoring screen for message DWBHKY 1506
DWAVKA – Bucket4 fill solenoid open circuit 1507
Wiring Diagram and monitoring screen for message DWAVKA 1508
DWAVKB – Bucket4 fill solenoid short circuit 1509
Wiring Diagram and monitoring screen for message DWAVKB 1510
DWAVKY – Bucket4 fill solenoid hot short circuit 1511
Wiring Diagram and monitoring screen for message DWAVKY 1512
DWAZKA – Bucket4 dump solenoid open circuit 1513
Wiring Diagram and monitoring screen for message DWAZKA 1514
DWAZKB – Bucket4 dump solenoid short circuit 1515
Wiring Diagram and monitoring screen for message DWAZKB 1516
DWAZKY – Bucket4 dump solenoid hot short circuit 1517
Wiring Diagram and monitoring screen for message DWAZKY 1518
DWBMKA – Stick4 out solenoid open circuit 1519
Wiring Diagram and monitoring screen for message DWBMKA 1520
DWBMKB – Stick4 out solenoid short circuit 1521
Wiring Diagram and monitoring screen for message DWBMKB 1522
DWBMKY – Stick4 out solenoid hot short circuit 1523
Wiring Diagram and monitoring screen for message DWBMKY 1524
DWBRKA – Stick4 in solenoid open circuit 1525
Wiring Diagram and monitoring screen for message DWBRKA 1526
DWBRKB – Stick4 in solenoid short circuit 1527
Wiring Diagram and monitoring screen for message DWBRKB 1528
DWBRKY – Stick4 in solenoid hot short circuit 1529
Wiring Diagram and monitoring screen for message DWBRKY 1530
DWKRKA – Travel4 right backward sol open circuit 1531
Wiring Diagram and monitoring screen for message DWKRKA 1532
DWKRKB – Travel4 right backward sol short circuit 1533
Wiring Diagram and monitoring screen for message DWKRKB 1534
DWKRKY – Travel4 right backward sol hot short 1535
Wiring Diagram and monitoring screen for message DWKRKY 1536
DWKMKA – Travel4 right forward sol open circuit 1537
Wiring Diagram and monitoring screen for message DWKMKA 1538
DWKMKB – Travel4 right forward sol short circuit 1539
Wiring Diagram and monitoring screen for message DWKMKB 1540
DWKMKY – Travel4 right forward sol hot short 1541
Wiring Diagram and monitoring screen for message DWKMKY 1542
DXEDKA – Hydraulic slew brake epc sol open circuit 1543
Wiring Diagram and monitoring screen for message DXEDKA 1544
DXEDKB – Hyd slew brake epc sol short circuit 1545
Wiring Diagram and monitoring screen for message DXEDKB 1546
DXEDKY – Hyd slew brake epc sol hot short circuit 1547
Wiring Diagram and monitoring screen for message DXEDKY 1548
DWKVKA – Boom4 float solenoid open circuit 1549
Wiring Diagram and monitoring screen for message DWKVKA 1550
DWKVKB – Boom4 float solenoid short circuit 1551
Wiring Diagram and monitoring screen for message DWKVKB 1552
DWKVKY – Boom4 float solenoid hot short circuit 1553
Wiring Diagram and monitoring screen for message DWKVKY 1554
DWKWKA – Stick1 float solenoid open circuit 1555
Wiring Diagram and monitoring screen for message DWKWKA 1556
DWKWKB – Stick1 float solenoid short circuit 1557
Wiring Diagram and monitoring screen for message DWKWKB 1558
DWKWKY – Stick1 float solenoid hot short circuit 1559
Wiring Diagram and monitoring screen for message DWKWKY 1560
DWKZKA – Stick4 float solenoid open circuit 1561
Wiring Diagram and monitoring screen for message DWKZKA 1562
DWKZKB – Stick4 float solenoid short circuit 1563
Wiring Diagram and monitoring screen for message DWKZKB 1564
DWKZKY – Stick4 float solenoid hot short circuit 1565
Wiring Diagram and monitoring screen for message DWKZKY 1566
DBY9KQ – Model Selection Abnormality 1567
Wiring Diagram and monitoring screen for message DBY9KQ 1568
DBYZKQ – Lever Control Selection Abnormality 1569
Wiring Diagram and monitoring screen for message DBYZKQ 1570
DBYYKQ – Attachment selection abnormality 1571
Wiring Diagram – Attachment selection abnormality (DBYYKQ) 1572
D562MA – Lock lever sol power cut abnorm(VALVE/S2) 1573
Wiring Diagram 1 and monitoring screen for message D562MA 1574
Wiring Diagram 2 for message D562MA 1575
D564MA – Ladder up sensor sol cut abnorm(VLV/S2) 1576
Monitoring screens and Wiring Diagram 1 for message D564MA 1577
Wiring Diagram 2 for message D564MA 1578
D566MA – Service arm sensor sol cut abnorm(VALV/S2) 1579
Wiring Diagram 1 and monitoring screens for message D566MA 1580
Wiring Diagram 2 for message D566MA 1581
DBY2KK – Solenoid Power Low Error(VALVE/S2 Con) 1582
Monitoring screen and Wiring Diagram 1 for message DBY2KK 1583
Wiring Diagram 2 for message DBY2KK – Safety circuit 1584
DBY0KQ – VALVE/S2 Con Selection Abnormality 1585
Wiring Diagram and monitoring screen for message DBY0KQ 1586
DJH2KX – Hydraulic oil level sensor abnormality 1587
Wiring Diagram and monitoring screen for message DJH2KX 1588
DJE3KX – Remote engine oil level1 sens abnormality 1589
Wiring Diagram and monitoring screen for message DJE3KX 1590
DH2GKX – Suction tank pressure sensor abnormality 1591
Wiring Diagram and monitoring screen for message DH2GKX 1592
DH2HKX – Oil cooler pressure sensor abnormality 1593
Wiring Diagram and monitoring screen for message DH2HKX 1594
DH2JKX – Preload valve return oil press abnormality 1595
Wiring Diagram and monitoring screen for message DH2JKX 1596
DHSUKX – X2 pressure sensor abnormality 1597
Wiring Diagram and monitoring screen for message DHSUKX 1598
DJF1KX – Fuel level sensor abnormality 1599
Wiring Diagram and monitoring screen for message DJF1KX 1600
DGE5MA – Ambient air temp sensor abnormality 1601
Wiring Diagram and monitoring screen for message DGE5MA 1602
DH2KKX – Return oil chamber press sensor abnormal 1603
Wiring Diagram and monitoring screen for message DH2KKX 1604
DH2LKX – Leak oil chamber press sensor abnormality 1605
Wiring Diagram and monitoring screen for message DH2LKX 1606
DJE5L4 – SLS sensor system abnormality 1607
Wiring Diagram and monitoring screen for message DJE5L4 1608
DJE6L4 – CLS sensor system abnormality 1609
Wiring Diagram and monitoring screen for message DJE6L4 1610
DBVLKA – Operating Lamp Open Circuit(KOMTRAX) 1611
Wiring Diagram for message DBVLKA 1612
DBVLKB – Operating Lamp Short Circuit(KOMTRAX) 1613
Wiring Diagram for message DBVLKB 1614
DBV1KK – KOMTRAX Plus source voltage Error 1615
Wiring Diagram for message DBV1KK 1616
DBV5KB – 5V sensor1 power abnormality 1617
Wiring Diagram 1 and monitoring screens for message DBV5KB 1618
Wiring Diagram 2 for message DBV5KB 1619
DBV6KB – 24V Sensor Power Abnormality 1621
Wiring Diagram 1 and monitoring screens for message DBV6KB 1622
Wiring Diagram 2 for message DBV6KB 1623
DAFGMC – GPS Module Error 1625
Wiring Diagram for message DAFGMC 1626
D862KA – GPS Antenna Open Circuit 1627
DBVVKR – Ethernet 1 Disconnection 1628
DBVWKR – Ethernet 2 Disconnection 1629
DA2RKR – CAN1 Discon (Pump Con) 1631
CAN1 overview for message DA2RKR 1632
DBWRKR – CAN1 Discon (Valve/M Con) 1633
CAN1 overview for message DBWRKR 1634
DBXRKR – CAN1 Discon (Valve/S1 Con) 1635
CAN1 overview for message DBXRKR 1636
DBYRKR – CAN1 Discon (Valve/S2 Con) 1637
CAN1 overview for message DBYRKR 1638
DB2QKR – CAN2 Discon (Engine Con) 1639
CAN2 overview for message DB2QKR 1640
Wiring Diagram for PWR supply at 52K014-1 (DB2QKR) 1641
DA2QKR – CAN2 Discon (Pump Con) 1643
CAN2 overview for message DA2QKR 1644
DBWQKR – CAN2 Discon (Valve/M Con) 1645
CAN2 overview for message DBWQKR 1646
DBXQKR – CAN2 Discon (Valve/S1 Con) 1647
CAN2 overview for message DBXQKR 1648
DBYQKR – CAN2 Discon (Valve/S2 Con) 1649
CAN2 overview for message DBYQKR 1650
DBVQKR – CAN2 Discon (KOMTRAX Plus) 1651
CAN2 overview for message DBVQKR 1652
DBPRKR – CAN1 Discon (KomVision) 1653
Wiring Diagram for DBPRKR 1654
DBPQKR – CAN2 Discon (KomVision) 1655
Wiring Diagram for DBPQKR 1656
D19YKB – Emergency Lighting Ladder Relay Short Circuit 1657
Wiring Diagram and monitoring screen for message D19YKB 1658
DV00KB – Shutdown Buzzer Short Circuit 1659
Wiring Diagram and monitoring screen for message DV00KB 1660
DAF0KM – Inconsistency of KomVision Setting 1661
DBP5KP – Camera Power Output Voltage Low 1663
Wiring Diagram for message DBP5KP 1664
DBP0NR – KomVision Controller High Temperature Error 1665
DBPVKR – CAN5 Discon (KomVision) 1666
DBPUKR – CAN4 Discon (KomVision) 1666
DPQ4KB – Short Circuit of KomVision Monitor ON/OFF Signal 1667
Wiring Diagram for message DPQ4KB 1668
DBP0KT – KomVision Controller Internal Error 1669
DBP0KM – KomVision Controller Setting Error 1670
DR10KA – Disconnection of Camera 1 NTSC Input 1671
DR20KA – Disconnection of Camera 2 NTSC Input 1671
DR30KA – Disconnection of Camera 3 NTSC Input 1671
DR40KA – Disconnection of Camera 4 NTSC Input 1671
DR50KA – Disconnection of Camera 5 NTSC Input 1671
DR60KA – Disconnection of Camera 6 NTSC Input 1671
DR90KA – Disconnection of Camera 7 NTSC Input 1671
Wiring Diagram for message DR10KA DR90KA 1672
DPQ4KT – KomVision Monitor Internal Error 1673
DBPLKA – Operating Lamp Open Circuit (KomVision) 1675
Wiring Diagram for message DBPLKA 1676
DBPLKB – Operating Lamp Short Circuit (KomVision) 1677
Wiring Diagram for message DBPLKB 1678
DBPWKR – Ethernet 1 Discon (KomVision) 1679
DBPXKR – Ethernet 2 Discon (KomVision) 1679
7 Troubleshooting by Symptoms 1681
7 1 Symptoms of the engine and related electrical system 1682
SEL001 – Engine does not start (engine does not rotate) 1682
Wiring Diagram 1 (batteries) for symptom code SEL001 1684
Wiring Diagram 2 (20S030 & 20S105) for symptom code SEL001 1685
Wiring Diagram 3 (engine enable) for symptom code SEL001 1686
Wiring Diagram 4 (starter motors) for symptom code SEL001 1687
SEL002 – Engine stops while in operation 1688
View onto the fuel system water separator (SEL002) 1689
SEL003 – Engine speed is hunting during boom-up movement 1690
SEL004 – Engine does not stop 1692
SEL005 – Engine lacks output (no power) 1693
Judgment Table for SEL005 1694
SEL006 – Engine does not start (Pre-lube does not stop) 1695
SEL007 – Oil consumption is excessive 1696
Judgment Table for SEL007 1697
SEL008 – Oil becomes contaminated quickly 1698
Judgment Table for SEL008 1699
SEL009 – Fuel consumption is excessive 1700
Judgment Table for SEL009 1701
SEL010 – Oil is in engine coolant 1702
Judgment Table for SEL010 1703
SEL011 – Oil level rises 1704
Judgment Table for SEL011 1705
SEL012 – Coolant temperature becomes too high (overheating) 1706
Judgment Table for SEL012 1707
7 2 Symptoms of the Hydraulic System 1708
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function) 1708
SHY002 – Engine speed sharply drops or engine stalls too much 1710
SHY003 – No work equipment, travel or slew movement 1711
SHY004 – Work equipment has too much hydraulic drift 1712
SHY005 – Work equipment has big time lag 1713
SHY006 – Machine deviates during travel movement 1714
SHY007 – Hydraulic system has lack of power 1715
SHY008 – Machine does not slew 1716
Slew brake block (SHY008) 1717
SHY009 – Slew acceleration is poor 1718
SHY010 – Excessive overrun when stopping slew movement 1720
SHY011 – Floating system without function (FSA only) 1722
SHY012 – Abnormal noise coming from SRV or MRV 1723
SHY013 – Track tensioning system without function 1724
Track tensioning – overview (SHY013) 1725
SHY014 – Ladder does not move, or slow movement 1726
SHY015 – Refilling arm does not move, or slow movement 1728
SHY016 – The hydr driven grease pump does not move 1730
SHY017 – Abnormal track chain movement during digging 1732
SHY018 – Slew parking brake without function 1733
SHY019 – Travel parking brake without function 1734
7 3 Symptoms of the Mechanical System 1736
SME001 – Abnormal noise is made 1736
Judgment Table for SME001 1737
SME002 – Abnormal noise around PTO / hydraulic pumps 1738
SME003 – Vibration is excessive (engine mountings) 1740
Judgment Table for SME003 1741
SME004 – Vibration is excessive (engine torsion) 1742
SME005 – There is a big shock when stopping slew movement 1743
SME006 – There is a big abnormal noise when moving/stopping slew movement 1744
SME007 – Fan blades make abnormal noise 1746
SME008 – Abnormal noise coming from a travel gearbox 1747
SME009 – Abnormal noise coming from the work equipment (lack of grease) 1749
SME010 – Abnormal idler movement 1751
SME011 – Leak at the PTO shaft seal 1752
7 4 Symptoms of Additional Systems 1754
SAD001 – Air conditioner for the cabin does not work 1754
View onto the A/C unit (SAD001) 1755
SAD002 – Air conditioner compressor clutch is burnt 1756
View onto the A/C compressor and its mounting (SAD002) 1757
SAD003 – Air conditioning system defective (pipes and hoses full of moisture) 1758
View onto the A/C filling and service station 1759
50 Disassembly and Assembly 1761
TOC 1763
1 Introduction 1771
1 1 Foreword 1772
1 2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 1773
1 3 Diagrams and illustrations in this manual 1773
1 4 Procedures for disassembling and assembling in this manual 1774
2 Safety 1775
2 1 Overview 1777
2 1 1 Method of using this manual 1777
2 2 General precautions 1779
2 2 1 General 1779
2 2 2 Personal protective clothing 1779
2 2 3 When using a hammer 1780
2 2 4 Proper tools 1780
2 2 5 Personnel 1780
2 2 6 Fire prevention 1781
2 2 7 Unauthorized modification 1781
2 3 Precautions for maintenance and repair 1782
2 3 1 General precautions 1782
2 3 2 Keep work place clean and tidy 1782
2 3 3 Precautions when welding 1783
2 3 4 Precaution with high pressure fluids 1783
2 3 4 1 Handling high pressure hoses and pipes 1783
2 3 5 Compressed air 1783
2 3 6 Waste materials 1784
3 Superstructure 1785
3 1 Superstructure overview 1786
3 2 Machine House (T4) 1788
3 2 1 Disconnection plate at the machine house 1790
3 2 1 1 Machine house hose ports – port allocations 1790
3 2 2 Machine house roof 1792
3 2 2 1 Disassembling of the machine house roof cover plates 1795
3 2 2 2 Assembling of the machine house roof cover plates 1802
3 2 3 Traverse assembly on machine house (T4 equipment) 1808
3 2 3 1 Disassembling of the complete traverse assembly (T4 equipment) 1808
3 2 3 2 Assembling of the complete traverse assembly (T4 equipment) 1812
3 2 3 3 Disassembling of the SCR catalysts (T4 equipment) 1816
3 2 3 4 Assembling of the SCR catalysts (T4 equipment) 1820
3 2 3 5 Disassembling of the DEF tank assembly (T4 equipment) 1825
3 2 3 6 Assembling of the DEF tank assembly (T4 equipment) 1829
3 2 4 Air intake system 1832
3 2 4 1 Disassembling of the air intake system 1832
3 2 4 2 Assembling of the air intake system 1835
3 2 5 Diesel engine 1838
3 2 5 1 Disassembling and assembling of the Alternator 1838
3 2 5 2 Disassembling and assembling of the starter motors 1838
3 2 5 3 Disassembling of the Diesel engine 1839
3 2 5 4 Assembling of the Diesel engine 1845
3 2 6 Batteries 1852
3 2 6 1 Disassembling of the batteries 1852
3 2 6 2 Assembling of the batteries 1854
3 2 7 Flexible coupling 1855
3 2 7 1 Disassembling of the CentaFlex coupling assembly 1855
3 2 7 2 Assembling of the CentaFlex coupling assembly 1858
3 2 7 3 Replacing the rubber rollers of the CentaFlex coupling 1860
3 2 8 Radiator fan and fan drive assembly 1862
3 2 8 1 Disassembling of the radiator fan 1864
3 2 8 2 Assembling of the radiator fan 1866
3 2 8 3 Disassembling of the radiator fan motor 1868
3 2 8 4 Assembling of the radiator fan motor 1870
3 2 8 5 Disassembling of the Radiator assembly 1872
3 2 8 6 Assembling of the radiator assembly 1877
3 2 9 Main pump assemblies 1882
3 2 9 1 Disassembling and assembling of the auxiliary pumps 1883
3 2 9 2 Disassembling of the main pump assemblies 1884
3 2 9 3 Assembling of the main pump assemblies 1888
3 2 10 Universal PTO 1892
3 2 10 1 Disassembling of the universal PTO 1892
3 2 10 2 Assembling of the universal PTO 1895
3 3 Hydraulic System 1898
3 3 1 Hydraulic oil cooler assembly 1898
3 3 1 1 Disassembling of hydraulic cooler fan and motor 1899
3 3 1 2 Assembling of hydraulic cooler fan and motor 1902
3 3 1 3 Disassembling of the hydraulic oil radiators 1905
3 3 1 4 Assembling of the hydraulic oil coolers 1909
3 3 1 5 Disassembling of the hydraulic oil cooler assembly 1912
3 3 1 6 Assembling of the hydraulic oil cooler assembly 1917
3 3 2 Hydraulic oil tank 1922
3 3 2 1 Disassembling of the main shut-off valve 1924
3 3 2 2 Assembling of the main shut-off valve 1926
3 3 2 3 Disassembling of the hydraulic oil tank 1928
3 3 2 4 Assembling of the hydraulic oil tank 1933
3 3 3 Main control valve blocks 1940
3 3 3 1 Disassembling of the main control valve blocks 1940
3 3 3 2 Assembling of the main control valve blocks 1943
3 3 3 3 Disassembling of the MRV at the main control valve blocks 1946
3 3 3 4 Assembling of the MRV at the main control valve blocks 1947
3 3 3 5 Disassembling of SRV on main control valve block 1948
3 3 3 6 Assembling of SRV on main control valve blocks 1949
3 3 3 7 Disassembling of ACV-/SRV-block on main control valve blocks 1950
3 3 3 8 Assembling of ACV-/SRV-block on main control valve blocks 1952
3 3 4 Distributor Manifold 1954
3 3 4 1 Disassembling of SRV-valve blocks / restrictor blocks at the distributor manifold 1955
3 3 4 2 Assembling of SRV-valve blocks / restrictor blocks at the distributor manifold 1957
3 3 4 3 Disassembling of anti cavitation valves at the distributor manifold 1959
3 3 4 4 Assembling of anti cavitation valves at the distributor manifold 1961
3 3 4 5 Disassembling of the Diffuser block at the manifold (FSA) 1963
3 3 4 6 Assembling of the Diffuser block at the manifold 1965
3 3 4 7 Disassembling of the distributor manifold 1966
3 3 4 8 Assembling of the distributor manifold 1969
3 4 Slew system 1972
3 4 1 Slew gears 1972
3 4 1 1 Disassembling of the slew gear 1973
3 4 1 2 Assembling of the slew gear 1976
3 4 2 Slew motor 1980
3 4 2 1 Disassembling of the slew motor 1981
3 4 2 2 Assembling of the slew motor 1984
3 4 3 Slew parking brake 1986
3 4 3 1 Disassembling of the slew parking brake of type 2063 1987
3 4 3 2 Assembling of the slew parking brake of type 2063 1990
3 4 3 3 Disassembling of the slew parking brake of type 632770 1993
3 4 3 4 Assembling of the slew parking brake of type 632770 1996
3 4 4 slew service brake valve 1999
3 4 4 1 Disassembling of the slew service brake valve 1999
3 4 4 2 Assembling of the of the slew service brake valve 2001
3 4 5 Slew circle 2003
3 4 5 1 Disassembling of the slew circle 2003
3 4 5 2 Assembling of the slew circle 2007
3 4 6 Slew circle lubrication pinion (dummy wheel) 2012
3 4 6 1 Disassembling of the lubrication pinion assembly 2012
3 4 6 2 Assembling of the lubrication pinion assembly 2013
3 5 Lubrication pumps 2014
3 5 1 Disassembling of the lubrication pump 2014
3 5 2 Assembling of the lubricating pump 2015
3 6 Operator’s cab 2016
3 6 1 Disassembling of the operator’s cab 2017
3 6 2 Assembling of the operator’s cab 2021
3 6 3 Disassembling of the operator’s cab together with the cab support frame 2024
3 6 4 Assembling of the operator’s cab together with the cab support frame 2028
3 6 5 Cab-mounts 2032
3 6 5 1 Disassembling of the cab-mounts 2032
3 6 5 2 Assembling of the cab-mounts 2034
3 6 6 Front window 2036
3 6 6 1 Disassembling of the front window 2036
3 6 6 2 Assembling of the front window 2037
3 6 7 Operator’s seat 2038
3 6 7 1 Disassembling of the operator’s seat 2038
3 6 7 2 Assembling of the operator’s seat 2039
3 7 Cab base 2040
3 7 1 Disassembling of the cab support frame 2041
3 7 2 Assembling of the cab support frame 2043
3 7 3 Disassembling of the cab base 2045
3 7 4 Assembling of the cab base 2047
3 8 Ladders and platforms 2049
3 8 1 Hydraulic access Ladder 2049
3 8 1 1 Disassembling of the hydraulic access ladder 2049
3 8 1 2 Assembling of the hydraulic access ladder 2051
3 8 2 Disassembling of the access ladder cylinder 2053
3 8 3 Assembling of the access ladder cylinder 2055
3 8 4 Fuel tank step 2056
3 8 4 1 Disassembling of the fuel tank step 2056
3 8 4 2 Assembling of the fuel tank step 2058
3 8 5 step platforms 2059
3 8 5 1 Disassembling of the upper step platform at fuel tank 2059
3 8 5 2 Assembling of the upper step platform at fuel tank 2061
3 8 5 3 Disassembling of the lower step platform at machine house 2062
3 8 5 4 Assembling of the lower step platform at machine house 2063
3 8 6 Emergency escape ladders 2064
3 8 6 1 Disassembling of the emergency escape ladder assembly at the cab base 2064
3 8 6 2 Assembling of the emergency escape ladder assembly at the cab base 2066
3 8 6 3 Disassembling of the emergency escape ladder assembly at the machine house 2067
3 8 6 4 Assembling of the emergency escape ladder assembly at the machine house 2069
3 9 Counterweight 2070
3 9 1 Disassembling of the counterweight 2071
3 9 2 Assembling of the counterweight 2073
3 10 Fuel tank 2076
3 10 1 Disassembling of the fuel tank 2076
3 10 2 Assembling of the fuel tank 2080
3 10 3 Fuel cooler box (T4 equipment) 2084
3 10 3 1 Disassembling of the fuel cooler box (T4 equipment) 2084
3 10 3 2 Assembling of the fuel cooler box (T4 equipment) 2086
3 11 Superstructure Lifting 2088
3 11 1 Disassemble the superstructure from the undercarriage 2088
3 11 2 Install the superstructure onto the undercarriage 2091
4 Undercarriage 2095
4 1 Undercarriage overview 2096
4 2 Travel system 2098
4 2 1 Crawler track 2098
4 2 1 1 Changing of the crawler track 2098
4 2 2 Sprocket 2105
4 2 2 1 Disassembling of the sprocket assembly 2105
4 2 2 2 Assembling of the sprocket assembly 2110
4 2 3 Guide wheel assembly 2113
4 2 3 1 Disassembling of the guide wheel assembly 2113
4 2 3 2 Assembling of the guide wheel assembly 2115
4 2 4 Track tensioning accumulators 2118
4 2 4 1 Disassembling of the low pressure accumulators 2118
4 2 4 2 Assembling of the low pressure accumulators 2120
4 2 4 3 Disassembling of the high pressure accumulators 2122
4 2 4 4 Assembling of the high pressure accumulators 2123
4 2 5 Track tension valve block 2124
4 2 5 1 Disassembling of the track tensioning valve block 2124
4 2 5 2 Assembling of the track tensioning valve block 2125
4 2 6 Track tensioning cylinders 2126
4 2 6 1 Disassembling of the track tensioning cylinders 2126
4 2 6 2 Assembling of the track tensioning cylinders 2128
4 2 7 Hydraulic hoses of the track tensioning system 2131
4 2 7 1 Precursory work 2131
4 2 7 2 Replace the hydraulic hoses inside the center body 2133
4 2 7 3 Replace the hydraulic hoses between center body and crawler frame 2133
4 2 7 4 Replace the hydraulic hoses inside the crawler frame 2135
4 2 7 5 Subsequent work 2135
4 2 8 Travel brake valve block (overspeed valve) 2136
4 2 8 1 Disassembling of the travel brake valve block 2136
4 2 8 2 Assembling of the travel brake valve block 2138
4 2 9 Travel motors 2140
4 2 9 1 Disassembling of the travel motors 2140
4 2 9 2 Assembling of the travel motors 2142
4 2 10 Travel parking brake 2144
4 2 10 1 Travel parking brake overview 2144
4 2 10 2 Disassembling of the travel parking brake of type 2063 2149
4 2 10 3 Assembling of the travel parking brake of type 2063 2152
4 2 10 4 Disassembling of the travel parking brake of type 631053 2155
4 2 10 5 Assembling of the travel parking brake of type 631053 2158
4 2 11 Travel gear box 2162
4 2 11 1 Disassembling of the travel gear box 2163
4 2 11 2 Assembling of the travel gear box 2165
4 2 12 Carrier roller 2168
4 2 12 1 Disassembling of the carrier roller assembly 2168
4 2 12 2 Assembling of the carrier roller assembly 2170
4 2 13 Track roller 2172
4 2 13 1 Disassembling of the track roller assembly 2172
4 2 13 2 Assembling of the track roller assembly 2174
4 3 Undercarriage center body 2176
4 3 1 Disassembling of the undercarriage center body and the crawler carriers 2176
4 3 2 Assembling of the undercarriage center body and the crawler carriers 2181
4 3 2 1 Install crawler carrier mounting bolts 2187
4 3 3 Rotary joint 2188
4 3 3 1 Disassembling of the rotary joint 2188
4 3 3 2 Assembling of the rotary joint 2192
5 Attachment 2197
5 1 Repair procedures 2198
5 1 1 Replacement of bushings at the attachment 2198
5 1 1 1 Disassembling of the bushings 2198
5 1 1 2 Installation of the bushings 2199
5 1 2 General installation instructions for attachment pins 2200
5 2 Backhoe Attachment (BHA) 2202
5 2 1 Overview 2202
5 2 2 Pin Sealing bucket – Steering Rod – bucket link rod 2204
5 2 3 Boom assembly 2206
5 2 3 1 Disassembling of the Boom 2206
5 2 3 2 Assembling of the boom 2208
5 2 3 3 Disassembling of the boom cylinders 2211
5 2 3 4 Assembling of the boom cylinders 2216
5 2 4 Stick assembly 2221
5 2 4 1 Disassembling of the Stick 2221
5 2 4 2 Assembling of the Stick 2226
5 2 4 3 Disassembling of the Stick Cylinders 2230
5 2 4 4 Assembling of the Stick cylinders 2234
5 2 5 Bucket and steering 2239
5 2 5 1 Disassembling of the bucket 2239
5 2 5 2 Assembling of the bucket 2243
5 2 5 3 Disassembling of the Bucket Cylinders 2246
5 2 5 4 Assembling of the Bucket Cylinders 2253
5 2 5 5 Disassembling of the bucket link rod 2260
5 2 5 6 Assembling of the bucket link rod 2263
5 2 5 7 Disassembling of the steering rods 2266
5 2 5 8 Assembling of the steering rods 2272
5 2 6 Hydraulic hoses at the backhoe attachment 2277
5 2 6 1 Replacing of the boom arc hoses 2277
5 2 6 2 Replacing of the lubrication hoses 2280
5 2 6 3 Replacing of the boom cylinder hoses 2281
5 2 6 4 Replacing of the stick cylinder hoses 2284
5 2 6 5 Replacing of the bucket cylinder hoses 2287
5 3 Front Shovel Attachment (FSA) 2290
5 3 1 Overview 2290
5 3 2 Using the Cylinder Mounting Device for Front shovel attachments (PN 967 000 40) 2292
5 3 2 1 Designated usage 2293
5 3 2 2 Non-designated usage 2293
5 3 3 Boom assembly 2294
5 3 3 1 Disassembling of the boom 2294
5 3 3 2 Assembling of the boom 2297
5 3 3 3 Disassembling of the boom cylinders 2300
5 3 3 4 Assembling of the boom cylinders 2305
5 3 4 Stick assembly 2310
5 3 4 1 Disassembling of the stick 2310
5 3 4 2 Assembling of the stick 2315
5 3 4 3 Disassembling of the stick cylinders 2320
5 3 4 4 Assembling of the stick cylinders 2324
5 3 5 Bull Clam bucket 2328
5 3 5 1 Disassembling of the bull clam bucket 2328
5 3 5 2 Assembling of the bull clam bucket 2332
5 3 5 3 Disassembling of the bucket cylinders 2336
5 3 5 4 Assembling of the bucket cylinders 2342
5 3 5 5 Disassembling of the clam cylinders 2348
5 3 5 6 Assembling of the clam cylinders 2353
5 3 6 Hydraulic hoses at the Faceshovel attachment 2359
5 3 6 1 Replacing of the boom arc hoses 2359
5 3 6 2 Replacing of the lubrication hoses 2362
5 3 6 3 Replacing of the boom cylinder hoses 2363
5 3 6 4 Replacing of the stick arc hoses 2366
5 3 6 5 Replacing of the stick cylinder hoses 2369
5 3 6 6 Replacing of the bucket cylinder hoses 2372
5 3 6 7 Replacing of the clam cylinder hoses 2374
5 4 Metering valves (grease injectors) at the attachment 2380
5 4 1 Disassembling of the metering valves (grease injectors) 2380
5 4 2 Assembling of the metering valves (grease injectors) 2382
5 5 Ground engaging tools (GET) 2383
5 5 1 Disassembling and assembling of the GET 2383
5 6 Cylinder bypass test 2385
6 Service Information 2387
6 1 Fluids and lubricants 2388
6 2 Lifting Gears 2388
6 3 Safety hints for sling accessory 2390
6 4 Weight tables 2391
6 4 1 Superstructure 2391
6 4 2 Undercarriage 2393
6 4 3 Backhoe attachment (BHA) 2394
6 4 4 Face shovel attachment (FSA) 2395
6 5 Torque charts according to KOMATSU company standard 2396
6 5 1 Metric standard thread 2396
6 5 2 Metric fine thread 2397
6 5 3 Cummins motor torques – metric 2398
6 5 4 Cummins motor torques – U S customary 2398
6 5 5 SAE-flange connections 2399
6 6 Blind plugs 2400
6 6 1 Dummy plates for SAE–flanges 2400
6 6 2 Classification of threads to the nominal width 2402
6 6 3 Plugs and fittings according to DIN 2353 2403
6 7 Conversion table 2404
6 7 1 Method of using the conversation table 2404
6 7 2 Millimeter – inch & kilogram – pound 2405
6 7 3 Liter – U S gallon & liter – U K gallon 2406
6 7 4 Nm- ft lb 2407
6 7 5 Bar – PSI – kPa – MPa 2408
6 7 6 Temperature 2409
6 8 Tools 2410
6 8 1 Standard tool case 2410
6 8 2 Used special tools (Overview) 2412
6 9 Work instructions 2415
6 9 1 Bleeding the track tensioning system 2415
6 9 2 Hints for hydraulic hose installation 2417
6 9 3 Remove / install the crawler carrier 2420
6 9 4 Repair procedure for the radiator assembly 2421
7 Parts & Service News 2423
7 1 List of relevant PARTS AND SERVICE NEWS 2424

S.V 11/12/24