KOMATSU PC4000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 08228 & up – PDF DOWNLOAD
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KOMATSU PC4000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 08228 & up – PDF DOWNLOAD
Description
KOMATSU PC4000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 08228 & up – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
KOMATSU PC4000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 08228 & up – PDF DOWNLOAD
BEFORE READING THIS MANUAL:
- This manual gives details of the operation and methods of inspection and maintenance 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 operation and maintenance of excavators. - Read, understand and follow all precautions and warnings in this manual and on the excavator before performing
operation and maintenance. 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 operation, inspection or maintenance 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 operation and maintenance of the excavator can be hazardous and could result in serious injury or death.
TABLE OF CONTENTS:
KOMATSU PC4000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 08228 & up – PDF DOWNLOAD
SHOP MANUAL Cover 1
00 FOREWORD & SAFETY 3
1 Foreword 5
1 1 BEFORE READING THIS MANUAL 6
1 2 CONTENTS OF THIS BINDER 7
1 2 1 Contacting the Service 7
1 2 2 Guarantee 7
1 3 DIVISION OF THE BINDER 8
2 Safety 9
2 1 SAFETY INFORMATION 10
2 2 OVERVIEW 11
2 2 1 NORMAL OPERATIONS 11
2 2 2 REGULAR MAINTENANCE 11
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 11
2 2 4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 11
2 3 SOUND PRESSURE AND VIBRATION LEVELs IN THE OPERATORโS 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 OPERATORโS COMPARTMENT 14
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 15
2 4 3 7 IF A PROBLEM IS FOUND 15
2 4 4 FIRE PREVENTION 15
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 15
2 4 4 2 ACTION IF FIRE OCCURS 17
2 4 4 3 EMERGENCY EXIT FROM OPERATORโS 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 OPERATORโS SEAT WITH LOCK 19
2 4 5 6 LEAVING THE MACHINE 19
2 4 6 BURN PREVENTION 19
2 4 6 1 Hot coolant 19
2 4 6 2 Hot oil 20
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 20
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 20
2 4 8 1 UNAUTHORIZED MODIFICATION 21
2 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 21
2 4 9 ELECTROMAGNETIC COMPATIBILITY (EMC) 21
2 4 10 PRECAUTIONS AT JOBSITE 22
2 4 10 1 VISIBILITY FROM OPERATORโS SEAT 23
2 4 10 2 CAMERA SYSTEM WITH MONITORS 23
2 4 10 3 ENSURE GOOD VISIBILITY 23
2 4 10 4 CHECKING SIGNS AND SIGNALMANโS SIGNALS 23
2 4 10 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 24
2 4 10 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 24
2 4 10 7 WORKING ON LOOSE GROUND 25
2 4 10 8 GAS, DUST, STEAM AND SMOKE 25
2 4 10 9 VENTILATION OF ENCLOSED AREAS 26
2 4 11 STARTING motor 27
2 4 11 1 WARNING TAG 27
2 4 11 2 CHECKS BEFORE STARTING motor 27
2 4 11 3 PRECAUTION WHEN STARTING motor 27
2 4 11 4 PRECAUTION IN COLD AREAS 28
2 4 12 OPERATION 28
2 4 12 1 CHECKS BEFORE OPERATION 28
2 4 12 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 29
2 4 12 3 PRECAUTIONS WHEN travelling 30
2 4 12 4 TRAVELLING ON SLOPES 31
2 4 12 5 OPERATIONS ON SLOPES 32
2 4 12 6 PROHIBITED OPERATIONS 32
2 4 12 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 33
2 4 12 8 PARKING THE MACHINE 33
2 4 12 9 TRANSPORTATION 33
2 5 PRECAUTION FOR MAINTENANCE 34
2 5 1 GENERAL PRECAUTIONS 34
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 35
2 5 1 2 STOP motor FOR MAINTENANCE 36
2 5 1 3 WARNING TAG 37
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 38
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 38
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 39
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 39
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 40
2 5 1 9 NOISE 40
2 5 1 10 WHEN USING A HAMMER 40
2 5 1 11 PROPER TOOLS 41
2 5 1 12 ACCUMULATOR 41
2 5 1 13 PERSONNEL 41
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 42
2 5 2 1 PRECAUTION WHEN WELDING 42
2 5 2 2 BATTERY HANDLING 42
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 43
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 43
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 44
2 5 3 3 REPLACEMENT OF HOSE LINES 44
2 5 3 4 INSPECTION OF HOSE LINES 44
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 45
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 45
2 5 3 7 AIR CONDITIONING MAINTENANCE 45
2 5 3 8 COMPRESSED AIR 46
2 5 3 9 WASTE MATERIALS 46
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 47
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 47
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 47
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 47
2 7 SPECIAL SAFETY EQUIPMENT 48
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR โFOPSโ FOR OPERATORโS CAB 49
2 7 2 OBJECT HANDLING 49
2 7 3 LIGHTING 49
2 7 4 WARNING BEACON 49
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2 7 5 2 INSTRUCTIONS FOR USE 51
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 53
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 53
2 7 5 5 INSTRUCTIONS FOR USE 55
01 SPECIFICATION 57
PC4000E-6 59
10 STRUCTURE & FUNCTION 67
TOC 69
1 Introduction 81
1 1 Foreword 82
1 2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 84
1 3 Explanation of abbreviations 85
1 4 Diagrams and illustrations in this manual 86
2 Specifications 87
2 1 Lifting Gears 88
2 2 Safety hints for sling accessory 90
2 3 Standard Tightening Torque Chart 91
2 4 Conversion Table 92
2 5 Blind plugs 98
2 6 Classification of threads to the nominal width 100
2 7 Plugs and fittings according to ISO 8434-1 / DIN 2353 101
3 Main assembly groups 103
3 1 General layout 104
3 2 Superstructure 106
3 3 Machine house 108
3 4 Hydraulic oil tank 110
3 5 Hydraulic oil cooler 112
3 6 High voltage switch cabinet 114
3 7 Cab base 120
3 7 1 Extra low voltage switch board (Location 11) 122
3 7 2 Low voltage switch board (Location 12) 122
3 8 Operatorโs cab 124
3 9 Control blocks 126
3 10 Slew gear 128
3 10 1 Slew gear L&S 128
3 10 2 Slew gear SIEBENHAAR 130
3 11 Rotary joint 132
3 12 Undercarriage 134
3 13 Slew ring 136
3 14 Attachment 138
3 14 1 Front Shovel Attachment (FSA) 138
3 14 2 Backhoe Attachment (BHA) 140
3 15 Counterweight 142
4 Drive 145
4 1 Electric drive – Safety and operation instruction documents 146
4 2 Prime drive assembly 148
4 3 Electric motors 150
4 3 1 Location of attaching parts 150
4 3 1 1 Motor type plate 151
4 3 1 2 Type plate for the motor bearings 152
4 3 2 Motor bearings & grease equipment 154
4 3 3 Monitoring of the motor bearing temperature 156
4 3 4 Monitoring of the motor winding temperature 157
4 3 5 Junction box for the motor monitoring device 158
4 3 6 Checking the bearing condition 159
4 3 7 Capacitor assembly 160
4 4 Air-to-air motor cooling system 162
4 5 Initial Start-up procedure 163
4 5 1 Main supply cable 164
4 5 2 Motor protection relay (SPAM 150 C) 166
4 5 3 Motor alignment 168
4 5 4 Motor rotation direction 170
4 5 5 Starting & Re-starting the electric motor 170
4 5 6 Supervision during the first motor running period 171
4 6 Flexible coupling 172
4 6 1 Coupling inspection 173
4 6 2 Coupling replacement 174
4 7 Pump distributor gearbox (PTO) 176
4 7 1 Pump drive shaft housing / spline lubrication 178
4 7 1 1 Oil level in the main pump drive shaft housing 179
4 7 2 PTO lubrication and cooling 180
4 7 2 1 Checks and adjustments 182
4 8 Hydraulic pumps โ location, drive speed and flow rates 184
4 8 1 Pump data 186
5 Hydraulic oil tank 187
5 1 General layout 188
5 2 Hydraulic oil tank, location of the electric equipment 190
5 3 Suction oil tank with strainers 192
5 4 Return oil collector pipe with strainer 194
5 5 Back pressure valve 196
5 6 Transfer pump 198
5 7 Return and leak oil filter 200
5 8 Breather filter 202
6 Hydraulic oil cooling 205
6 1 Overall view of the hydraulic oil cooling 206
6 2 Function of the hydraulic oil cooling circuit 208
6 3 Adjustment of the back pressure valve 210
6 4 Two stage cooler fan RPM control 212
6 4 1 Pressure reducing valve 214
6 4 2 Solenoid valves 216
6 4 3 Fan pump 218
6 5 Checks and Adjustments of the cooler fan drive speeds 220
6 5 1 Function Check of Fan Speed Control 224
7 Controlling 225
7 1 General layout 226
7 2 Control and filter panel 228
7 3 Valve cartridge block 230
7 4 Pilot pressure supply and adjustments 232
7 4 1 Pilot pressure control (PPC) circuit 232
7 4 2 Checks and adjustment of pilot pressure 236
7 4 3 Remote control valves arrangement 238
7 5 Function of the electro-hydraulic control system 240
7 5 1 Electronic hand lever (joystick) 244
7 5 1 1 Voltage supply of hand lever 20S020 245
7 5 1 2 Direction signal course from hand lever to controllers 246
7 5 1 3 Double ratiometric* output diagram 247
7 6 Foot pedal control 248
7 6 0 1 Voltage supply of Foot lever (20S021a) 250
7 6 0 2 Direction signal course from foot pedal to controllers 251
7 6 0 3 Double ratiometric* output diagram for 2 direction pedal 252
7 6 0 4 Single ratiometric* output diagram for 1 direction pedal 252
7 7 Hand lever & foot pedal monitoring 253
7 7 1 Lever monitoring screen (exemplary) 254
7 7 2 Valve monitoring screen (exemplary) 256
7 8 Valve solenoid adjustment 257
7 8 1 Overview sol min/max current & adjustment range 258
7 9 ACCEL & DECEL time adjustment 259
7 9 1 Accel & Decel times 259
8 Components 263
8 1 Main control blocks and high pressure filters (FSA) 264
8 2 Main control blocks and high pressure filters (BHA) 266
8 3 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) 268
8 4 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) 270
8 5 Single control blocks (floating) for stick and boom (FSA) 272
8 6 Restrictor block with secondary relief valve 274
8 7 Anti-cavitation valve (ACV) block 276
8 8 Remote control valves 278
8 9 4/3 Directional solenoid valves 280
8 10 Proportional solenoid valves 282
8 11 High-pressure filter (screen) 284
8 12 Control blocks and valves 286
8 12 1 Spool types 292
8 12 2 MRV, SRV and ACV 294
8 12 3 Load holding valve 296
8 13 Travel brake valve 300
8 14 Pressure reducing valve 302
8 15 4/2 Directional valves 304
8 16 Pressure double stage valve 306
8 17 Hydraulic cylinder 308
8 17 1 Cylinder data markings 311
9 Main hydraulic pumps and pump regulation 313
9 1 General 314
9 1 1 Pump locations and pump data 316
9 2 Main pumps 318
9 2 1 Hydraulic pump type HPV375+375 318
9 2 1 1 Main pump sectional drawings 320
9 2 2 Servo valve 322
9 2 2 1 VC valve ๏ servo piston 323
9 2 2 2 EPC valve 328
9 3 Electronic pump regulation system 330
9 3 1 Cut-off function 332
9 3 2 Slew control 333
9 3 3 Altitude pump displacement 333
9 3 4 Temperature control 334
9 3 4 1 Hydraulic oil temperature charts 334
9 3 4 2 Pump flow control 335
9 3 5 Energy efficiency 335
9 4 Pump controller (14K305) 336
9 4 1 pin arrangement at the connectors of the pump controller (14K305) 338
9 5 Monitoring, error indication, adjustment 342
9 5 1 Monitoring items of the pump controller 342
9 5 2 Error indication of the pump controller 346
9 5 2 1 Error messages (pump controller) – Mechanical systems 346
9 5 2 2 Caution symbols (pump controller) 347
9 5 2 3 Failure codes for pump controller 347
9 5 3 Adjustable parameters of the pump controller 348
9 5 3 1 Pump sol โminโ current values according to pump type plate 350
9 5 3 2 Pump sol โmaxโ current values according to pump type plate 351
9 6 Checks and adjustments 353
9 6 1 Motor power check 353
9 6 2 Cut-off function check 356
9 6 2 1 Cut-off for clam close (FSA only) 357
9 7 Electronic load limiting control 358
9 7 1 Load limiting control input signals at 14K305 359
9 7 2 Load limiting control output signals from 14K305 360
9 7 3 Signal rectifier module (12T431) 361
9 7 4 Checks and adjustment of 12T431 364
9 7 4 1 Testing the signal rectifier 12T431 for voltage 365
9 7 4 2 Testing the signal rectifier 12T431 for current 365
10 Operating hydraulics 367
10 1 General 368
10 1 1 Floating system (FSA only) 370
10 2 Hydraulics for the attachment cylinders 374
10 2 1 Electric / hydraulic flowchart “Boom UP” (FSA) 374
10 2 2 Electric / hydraulic flowchart “boom up” (BHA) 376
10 2 3 Electric / hydraulic flowchart “boom down” (FSA) 378
10 2 4 Electric / hydraulic flowchart “Boom down” (BHA) 380
10 2 5 Electric / hydraulic flowchart “Stick out” (FSA) 382
10 2 6 Electric / hydraulic flowchart “Stick out” (BHA) 384
10 2 7 Electric / hydraulic flowchart “Stick in” (FSA) 386
10 2 8 Electric / hydraulic flowchart “Stick in” (BHA) 388
10 2 9 Electric / hydraulic flowchart “Bucket fill” (FSA) 390
10 2 10 Electric / hydraulic flowchart “Bucket fill” (BHA) 392
10 2 11 Electric / hydraulic flowchart “Bucket dump” (FSA) 394
10 2 12 Electric / hydraulic flowchart “Bucket dump” (BHA) 396
10 2 13 Electric / hydraulic flowchart “Clam open” (FSA) 398
10 2 14 Electric / hydraulic flowchart “Clam close” (FSA) 400
10 2 15 Checks & adjustments of the main relief valve (MRV) 402
10 2 16 Checks and adjustments of the secondary relief valves (SRV) 404
10 2 16 1 Boom cylinders, piston side (BHA & FSA), boom up 404
10 2 16 2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down 408
10 2 16 3 Stick cylinders, piston side (FSA), stick out 412
10 2 16 4 Stick cylinders, piston side (BHA), stick in 416
10 2 16 5 Stick cylinders, piston rod side (FSA), stick in 420
10 2 16 6 Stick cylinders, piston rod side (BHA), stick out 424
10 2 16 7 Bucket cylinders, piston side (FSA), bucket fill 428
10 2 16 8 Bucket cylinders, piston side (BHA), bucket fill 432
10 2 16 9 Bucket cylinders, piston rod side (FSA), bucket dump 436
10 2 16 10 Bucket cylinders, piston rod side (BHA), bucket dump 440
10 2 16 11 Clam cylinders, piston rod side (FSA), clam open 444
10 2 16 12 Clam cylinders, piston side (FSA), clam close 448
10 2 17 Checks and adjustments of the lowering speed 452
10 2 17 1 Checks and adjustments of the lowering speed โ boom (FSA) 452
10 2 17 2 Checks and adjustments of the lowering speed โ boom (BHA) 458
10 2 17 3 Checks and adjustments of the lowering speed โ stick (FSA) 460
10 2 17 4 Checks and adjustments of the lowering speed โ stick (BHA) 466
10 2 17 5 Checks and adjustments of the lowering speed โ bucket (FSA) 468
10 2 17 6 Checks and adjustments of the lowering speed โ bucket (BHA) 470
10 2 17 7 Checks and adjustments of the lowering speed โ clam (FSA) 472
10 3 Hydraulics for the slew circuit 474
10 3 1 Slew circuit 474
10 3 2 Slew motor 478
10 3 3 Slew gearbox (L&S) 480
10 3 4 Slew gearbox (SIEBENHAAR) 482
10 3 5 Slew parking brake (L&S) 484
10 3 6 Slew parking brake (SIEBENHAAR) 486
10 3 7 Slew brake valve 488
10 3 8 Electric / hydraulic flowchart “Slew left” 492
10 3 9 Electric / hydraulic flowchart “Slew right” 494
10 3 10 Checks and adjustments for the slew circuit 496
10 3 10 1 checks & adjustments, slew speed 496
10 3 10 2 Checks & adjustments, double stage valve 498
10 3 10 3 Checks of the brake pilot pressure 501
10 3 11 Function check for the hydraulic slew brake 502
10 3 12 Function check for the slew parking brake 504
10 4 Hydraulics for the travel system 506
10 4 1 Travel circuit 506
10 4 2 Travel motor 508
10 4 3 Rotary joint 510
10 4 4 Travel gearbox 512
10 4 4 1 Travel gearbox (L & S) 512
10 4 4 2 Travel gearbox (Zollern) 514
10 4 5 Travel parking brake 516
10 4 5 1 Travel parking brake (Zollern) 516
10 4 5 2 Travel parking brake (L&S) 517
10 5 Travel brake valve 518
10 5 1 Electric / hydraulic flowchart “travel forward” 520
10 5 2 Electric / hydraulic flowchart “travel backwards 522
10 5 3 Checks and adjustments 524
10 5 3 1 Checks and adjustments for the travel circuit 524
10 5 3 2 Function check for the travel parking brake 528
11 Hydraulic track tensioning system 531
11 1 General 532
11 2 Functional description 534
11 3 Double stage valve 536
11 4 Tensioning cylinder 538
11 5 Adjustments / checks 540
12 Access ladder, hydraulically operated 543
12 1 General 544
12 2 Function of the hydraulically operated access ladder 546
12 3 Adjustments / checks 550
13 Central refilling system 553
13 1 General 554
13 1 1 Central refilling system overview 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 583
15 4 1 Cover page of the Komatsu W/D 583
15 4 2 Example 1 from the schematics in the W/D 585
15 4 3 Example 2 from the schematics in the W/D 587
15 4 4 Table of contents in the W/D (page 1 of 2) 589
15 4 5 Location list 591
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 KOMTRAX Plus Monitoring & Control System 605
16 1 General 606
16 1 1 Global layout PC4000E-6 606
16 1 2 Controller system overview PC4000E-6 607
16 1 3 Interface connection 609
16 1 4 General description 610
16 2 KOMTRAX Plus – Operator level 611
16 2 1 Main gauge screens 612
16 2 2 Operator menus & icons & functions of keys F1 F6 616
16 2 2 1 Operator menu: Energy Consumption – Operation Records 618
16 2 2 2 Operator menu: Energy Consumption – Average Energy Consumption Logs 620
16 2 2 3 Operator menu: Machine Setting 622
16 2 2 4 Operator menu: Maintenance 623
16 2 2 5 Reset of โremaining timeโ till next maintenance interval 625
16 2 2 6 Usage limitation 626
16 2 2 7 Operator menu: Monitor Setting – Screen Adjustment 627
16 2 2 8 Operator menu: Monitor Setting – Clock Adjustment – Calender 628
16 2 2 9 Operator menu: Monitor Setting – Clock Adjustment – Time 629
16 2 2 10 Operator menu: Monitor Setting – Clock Adjustment – 12h/24h Mode 630
16 2 2 11 Operator menu: Monitor Setting – Clock Adjustment – Daylight Saving Time 631
16 2 2 12 Operator menu: Monitor Setting – Language & ID Key Information 632
16 3 Error and status indication on the operator level 633
16 3 1 Prompts (status indications) 633
16 3 2 Cautions 634
16 3 3 Emergency shutdown screen (example) 635
16 3 4 Fault levels for error messages 636
16 3 5 Action code L01 638
16 3 6 Action code L02 639
16 3 7 Action code L03 640
16 3 8 Action code L04 641
16 3 9 Error list 642
16 4 Table of failure codes 643
16 4 1 Failure codes without monitor indication 656
16 4 2 Additional text information for action codes 656
16 5 Flow charts of KOMTRAX Plus screens 657
16 5 1 Flow chart Operator Level 657
16 5 2 Flow chart Service Level 658
16 6 KOMTRAX Plus service level 659
16 6 1 Entering the Service Level 659
16 6 2 Key symbols (F1 F6) on the Service Level 661
16 6 3 Service Menu selection screens 662
16 6 4 Service Menu – item 01 Monitoring / Custom 664
16 6 4 1 Monitoring list for: ELEC controller 664
16 6 4 2 Monitoring list for: PUMP controller 666
16 6 4 3 Monitoring list for: VALVE0 controller 669
16 6 4 4 Monitoring list for: VALVE1 controller 672
16 6 4 5 Monitoring list for: VALVE2 controller 675
16 6 4 6 Monitoring list for: MON (monitor) 677
16 6 4 7 Monitoring list for: KOM PLS (K+ controller) 679
16 6 5 How to perform the monitoring function 682
16 6 6 Service Menu – item 02 PM Clinic 684
16 6 6 1 PM Clinic (General) 684
16 6 6 2 PM Clinic (Power Check) 685
16 6 6 3 Functions of PM CLINIC (POWER CHECK) 686
16 6 7 Service Menu – item 03 Memory Clear 687
16 6 8 Service Menu – item 04 Abnormality record 688
16 6 8 1 Reset error messages 689
16 6 9 Service Menu – item 05 Maintenance record 690
16 6 10 Service Menu – item 06 Maintenance Mode Setting 691
16 6 11 Service Menu – item 07 Snap Shot 692
16 6 12 Service Menu – item 08 Phone Number Entry 693
16 6 13 Service Menu – item 09 Unit 694
16 6 14 Service Menu – item 10 Adjustment 695
16 6 14 1 Adjustments for: ELEC controller 695
16 6 14 2 Adjustments for: PUMP controller 697
16 6 14 3 Pump sol โminโ current values according to pump type plate 700
16 6 14 4 Pump sol โmaxโ current values according to pump type plate 701
16 6 14 5 Adjustments for: VALVE0 controller 702
16 6 14 6 Accel & Decel times 709
16 6 14 7 Adjustments for: VALVE2 controller 710
16 6 15 Service Menu – item 11 Machine Configuration 712
16 6 15 1 Details of Machine Configuration for PC4000E-6 713
16 7 Wiring of the KOMTRAX Plus controller 716
16 7 0 1 Memories in the KOMTRAX Plus controller 719
16 8 Interface-Connection to K+ controller 720
16 9 KOMTRAX Plus controller 721
16 10 7-segment error code indication 722
16 11 CR720 controller 723
16 11 1 Location of CR720 controllers 724
16 11 2 In case of CR720 trouble 724
16 11 3 Connectors and pin arrangement of CR720 controllers 726
16 12 Controller replacement procedure 727
17 Lubrication system 733
17 1 General overview (SLS & CLS 1 ) 734
17 1 1 General description 735
17 2 Basic function of the lubrication systems 736
17 3 Lubrication systems (CLS 1 & SLS) 738
17 3 1 Lubrication pump station 738
17 3 2 General Information on CLS 1 740
17 3 3 General information on the SLS 740
17 3 4 Manual lube activation 740
17 4 Lubrication cycle 741
17 4 1 Operation and control 741
17 4 2 Lubrication cycle โ processing 742
17 4 3 Time segments & switch points of a lubrication cycle 743
17 4 4 Lubrication modes 744
17 4 4 1 Automatic lubrication mode 744
17 4 4 2 Manual lubrication mode 744
17 4 4 3 Reduced Pause Time for service 744
17 5 Hydraulically driven lube pump 746
17 5 1 Adjustment of lube pump speed & working pressure 748
17 5 1 1 Stroke speed adjustment 749
17 5 1 2 Working pressure adjustment 750
17 6 Lubricant injectors 752
17 6 1 Tightening torques for fittings at grease injectors 753
17 6 2 Description 753
17 6 3 Adjustment of the lubricant output 754
17 6 4 Operation principle of lubricant injectors 756
17 6 4 1 Function description 757
17 6 5 Connection of one or more injectors 758
17 7 End-line switch 760
17 7 1 Description 761
17 7 2 Vent valve description 761
17 7 3 CLS 1 end-line switch adjustment 762
17 7 4 SLS end-line switch adjustment 764
17 8 Lubricant level sensors 766
17 8 1 Description 767
17 8 1 1 Checks 767
17 9 Commissioning 768
17 9 1 Commissioning of the CLS 1 lubrication system 768
17 9 2 Fine adjustment 769
17 9 3 Commissioning of the SLS lubrication system 770
18 Deep temperature equipment (option) 773
18 1 General information 774
18 1 1 Introduction 774
18 1 2 Deep temperature components overview 774
18 1 3 Power supply preconditions for preheating 775
18 1 4 Power requirements for preheating systems 776
18 2 Preheating procedure 777
18 2 1 Global flow chart of the preheating procedure 777
18 2 2 Starting the preheating procedure 778
18 2 3 Preheating of operatorโs cab and Diesel engine [coolant system] 779
18 2 4 Preheating of lubricants and superstructure (Diesel) [electric system] 780
18 3 Constant heating of travel motors (TTT equipment below-40ยฐC only) 781
18 4 Component location 782
18 4 1 Electric heating elements for hydraulic & batteries [electric machine] 782
18 4 2 Electric heating elements for hydraulics [Diesel machine] 784
18 4 3 Electric heating elements for engines & batteries [Diesel machine] 786
18 5 Components of TT equipment 788
18 5 1 Preheating components on a Diesel machine 788
18 5 2 Preheating components on an electric machine 789
18 5 3 Exemplary Wiring Diagrams for preheating systems 790
18 5 3 1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 790
18 5 3 2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 791
18 5 3 3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 792
18 5 3 4 Wiring diagram “Suction Oil Manifold Preheating” 793
18 5 3 5 Wiring diagram “PTO Preheating” 794
18 5 3 6 Wiring diagram “Battery heater pads” 795
40 TROUBLESHOOTING 797
TOC 799
1 Introduction 827
1 1 Overview 828
1 1 1 General advice when using troubleshooting charts 828
1 2 General Precautions 829
2 General Information for Troubleshooting 831
2 1 Preparations For Work 832
2 2 Precautions During Work 832
2 3 Precautions When Carrying Out Any Operation 833
2 3 1 Precautions when carrying out removal work 833
2 3 2 Precautions when carrying out installation work 833
2 3 3 Precautions when completing the operation 834
2 4 Fundamental Requirements for Trouble shooting 835
2 4 1 Technical documentation 835
2 4 2 Tools 835
2 4 2 1 Reference Guide for Deutsch Removal Tools 839
2 4 3 Personnel 840
2 5 Points To Remember When Trouble- shooting 840
2 6 Sequence Of Events In Troubleshooting 842
2 7 Checks Before Troubleshooting 843
2 8 Handling Of Electric Equipment And Hydraulic Components 844
2 8 1 Points to remember when handling electric equipment 844
2 8 2 Points To Remember When Handling Hydraulic Equipment 847
2 9 General working procedures 849
2 9 1 Air Bleeding of Various Hydraulic Parts 849
2 9 2 Air bleeding from the hydraulic pumps 849
2 9 3 Air bleeding from hydraulic cylinders 849
2 10 Cylinder bypass test 850
2 11 Basics about “How to crimp” 851
2 11 1 Stripping a wire for use with the HDT 48 crimp tool 851
2 11 2 View onto the Deutsch crimp tool HDT 48 851
2 11 3 Adjustment of the wire size at the Deutsch crimp tool HDT 48 852
2 11 3 1 Wire cross section units in mm2 and AWG 852
2 11 4 Crimping instructions (for Deutsch crimp tool HDT 48) 853
2 12 Cable Shielding 854
3 Mounting Locations and Connector Types 855
3 1 Component Location (exemplarily) 856
3 1 1 Side View onto the Excavator 856
3 1 2 Superstructure 858
3 1 3 Machine House 860
3 2 Rotary joint 862
3 3 Capacitor 864
3 4 High Voltage Switch Cabinet – View 1 866
3 4 1 High Voltage Switch Cabinet – View 2 868
3 4 2 High Voltage Switch Cabinet – View 3 870
3 5 Cab Support 872
3 5 1 Extra low voltage switch board (Location 11) 874
3 5 2 Low voltage switch board (Location 12) 874
3 6 Location of the Control Blocks 876
3 7 Control and filter panel – location of components 878
3 8 Location of the suction oil tank with strainers 880
3 9 Arrangement of the remote control valves 882
3 10 Hydraulic oil tank – Location of the electrical components 884
3 11 General overview on SLS & CLS1 886
3 12 Batteries, battery main switches & safety switch for maintenance 888
3 13 Hydraulically operated access ladder 890
3 14 Receiver panel for the refilling system 892
3 15 Connector Types Overview 894
4 Standard Value Table for Electrical Components 899
5 Tables for Testing and Troubleshooting 915
5 1 Test Value Tables for Temperature Sensors (PT100) 916
5 2 Table of failure codes 918
5 3 Tables of Symptom Codes 931
5 3 1 Symptoms of the E-Motor(s) and Related parts 931
5 3 2 Symptoms of the Hydraulic System 931
5 3 3 Symptoms of the Mechanical System 932
5 3 4 SYMPTOMS OF ADDITIONAL SYSTEMS 932
5 4 Cable colour identification 932
6 Troubleshooting by Trouble Code 933
B@HANS – Hyd Oil Overheat 934
Hydraulic oil temperature table 935
Location and W/D of 57K506a-1 / 57K506b-1 for message B@HANS 936
6A1BMA – Trouble Shut-Off (gate) valve not open error 937
View onto the gap of proximity switch 40B031 938
Wiring Diagram (40B031) for message 6A1BMA 939
K@3A00 – Fire In System 940
Wiring Diagram (fire warning) for message K@3A00 941
Wiring Diagram (controller input of 20K351) for message K@3A00 942
Wiring Diagram (10B350 in the emergency stop line) for message K@3A00 943
B@F0MA – CLS1 Lubrication System Error 944
B@CPMA – SLS Lubrication System Error 945
K@3B00 – Fire in the switch cabinet 946
Wiring Diagram 1 (temperature sensors) for message K@3B00 947
Wiring Diagram 2 (control unit in the cab) for message G00059 948
G@01NS – Electric motor1 winding overheat 949
Monitoring motor winding temperature & net-line voltage for G@01NS 950
Wiring Diagram (monitoring motor winding temperature) for G@01NS 951
G@02NS – Electric motor1 bearing overheat 952
Monitoring motor bearing temperature for G@02NS 953
Wiring Diagram (monitoring motor bearing temperature) for G@02NS 954
G@03KG – Capacitor1 voltage high error 955
Wiring Diagram (capacitor pressure monitoring) for G@03KG 956
Capacitor pressure monitoring screen for message G@03KG 956
G@00K3 – Ground leakage tripped 957
Wiring Diagram (12F431) for message G@00K3 958
G@00MA – Electric motor1 abnormality 959
Monitoring motor protection relay for G@00MA 960
G@00NZ – 3 phase current rotation direction error 961
Wiring Diagram (phase sequence monitoring) for message G@00NZ 962
Phase sequence relay monitoring for message G@00NZ 963
G@00N8 – Trouble restart motor 1, temperature too high 964
Monitoring motor protection relay for G@00N8 (motor start blocked) 965
G@20MA -Trouble cab heater safety relay 966
Wiring Diagram 1 for G@20MA 967
Wiring Diagram 2 for G@20MA 968
B@F0N9 – CLS1 pressure increase time too long 969
B@CPN9 – SLS pressure increase time too long 969
Allocation of vent valves and end-of-line switches 970
View onto the vent valve (62Q507a & 62Q509a) 971
Wiring Diagram – lube pump & vent valve (CLS1 & SLS) 972
B@F0N0 – CLS1 pressure decrease time too long 973
B@CPN0 – SLS pressure decrease time too long 973
View onto the vent valve (62Q507a & 62Q509a) 974
B@F0ZK – CLS1 grease level too low 975
B@CPZK – SLS grease level too low 975
Wiring Diagram – grease level sensors (CLS1 & SLS) 977
B@HAZK – Hydraulic oil level too low 978
Hydraulic oil level in defined machine position 979
Wiring Diagram – hydraulic oil level sensor 40B004 980
Wiring Diagram – hydraulic oil level pressure transducer 40B105 981
B@CBNS – PTO1 Gear Oil Temp High 982
View onto the universal pump distributor gearbox (PTO) 984
B@CBZG – PTO1 Gear Lubrication Error 985
PTO lube oil pressure monitoring 986
Shutdown adjustment for PTO lube oil pressure 986
G@06N8 – Transformer1 Temp Too High 987
Transformer temperature signal & motor voltage monitoring 988
Wiring Diagram – transformer temperature monitoring 989
G@04MA – Earth Fault Tripped 990
RCD LV and welding sockets monitoring 991
Wiring Diagram – controller input for G@04MA 991
Wiring Diagram – 12F451 & 12F452 (option) 992
G@22N8 – Trouble temperature cab base 993
Cab base temperature signal indication 994
Wiring Diagram – temperature monitoring LV cabinet (10B001) 994
View onto temperature sensor 10B001 995
G@23N8 – Trouble temperature high voltage cabinet 996
HV cabinet temperature signal indication 997
Wiring Diagram – temperature monitoring HV cabinet (32B802) 997
View onto temperature sensor 32B802 998
G@24NS – Cab Heating1 Error 999
G@25NS – Cab Heating2 Error 999
View onto the heater air inlet & outlet grids in the operatorโs cab 1000
View onto the heater air inlet & outlet grids in the operatorโs cab 1001
Wiring Diagram – control of heater overheat protection (100ยฐC) 1002
G@40KU – Emergency Voltage Too High 1003
Emergency voltage monitoring screen for message G@40KU 1003
G@40KL – Emergency Voltage Too Low 1004
Emergency voltage monitoring screen for message G@40KL 1004
B@H2NX – Breather Filter Clogging 1005
Location of 40B024 and hydraulic oil level definitions 1006
B@M9NX – PTO1 Gear Oil Filter Clogging 1007
View onto the PTO1 gear oil filter with pressure sensor 57B027-1 1008
B@HBNX – Return Oil Filter Clogging 1009
B@L4NX – Leak Oil Filter Clogging 1010
B@L5N9 – Pilot Press X2 Too Low 1011
Valve cartridge block, location of components 1012
B@L5N0 – Pilot Press X2 Too High 1013
Valve cartridge block, location of components 1014
B@HANX – Screen At Hyd Cooler Entry Clogging 1015
Hydraulic oil tank & transfer pump, location of components 1016
G@00MC – Motor1 Main Relay Circuit Abnormality 1018
G@00MC – failure detection criteria 1019
Wiring Diagram 1 for message G@00MC 1022
Wiring Diagram 2 for message G@00MC 1023
Wiring Diagram 3 for message G@00MC 1024
989HMA – Emergency stop line abnormality 1025
Wiring Diagram – emergency line for 989HMA 1026
Monitoring screens for message 989HMA 1027
DGT3MA – PTO1 oil temperature sensor abnormality 1028
Wiring Diagram and location of 57B049 1029
DGH2MA – Hydraulic oil temp sensor abnormality 1030
Wiring Diagram and monitoring selection for 59B015 1031
DHQ7MA – PTO1 lube pressure sensor abnormality 1032
Wiring Diagram and monitoring selection for 57B017-1 1033
G@00KP – Motor1 voltage low error 1034
Wiring Diagram of signal rectifier module 12T431 1036
DHPEMA – Pump-1/2 pressure sensor abnormality 1037
DHPGMA – Pump-3/4 pressure sensor abnormality 1037
DHPJMA – Pump-5/6 pressure sensor abnormality 1037
DHPLMA – Pump-7/8 pressure sensor abnormality 1037
Wiring Diagram – power and GND supply for pump pressure transducers 1039
DJK3MA – Motor voltage sensor abnormality 1040
Wiring Diagram of signal rectifier module 12T431 1041
DJK4MA – Motor current sensor abnormality 1042
Wiring Diagram of signal rectifier module 12T431 1043
DA27KP – 24V sensor power abnormality 1044
Wiring Diagram – 24V sensor power supply for DA27KP 1045
DA26KP – 5V sensor2 power abnormality 1046
Wiring Diagram – 5V sensor power supply for DA26KP 1047
DA22KK – Solenoid Power Low Error(Pump Con) 1048
DA22MA – Solenoid Power Circuit Abnormality 1049
Wiring Diagram 1 – emergency stop line for DA22MA 1050
Wiring Diagram 2 for DA22MA 1051
DXAAKA – Pump1 Solenoid open circuit 1052
DXABKA – Pump2 Solenoid open circuit 1052
DXACKA – Pump3 Solenoid open circuit 1052
DXADKA – Pump4 Solenoid open circuit 1052
DXAEKA – Pump5 Solenoid open circuit 1052
DXAFKA – Pump6 Solenoid open circuit 1052
DXAGKA – Pump7 Solenoid open circuit 1052
DXAHKA – Pump8 Solenoid open circuit 1052
Wiring Diagram – EPC valve control 1054
DXAAKB – Pump1 Solenoid short circuit 1055
DXABKB – Pump2 Solenoid short circuit 1055
DXACKB – Pump3 Solenoid short circuit 1055
DXADKB – Pump4 Solenoid short circuit 1055
DXAEKB – Pump5 Solenoid short circuit 1055
DXAFKB – Pump6 Solenoid short circuit 1055
DXAGKB – Pump7 Solenoid short circuit 1055
DXAHKB – Pump8 Solenoid short circuit 1055
Wiring Diagram – EPC valve control 1057
DWA5KA – CLS pump solenoid open circuit 1058
DWA8KA – SLS pump solenoid open circuit 1058
Wiring Diagram – CLS/SLS pump solenoid control 1059
DWA5KB – CLS pump solenoid short circuit 1060
DWA8KB – SLS pump solenoid short circuit 1060
Wiring Diagram – CLS/SLS pump solenoid control 1061
DWA5KY – CLS pump solenoid hot short circuit 1062
DWA8KY – SLS pump solenoid hot short circuit 1062
Wiring Diagram – CLS/SLS pump solenoid / hot short circuit 1063
DWA7KA – CLS line release solenoid open circuit 1064
DWA9KA – SLS lube line release sol open circuit 1064
Wiring Diagram – CLS/SLS lube line release solenoid control 1065
DWA7KB – CLS line release solenoid short circuit 1066
DWA9KB – SLS lube line release solenoid short circuit 1066
Wiring Diagram – CLS/SLS lube line release solenoid control 1067
DWA7KY – CLS line release sol hot short circuit 1068
DWA9KY – SLS lube line release sol hot short circuit 1068
Wiring Diagram – CLS/SLS lube line release solenoid / hot short circuit 1069
DWAAKA – PTO lube preload solenoid open circuit 1070
Wiring Diagram and monitoring screen for message DWAAKA 1071
DWAAKB – PTO lube preload solenoid short circuit 1072
Wiring Diagram and monitoring screen for message DWAAKB 1073
DWAAKY – PTO lube preload sol hot short circuit 1074
Wiring Diagram for message DWAAKY 1075
D166KA – Oil cooler fan sol(Min)relay open circuit 1076
Wiring Diagram – relay 11K068 for 57K506a (D166KA) 1077
D166KB – Oil cooler fan sol(Min)relay short circuit 1078
Wiring Diagram – relay 11K068 for 57K506a (D166KB) 1079
D167KA – Oil cooler fan sol(Mid)relay open circuit 1080
Wiring Diagram – relay 11K069 for 57K506b (D167KA) 1081
D167KB – Oil cooler fan sol(Mid)relay short circuit 1082
Wiring Diagram – relay 11K069 for 57K506b (D167KB) 1083
D168KA – Oil cooler preload sol relay open circuit 1084
Wiring Diagram – relay 11K070 for 40K601 (D168KA) 1085
D168KB – Oil cooler preload sol relay short circuit 1086
Wiring Diagram – relay 11K070 for 40K601 (D168KB) 1087
D1E9KB – Wiper fast relay short circuit 1088
D1ETKB – Wiper slow relay short circuit 1088
D1EBKB – Wiper stop relay short circuit 1088
Wiring Diagram – wiper motor control 1089
D1E9KA – Wiper fast relay open circuit 1090
D1ETKA – Wiper slow relay open circuit 1090
D1EBKA – Wiper stop relay open circuit 1090
Wiring Diagram – wiper motor control 1091
D162KA – Horn relay open circuit 1092
Wiring Diagram – signal horn control 1093
D162KB – Horn relay short circuit 1094
Wiring Diagram – signal horn control 1095
D1F0KA – Engine1/motor1 shutdown relay open circuit 1096
Wiring Diagram 1 – engine1/motor1 shutdown relay 12K408a-1 1097
Wiring Diagram 2 – engine1/motor1 shutdown relay 12K408a-1 1098
D1F0KB – Engine1/motor1 shutdown relay short circuit 1099
Wiring Diagram 1 – engine1/motor1 shutdown relay 12K408a-1 1100
Wiring Diagram 2 – engine1/motor1 shutdown relay 12K408a-1 1101
D1F0KY – Engine1/motor1 shutdown relay hot short 1102
Wiring Diagram 1 for D1F0KY 1103
Wiring Diagram 2 for D1F0KY 1104
D110KA – Battery relay open circuit 1105
Wiring Diagram – battery relay 11Q044d 1106
D110KB – Battery relay short circuit 1107
Wiring Diagram – battery relay 11Q044d 1108
DA29KQ – Model Selection Abnormality 1109
Monitoring screen for machine selection 1109
Wiring Diagram – model selection abnormality (DA29KQ) 1110
DA2YKQ – Motor Selection Abnormality 1111
Monitoring screen for motor selection 1111
Wiring Diagram – motor selection abnormality (DA2YKQ) 1112
DA2XKQ – Motor1 Frequency Select Abnormality 1113
Monitoring screen for frequency selection 1113
Wiring Diagram – motor frequency select abnormality (DA2XKQ) 1114
DA20KQ – Pump Con Selection Abnormality 1115
Monitoring screen for pump controller selection 1115
DA20MC – Pump Con Error 1116
DDABMC – Lock lever switch abnormality 1117
Wiring Diagram – lock lever switch 20S105 (DDABMC) 1118
DKURMA – R lever right-left potentio abnormality 1119
Wiring Diagram – right lever right-left potentiometer input (DKURMA) 1120
DKUSMA – R lever right-left redu pot abnorm(VALVE/M) 1121
Wiring Diagram – right lever redundant right-left potentiometer input (DKUSMA) 1122
DKUQL8 – R lever right-left potentio error 1123
Wiring Diagram – right lever main + redundant right-left signal voltage (DKUQL8) 1124
DKUQL4 – R lever right-left sig mismatch(VALVE/M) 1125
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1 1127
DKUNMA – R lever front-back potentio abnormality 1128
Wiring Diagram – right lever front-back potentiometer input (DKUNMA) 1129
DKUPMA – R lever front-back redu pot abnorm(VALVE/M) 1130
Wiring Diagram – right lever redundant front-back potentiometer input (DKUPMA) 1131
DKUML8 – R lever front-back potentio error 1132
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8) 1133
DKUML4 – R lever front-back sig mismatch(VALVE/M) 1134
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1 1136
DKUXMA – Left lever right-left potentio abnormality 1137
Wiring Diagram – left lever right-left potentiometer input (DKUXMA) 1138
DKUYMA – L lever right-left redu pot abnorm(VALVE/M) 1139
Wiring Diagram – left lever redundant right-left potentiometer input (DKUYMA) 1140
DKUWL8 – L lever right-left potentio error 1141
Wiring Diagram – left lever main + redundant right-left signal voltage (DKUWL8) 1142
DKUWL4 – L lever right-left sig mismatch(VALVE/M) 1143
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1 1145
DKUUMA – L lever front-back potentio abnormality 1146
Wiring Diagram – left lever front-back potentiometer input (DKUUMA) 1147
DKUVMA – L lever front-back redu pot abnorm(VALVE/M) 1148
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/M) for DKUVMA 1149
DKUTL8 – L lever front-back potentio error 1150
Wiring Diagram – L lever front-back potentio error (DKUTL8) 1151
DKUTL4 – L lever front-back sig mismatch(VALVE/M) 1152
Wiring Diagram – L lever front-back sig mismatch(VALVE/M) for DKUTL4 1154
DKW1MA – R pedal potentio abnormality 1155
Wiring Diagram – R pedal potentio abnormality (DKW1MA) 1156
DKW2MA – R pedal redundant pot abnormality(VALVE/M) 1157
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA 1158
DKW0L8 – R pedal potentio error 1159
Wiring Diagram – R pedal potentio error (DKW0L8) 1160
DKW0L4 – R pedal signal mismatch(VALVE/M Con) 1161
Wiring Diagram – R pedal signal mismatch(VALVE/M Con) for DKW0L4 1163
DKW4MA – L pedal potentio abnormality 1164
Wiring Diagram – L pedal potentio abnormality (DKW4MA) 1165
DKW5MA – L pedal redundant pot abnormality(VALVE/M) 1166
Wiring Diagram – L pedal redundant pot abnormality(VALVE/M) for DKW5MA 1167
DKW3L8 – L pedal potentio error 1168
Wiring Diagram – L pedal potentio error (DKW3L8) 1169
DKW3L4 – L pedal signal mismatch(VALVE/M Con) 1170
Wiring Diagram – L pedal signal mismatch(VALVE/M Con) for DKW3L4 1172
DKW7MA – Clam open potentio abnormality 1173
Wiring Diagram – Clam open potentio abnormality (DKW7MA) 1174
DKW8MA – Clam open redu pot abnormality(VALVE/M) 1175
Wiring Diagram – Clam open redu pot abnormality(VALVE/M) for DKW8MA 1176
DKW6L8 – Clam open potentio error 1177
Wiring Diagram – Clam open potentio error (DKW6L8) 1178
DKW6L4 – Clam open signal mismatch(VALVE/M Con) 1179
Wiring Diagram – Clam open signal mismatch(VALVE/M Con) for DKW6L4 1181
DKWAMA – Clam close potentio abnormality 1182
Wiring Diagram – Clam close potentio abnormality (DKWAMA) 1183
DKWBMA – Clam close redundant pot abnorm(VALVE/M) 1184
Wiring Diagram – Clam close redundant pot abnorm(VALVE/M) for DKWBMA 1185
DKW9L8 – Clam close potentio error 1186
Wiring Diagram – Clam close potentio error (DKW9L8) 1187
DKW9L4 – Clam close signal mismatch(VALVE/M Con) 1188
Wiring Diagram – Clam close signal mismatch(VALVE/M Con) for DKW9L4 1190
DKWDMA – Hydraulic slew brake potentio abnormality 1191
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA) 1192
DKWEMA – Hyd slew brake redu pot abnorm(VALVE/M) 1193
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/M) for DKWEMA 1194
DKWCL8 – Hydraulic slew brake potentio error 1195
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8) 1196
DKWCL4 – Hyd slew brake sig mismatch(VALVE/M) 1197
Wiring Diagram – Hyd slew brake sig mismatch(VALVE/M) for DKWCL4 1199
DW4BKA – Travel parking brake solenoid open circuit 1200
Wiring Diagram and monitoring screen for message DW4BKA 1201
DW4BKB – Travel parking brake sol short circuit 1202
Wiring Diagram – Travel parking brake sol short circuit (DW4BKB) 1203
DW4BKY – Travel parking brake sol hot short circuit 1204
Wiring Diagram – Travel parking brake sol hot short circuit (DW4BKY) 1205
DW45KA – Slew parking brake solenoid open circuit 1206
Wiring Diagram and monitoring screen for message DW45KA 1207
DW45KB – Slew parking brake solenoid short circuit 1208
Wiring Diagram – Slew parking brake solenoid short circuit (DW45KB) 1209
DW45KY – Slew parking brake sol hot short circuit 1210
Wiring Diagram – Slew parking brake sol hot short circuit (DW45KY) 1211
DXN0KA – Slew1 epc solenoid open circuit 1212
DXN1KA – Bucket/Boom1 epc solenoid open circuit 1212
DXN2KA – Boom1 epc solenoid open circuit (BH only) 1212
DXN3KA – Stick1 epc solenoid open circuit 1212
DXN4KA – Boom2 epc solenoid open circuit 1212
DXN5KA – Clam2 epc solenoid open circuit 1212
DXN6KA – Stick2 epc solenoid open circuit (BH only) 1212
DXN7KA – Stick/Bucket2 epc solenoid open circuit 1212
DXN8KA – Bucket2 epc solenoid open circuit (BH only) 1212
DXN9KA – Travel2 left epc solenoid open circuit 1212
DXNAKA – Slew3 epc solenoid open circuit 1212
DXNBKA – Bucket3 epc solenoid open circuit 1212
DXNCKA – Boom3 epc solenoid open circuit 1212
DXNDKA – Boom4 epc solenoid open circuit 1212
DXNEKA – Bucket4 epc solenoid open circuit 1212
DXNFKA – Stick4 epc solenoid open circuit 1212
DXNGKA – Travel4 right epc solenoid open circuit 1212
Details of the above 6-digit failure codes (front shovel attachment only) 1213
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 1214
Wiring Diagram for EPC 61K624 – 61K625 1215
Wiring Diagram for EPC 61K626 – 61K627 1216
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 1217
Wiring Diagram for EPC 61K632 – 61K633 1218
Wiring Diagram for EPC 61K634 – 61K635 1219
Exemplary monitoring screens 1220
DXN0KB – Slew1 epc solenoid short circuit 1221
DXN1KB – Bucket/Boom1 epc solenoid short circuit 1221
DXN2KB – Boom1 epc solenoid short circuit (BH only) 1221
DXN3KB – Stick1 epc solenoid short circuit 1221
DXN4KB – Boom2 epc solenoid short circuit 1221
DXN5KB – Clam2 epc solenoid short circuit 1221
DXN6KB – Stick2 epc solenoid short circuit (BH only) 1221
DXN7KB – Stick/Bucket2 epc solenoid short circuit 1221
DXN8KB – Bucket2 epc solenoid short circuit (BH only) 1221
DXN9KB – Travel2 left epc solenoid short circuit 1221
DXNAKB – Slew3 epc solenoid short circuit 1221
DXNBKB – Bucket3 epc solenoid short circuit 1221
DXNCKB – Boom3 epc solenoid short circuit 1221
DXNDKB – Boom4 epc solenoid short circuit 1221
DXNEKB – Bucket4 epc solenoid short circuit 1221
DXNFKB – Stick4 epc solenoid short circuit 1221
DXNGKB – Travel4 right epc solenoid short circuit 1221
Details of the above 6-digit failure codes (front shovel attachment only) 1222
DXN0KY – Slew1 epc solenoid hot short circuit 1223
DXN1KY – Bucket/Boom1 epc sol hot short circuit 1223
DXN2KY – Boom1 epc solenoid hot short circuit (BH only) 1223
DXN3KY – Stick1 epc solenoid hot short circuit 1223
DXN4KY – Boom2 epc solenoid hot short circuit 1223
DXN5KY – Clam2 epc solenoid hot short circuit 1223
DXN6KY – Stick2 epc solenoid hot short circuit (BH only) 1223
DXN7KY – Stick/Bucket2 epc sol hot short circuit 1223
DXN8KY – Bucket2 epc solenoid hot short circuit (BH only) 1223
DXN9KY – Travel2 left epc sol hot short circuit 1223
DXNAKY – Slew3 epc solenoid hot short circuit 1223
DXNBKY – Bucket3 epc solenoid hot short circuit 1223
DXNCKY – Boom3 epc solenoid hot short circuit 1223
DXNDKY – Boom4 epc solenoid hot short circuit 1223
DXNEKY – Bucket4 epc solenoid hot short circuit 1223
DXNFKY – Stick4 epc solenoid hot short circuit 1223
DXNGKY – Travel4 right epc sol hot short circuit 1223
Details of the above 6-digit failure codes (front shovel attachment only) 1224
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 1225
Wiring Diagram for EPC 61K624 – 61K625 1226
Wiring Diagram for EPC 61K626 – 61K627 1227
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 1228
Wiring Diagram for EPC 61K632 – 61K633 1229
Wiring Diagram for EPC 61K634 – 61K635 1230
DWADKA – Ladder speed control solenoid open circuit 1231
Wiring Diagram and monitoring screen for message DWADKA 1232
DWADKB – Ladder speed control sol short circuit 1233
Wiring Diagram and monitoring screen for message DWADKB 1234
DWADKY – Ladder speed control sol hot short circuit 1235
Wiring Diagram – Ladder speed control sol hot short circuit (DWADKY) 1236
DBW5MA – 5V sensor1 power abnormality 1237
DBW6MA – 5V sensor2 power abnormality 1237
Wiring Diagram – 5V power supply and GND output at VALVE0 1241
DBW9KQ – Model Selection Abnormality 1242
Monitoring screen for machine selection 1242
Wiring Diagram – model selection abnormality (DBW9KQ) 1243
DBWZKQ – Lever control selection abnormality 1244
Monitoring screen for lever control (lever pattern) selection 1244
Wiring Diagram – Lever control selection abnormality (DBWZKQ) 1245
DBWYKQ – Attachment selection abnormality 1246
Monitoring screen for attachment selection 1246
Wiring Diagram – Attachment selection abnormality (DBWYKQ) 1247
DBW2KK – Solenoid Power Low Error(VALVE/M Con) 1248
DBW0KQ – VALVE/M Con Selection Abnormality 1250
Wiring Diagram and monitoring screen for message DBW0KQ 1251
DDDWMC – Ladder operation switch abnormality 1252
Wiring Diagram and monitoring screen for message DDDWMC 1253
DKWHMA – R lever right-left redu pot abnorm(VLV/S1) 1254
Wiring Diagram – right lever redundant right-left potentiometer input (DKWHMA) 1255
DKWFL4 – R lever right-left sig mismatch(VALVE/S1) 1256
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1 1258
DKWLMA – R lever front-back redu pot abnorm(VLV/S1) 1259
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA) 1260
DKWJL4 – R lever front-back sig mismatch(VALVE/S1) 1261
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1 1263
DKWPMA – L lever right-left redu pot abnorm(VLV/S1) 1264
Wiring Diagram – left lever redundant right-left potentiometer input (DKWPMA) 1265
DKWML4 – L lever right-left sig mismatch(VALVE/S1) 1266
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1 1268
DKWSMA – L lever front-back redu pot abnorm(VLV/S1) 1269
Wiring Diagram – L lever front-back redu pot abnorm(VLV/S1) for DKWSMA 1270
DKWQL4 – L lever front-back sig mismatch(VALVE/S1) 1271
Wiring Diagram – L lever front-back sig mismatch(VALVE/S1) for DKWQL4 1273
DKWVMA – R pedal red pot abnormality(VALVE/S1) 1274
Wiring Diagram – R pedal red pot abnormality(VALVE/S1) for DKWVMA 1275
DKWTL4 – R pedal signal mismatch(VALVE/S1 Con) 1276
Wiring Diagram – R pedal signal mismatch(VALVE/S1 Con) for DKWTL4 1278
DKWYMA – L pedal red pot abnormality(VALVE/S1) 1279
Wiring Diagram – L pedal red pot abnormality(VALVE/S1) for DKWYMA 1280
DKWWL4 – L pedal signal mismatch(VALVE/S1 Con) 1281
Wiring Diagram – L pedal signal mismatch(VALVE/S1 Con) for DKWWL4 1283
DKX2MA – Clam open redu pot abnormality(VALVE/S1) 1284
Wiring Diagram – Clam open redu pot abnormality(VALVE/S1)) for DKX2MA 1285
DKX0L4 – Clam open signal mismatch(VALVE/S1 Con) 1286
Wiring Diagram – Clam open signal mismatch(VALVE/S1 Con) for DKX0L4 1288
DKX5MA – Clam close redu pot abnormality(VALVE/S1) 1289
Wiring Diagram – Clam close redu pot abnormality(VALVE/S1) for DKX5MA 1290
DKX3L4 – Clam close signal mismatch(VALVE/S1 Con) 1291
Wiring Diagram – Clam close signal mismatch(VALVE/S1 Con) for DKX3L4 1293
DKX8MA – Hyd slew brake redu pot abnorm(VALVE/S1) 1294
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/S1) for DKX8MA 1295
DKX6L4 – Hyd slew brake signal mismatch(VALVE/S1) 1296
Wiring Diagram – Hyd slew brake signal mismatch(VALVE/S1) for DKWCL4 1298
DWNRKA – Ladder up solenoid open circuit 1300
Wiring Diagram and monitoring screen for message DWNRKA 1301
DWNRKB – Ladder up solenoid short circuit 1302
Wiring Diagram and monitoring screen for message DWNRKB 1303
DWNRKY – Ladder up solenoid hot short circuit 1304
Wiring Diagram – Ladder up solenoid hot short circuit (DWNRKY) 1305
DW7RKA – Hydraulic slew brake solenoid open circuit 1306
Wiring Diagram and monitoring screen for message DW7RKA 1307
DW7RKB – Hydraulic slew brake sol short circuit 1308
Wiring Diagram and monitoring screen for message DW7RKB 1309
DW7RKY – Hyd slew brake sol hot short circuit 1310
Wiring Diagram – Hyd slew brake sol hot short circuit (DW7RKY) 1311
DWANKA – Slew1 right solenoid open circuit 1312
Wiring Diagram and monitoring screen for message DWANKA 1313
DWANKB – Slew1 right solenoid short circuit 1314
Wiring Diagram and monitoring screen for message DWANKB 1315
DWANKY – Slew1 right solenoid hot short circuit 1316
Wiring Diagram and monitoring screen for message DWANKY 1317
DWAJKA – Slew1 left solenoid open circuit 1318
Wiring Diagram and monitoring screen for message DWAJKA 1319
DWAJKB – Slew1 left solenoid short circuit 1320
Wiring Diagram and monitoring screen for message DWAJKB 1321
DWAJKY – Slew1 left solenoid hot short circuit 1322
Wiring Diagram and monitoring screen for message DWAJKY 1323
DWASKA – Bucket1 fill solenoid open circuit 1324
Wiring Diagram and monitoring screen for message DWASKA 1325
DWASKB – Bucket1 fill solenoid short circuit 1326
Wiring Diagram and monitoring screen for message DWASKB 1327
DWASKY – Bucket1 fill solenoid hot short circuit 1328
Wiring Diagram and monitoring screen for message DWASKY 1329
DWBEKA – Boom1 down solenoid open circuit 1330
Wiring Diagram and monitoring screen for message DWBEKA 1331
DWBEKB – Boom1 down solenoid short circuit 1332
Wiring Diagram and monitoring screen for message DWBEKB 1333
DWBEKY – Boom1 down solenoid hot short circuit 1334
Wiring Diagram and monitoring screen for message DWBEKY 1335
DWBAKA – Boom1 up solenoid open circuit 1336
Wiring Diagram and monitoring screen for message DWBAKA 1337
DWBAKB – Boom1 up solenoid short circuit 1338
Wiring Diagram and monitoring screen for message DWBAKB 1339
DWBAKY – Boom1 up solenoid hot short circuit 1340
Wiring Diagram and monitoring screen for message DWBAKY 1341
DWBJKA – Stick1 out solenoid open circuit 1342
Wiring Diagram and monitoring screen for message DWBJKA 1343
DWBJKB – Stick1 out solenoid short circuit 1344
Wiring Diagram and monitoring screen for message DWBJKB 1345
DWBJKY – Stick1 out solenoid hot short circuit 1346
Wiring Diagram and monitoring screen for message DWBJKY 1347
DWBNKA – Stick1 in solenoid open circuit 1348
Wiring Diagram and monitoring screen for message DWBNKA 1349
DWBNKB – Stick1 in solenoid short circuit 1350
Wiring Diagram and monitoring screen for message DWBNKB 1351
DWBNKY – Stick1 in solenoid hot short circuit 1352
Wiring Diagram and monitoring screen for message DWBNKY 1353
DWBBKA – Boom2 up solenoid open circuit 1354
Wiring Diagram and monitoring screen for message DWBBKA 1355
DWBBKB – Boom2 up solenoid short circuit 1356
Wiring Diagram and monitoring screen for message DWBBKB 1357
DWBBKY – Boom2 up solenoid hot short circuit 1358
Wiring Diagram and monitoring screen for message DWBBKY 1359
DWBFKA – Boom2 down solenoid open circuit 1360
Wiring Diagram and monitoring screen for message DWBFKA 1361
DWBFKB – Boom2 down solenoid short circuit 1362
Wiring Diagram and monitoring screen for message DWBFKB 1363
DWBFKY – Boom2 down solenoid hot short circuit 1364
Wiring Diagram and monitoring screen for message DWBFKY 1365
DWBXKA – Clam2 close solenoid open circuit 1366
Wiring Diagram and monitoring screen for message DWBXKA 1367
DWBXKB – Clam2 close solenoid short circuit 1368
Wiring Diagram and monitoring screen for message DWBXKB 1369
DWBXKY – Clam2 close solenoid hot short circuit 1370
Wiring Diagram and monitoring screen for message DWBXKY 1371
DWBKKA – Stick2 out solenoid open circuit 1372
Wiring Diagram and monitoring screen for message DWBKKA 1373
DWBKKB – Stick2 out solenoid short circuit 1374
Wiring Diagram and monitoring screen for message DWBKKB 1375
DWBKKY – Stick2 out solenoid hot short circuit 1376
Wiring Diagram and monitoring screen for message DWBKKY 1377
DWBTKA – Clam2 open solenoid open circuit 1378
Wiring Diagram and monitoring screen for message DWBTKA 1379
DWBTKB – Clam2 open solenoid short circuit 1380
Wiring Diagram and monitoring screen for message DWBTKB 1381
DWBTKY – Clam2 open solenoid hot short circuit 1382
Wiring Diagram and monitoring screen for message DWBTKY 1383
DWBPKA – Stick2 in solenoid open circuit 1384
Wiring Diagram and monitoring screen for message DWBPKA 1385
DWBPKB – Stick2 in solenoid short circuit 1386
Wiring Diagram and monitoring screen for message DWBPKB 1387
DWBPKY – Stick2 in solenoid hot short circuit 1388
Wiring Diagram and monitoring screen for message DWBPKY 1389
DWATKA – Bucket2 fill solenoid open circuit 1390
Wiring Diagram and monitoring screen for message DWATKA 1391
DWATKB – Bucket2 fill solenoid short circuit 1392
Wiring Diagram and monitoring screen for message DWATKB 1393
DWATKY – Bucket2 fill solenoid hot short circuit 1394
Wiring Diagram and monitoring screen for message DWATKY 1395
DWAXKA – Bucket2 dump solenoid open circuit 1396
Wiring Diagram and monitoring screen for message DWAXKA 1397
DWAXKB – Bucket2 dump solenoid short circuit 1398
Wiring Diagram and monitoring screen for message DWAXKB 1399
DWAXKY – Bucket2 dump solenoid hot short circuit 1400
Wiring Diagram and monitoring screen for message DWAXKY 1401
DWKFKA – Travel2 left backward sol open circuit 1402
Wiring Diagram and monitoring screen for message DWKFKA 1403
DWKFKB – Travel2 left backward sol short circuit 1404
Wiring Diagram and monitoring screen for message DWKFKB 1405
DWKFKY – Travel2 left backward sol hot short circuit 1406
Wiring Diagram and monitoring screen for message DWKFKY 1407
DWKBKA – Travel2 left forward sol open circuit 1408
Wiring Diagram and monitoring screen for message DWKBKA 1409
DWKBKB – Travel2 left forward sol short circuit 1410
Wiring Diagram and monitoring screen for message DWKBKB 1411
DWKBKY – Travel2 left forward sol hot short 1412
Wiring Diagram and monitoring screen for message DWKBKY 1413
D5ZWKA – Travel hour meter open circuit 1414
Wiring Diagram and monitoring screen for message D5ZWKA 1415
D5ZWKB – Travel hour meter short circuit 1416
Wiring Diagram and monitoring screen for message D5ZWKB 1417
D1EUKA – Travel alarm relay open circuit 1418
Wiring Diagram and monitoring screen for message D1EUKA 1419
D1EUKB – Travel alarm relay short circuit 1420
Wiring Diagram and monitoring screen for message D1EUKB 1421
DBX9KQ – Model Selection Abnormality 1422
Wiring Diagram and monitoring screen for message DBX9KQ 1423
DBXZKQ – Lever Control Selection Abnormality 1424
Wiring Diagram and monitoring screen for message DBXZKQ 1425
DBXYKQ – Attachment selection abnormality 1426
Wiring Diagram – Attachment selection abnormality (DBXYKQ) 1427
D561MA – Lock lever sol power cut abnorm(VALVE/S1) 1428
Wiring Diagram 1 for message D561MA 1429
Wiring Diagram 2 for message D561MA 1430
Wiring Diagram 3 for message D561MA 1431
D563MA – Ladder up sensor sol cut abnorm(VLV/S1) 1432
Wiring Diagram 1 for message D563MA 1433
Wiring Diagram 2 for message D563MA 1434
Wiring Diagram 3 for message D563MA 1435
DBX2KK – Solenoid Power Low Error(VALVE/S1 Con) 1436
Wiring Diagram 1 for message DBX2KK 1437
Wiring Diagram 2 for message DBX2KK 1438
Wiring Diagram 3 for message DBX2KK 1439
DBX0KQ – VALVE/S1 Con Selection Abnormality 1440
Wiring Diagram and monitoring screen for message DBX0KQ 1441
DBX0MA – VALVE/S1 Con Error 1442
DWAQKA – Slew3 right solenoid open circuit 1444
Wiring Diagram and monitoring screen for message DWAQKA 1445
DWAQKB – Slew3 right solenoid short circuit 1446
Wiring Diagram and monitoring screen for message DWAQKB 1447
DWAQKY – Slew3 right solenoid hot short circuit 1448
Wiring Diagram and monitoring screen for message DWAQKY 1449
DWALKA – Slew3 left solenoid open circuit 1450
Wiring Diagram and monitoring screen for message DWALKA 1451
DWALKB – Slew3 left solenoid short circuit 1452
Wiring Diagram and monitoring screen for message DWALKB 1453
DWALKY – Slew3 left solenoid hot short circuit 1454
Wiring Diagram and monitoring screen for message DWALKY 1455
DWAUKA – Bucket3 fill solenoid open circuit 1456
Wiring Diagram and monitoring screen for message DWAUKA 1457
DWAUKB – Bucket3 fill solenoid short circuit 1458
Wiring Diagram and monitoring screen for message DWAUKB 1459
DWAUKY – Bucket3 fill solenoid hot short circuit 1460
Wiring Diagram and monitoring screen for message DWAUKY 1461
DWAYKA – Bucket3 dump solenoid open circuit 1462
Wiring Diagram and monitoring screen for message DWAYKA 1463
DWAYKB – Bucket3 dump solenoid short circuit 1464
Wiring Diagram and monitoring screen for message DWAYKB 1465
DWAYKY – Bucket3 dump solenoid hot short circuit 1466
Wiring Diagram and monitoring screen for message DWAYKY 1467
DWBGKA – Boom3 down solenoid open circuit 1468
Wiring Diagram and monitoring screen for message DWBGKA 1469
DWBGKB – Boom3 down solenoid short circuit 1470
Wiring Diagram and monitoring screen for message DWBGKB 1471
DWBGKY – Boom3 down solenoid hot short circuit 1472
Wiring Diagram and monitoring screen for message DWBGKY 1473
DWBDKA – Boom4 up solenoid open circuit 1474
Wiring Diagram and monitoring screen for message DWBDKA 1475
DWBDKB – Boom4 up solenoid short circuit 1476
Wiring Diagram and monitoring screen for message DWBDKB 1477
DWBDKY – Boom4 up solenoid hot short circuit 1478
Wiring Diagram and monitoring screen for message DWBDKY 1479
DWBHKA – Boom4 down solenoid open circuit 1480
Wiring Diagram and monitoring screen for message DWBHKA 1481
DWBHKB – Boom4 down solenoid short circuit 1482
Wiring Diagram and monitoring screen for message DWBHKB 1483
DWBHKY – Boom4 down solenoid hot short circuit 1484
Wiring Diagram and monitoring screen for message DWBHKY 1485
DWAVKA – Bucket4 fill solenoid open circuit 1486
Wiring Diagram and monitoring screen for message DWAVKA 1487
DWAVKB – Bucket4 fill solenoid short circuit 1488
Wiring Diagram and monitoring screen for message DWAVKB 1489
DWAVKY – Bucket4 fill solenoid hot short circuit 1490
Wiring Diagram and monitoring screen for message DWAVKY 1491
DWAZKA – Bucket4 dump solenoid open circuit 1492
Wiring Diagram and monitoring screen for message DWAZKA 1493
DWAZKB – Bucket4 dump solenoid short circuit 1494
Wiring Diagram and monitoring screen for message DWAZKB 1495
DWAZKY – Bucket4 dump solenoid hot short circuit 1496
Wiring Diagram and monitoring screen for message DWAZKY 1497
DWBMKA – Stick4 out solenoid open circuit 1498
Wiring Diagram and monitoring screen for message DWBMKA 1499
DWBMKB – Stick4 out solenoid short circuit 1500
Wiring Diagram and monitoring screen for message DWBMKB 1501
DWBMKY – Stick4 out solenoid hot short circuit 1502
Wiring Diagram and monitoring screen for message DWBMKY 1503
DWBRKA – Stick4 in solenoid open circuit 1504
Wiring Diagram and monitoring screen for message DWBRKA 1505
DWBRKB – Stick4 in solenoid short circuit 1506
Wiring Diagram and monitoring screen for message DWBRKB 1507
DWBRKY – Stick4 in solenoid hot short circuit 1508
Wiring Diagram and monitoring screen for message DWBRKY 1509
DWKRKA – Travel4 right backward sol open circuit 1510
Wiring Diagram and monitoring screen for message DWKRKA 1511
DWKRKB – Travel4 right backward sol short circuit 1512
Wiring Diagram and monitoring screen for message DWKRKB 1513
DWKRKY – Travel4 right backward sol hot short 1514
Wiring Diagram and monitoring screen for message DWKRKY 1515
DWKMKA – Travel4 right forward sol open circuit 1516
Wiring Diagram and monitoring screen for message DWKMKA 1517
DWKMKB – Travel4 right forward sol short circuit 1518
Wiring Diagram and monitoring screen for message DWKMKB 1519
DWKMKY – Travel4 right forward sol hot short 1520
Wiring Diagram and monitoring screen for message DWKMKY 1521
DXEDKA – Hydraulic slew brake epc sol open circuit 1522
Wiring Diagram and monitoring screen for message DXEDKA 1523
DXEDKB – Hyd slew brake epc sol short circuit 1524
Wiring Diagram and monitoring screen for message DXEDKB 1525
DXEDKY – Hyd slew brake epc sol hot short circuit 1526
Wiring Diagram and monitoring screen for message DXEDKY 1527
DWKVKA – Boom4 float solenoid open circuit 1528
Wiring Diagram and monitoring screen for message DWKVKA 1529
DWKVKB – Boom4 float solenoid short circuit 1530
Wiring Diagram and monitoring screen for message DWKVKB 1531
DWKVKY – Boom4 float solenoid hot short circuit 1532
Wiring Diagram and monitoring screen for message DWKVKY 1533
DWKWKA – Stick1 float solenoid open circuit 1534
Wiring Diagram and monitoring screen for message DWKWKA 1535
DWKWKB – Stick1 float solenoid short circuit 1536
Wiring Diagram and monitoring screen for message DWKWKB 1537
DWKWKY – Stick1 float solenoid hot short circuit 1538
Wiring Diagram and monitoring screen for message DWKWKY 1539
DWKZKA – Stick4 float solenoid open circuit 1540
Wiring Diagram and monitoring screen for message DWKZKA 1541
DWKZKB – Stick4 float solenoid short circuit 1542
Wiring Diagram and monitoring screen for message DWKZKB 1543
DWKZKY – Stick4 float solenoid hot short circuit 1544
Wiring Diagram and monitoring screen for message DWKZKY 1545
DBY9KQ – Model Selection Abnormality 1546
Wiring Diagram and monitoring screen for message DBY9KQ 1547
DBYZKQ – Lever Control Selection Abnormality 1548
Wiring Diagram and monitoring screen for message DBYZKQ 1549
DBYYKQ – Attachment selection abnormality 1550
Wiring Diagram – Attachment selection abnormality (DBYYKQ) 1551
D562MA – Lock lever sol power cut abnorm(VALVE/S2) 1552
Wiring Diagram 1 and monitoring screen for message D562MA 1553
Wiring Diagram 2 for message D562MA 1554
Wiring Diagram 3 for message D562MA 1555
D564MA – Ladder up sensor sol cut abnorm(VLV/S2) 1556
Wiring Diagram 1 for message D564MA 1557
Wiring Diagram 2 for message D564MA 1558
Wiring Diagram 3 for message D564MA 1559
DBY2KK – Solenoid Power Low Error(VALVE/S2 Con) 1560
Wiring Diagram 1 for message DBY2KK 1561
Wiring Diagram 2 for message DBY2KK 1562
Wiring Diagram 3 for message DBY2KK 1563
DBY0KQ – VALVE/S2 Con Selection Abnormality 1564
Wiring Diagram and monitoring screen for message DBY0KQ 1565
DBY0MA – VALVE/S2 Con Error 1566
DGB0MA – Motor1 bearing D end temp sensor abnormal 1568
Wiring Diagram and monitoring screen for message DGB0MA 1569
DGB1MA – Motor1 bearing no D E temp sensor abnormal 1570
Wiring Diagram and monitoring screen for message DGB1MA 1571
DGB6MA – Motor1 winding temp sensor1 abnormality 1572
DGB7MA – Motor1 winding temp sensor2 abnormality 1572
DGB8MA – Motor1 winding temp sensor3 abnormality 1572
Wiring Diagram and monitoring screen for message DGB6MA 1574
D552KK – Batt volt emergency power supply abnormal 1576
Emergency voltage monitoring screen for message D552KK 1576
Wiring Diagram for message D552KK 1577
D1HEKA – Heating cab contactor1 open circuit 1578
Wiring Diagram and monitoring screen for message D1HEKA 1579
D1HEKB – Heating cab contactor1 short circuit 1580
Wiring Diagram and monitoring screen for message D1HEKB 1581
D1HFKA – Heating cab contactor2 open circuit 1582
Wiring Diagram and monitoring screen for message D1HFKA 1583
D1HFKB – Heating cab contactor2 short circuit 1584
Wiring Diagram and monitoring screen for message D1HFKB 1585
D1HGKA – Heating cab contactor3 open circuit 1586
Wiring Diagram and monitoring screen for message D1HGKA 1587
D1HGKB – Heating cab contactor3 short circuit 1588
Wiring Diagram and monitoring screen for message D1HGKB 1589
D1HHKA – Electric heating error reset line open 1590
Wiring Diagram and monitoring screen for message D1HHKA 1591
D1HHKB – Electric heating error reset line short 1592
Wiring Diagram and monitoring screen for message D1HHKB 1593
D1HJKA – Motor1 standstill heating contactor open 1594
Wiring Diagram and monitoring screen for message D1HJKA 1595
D1HJKB – Motor1 standstill heating contactor short 1596
Wiring Diagram and monitoring screen for message D1HJKB 1597
D1HLKA – Blower cabinet wall relay open circuit 1598
Wiring Diagram and monitoring screen for message D1HLKA 1599
D1HLKB – Blower cabinet wall relay short circuit 1600
Wiring Diagram and monitoring screen for message D1HLKB 1601
D1HMKA – Blower operator seat relay open circuit 1602
Wiring Diagram and monitoring screen for message D1HMKA 1603
D1HMKB – Blower operator seat relay short circuit 1604
Wiring Diagram and monitoring screen for message D1HMKB 1605
K@3AMA – Fire supp switch cabinet circuit abnormal 1606
Wiring Diagram and monitoring screen for message K@3AMA 1607
DCP9KQ – Model Selection Abnormality 1608
Wiring Diagram and monitoring screen for message DCP9KQ 1609
DCP2KK – Solenoid Power Low Error(ELEC Con) 1610
Wiring Diagram and monitoring screen for message DCP2KK 1611
DAP0KQ – ELECTRIC Con Selection Abnormality 1612
Wiring Diagram and monitoring screen for message DAP0KQ 1613
DCP0MA – ELECTRIC Con Error 1614
DJH2L5 – Hydraulic oil level signal mismatch 1616
Wiring Diagram and monitoring screen for message DJH2L5 1617
DJH2KX – Hydraulic oil level sensor abnormality 1618
Wiring Diagram and monitoring screen for message DJH2KX 1619
DH2GKX – Suction tank pressure sensor abnormality 1620
Wiring Diagram and monitoring screen for message DH2GKX 1621
DH2HKX – Oil cooler pressure sensor abnormality 1622
Wiring Diagram and monitoring screen for message DH2HKX 1623
DH2JKX – Preload valve return oil press abnormality 1624
Wiring Diagram and monitoring screen for message DH2JKX 1625
DHSUKX – X2 pressure sensor abnormality 1626
Wiring Diagram and monitoring screen for message DHSUKX 1627
DGE5MA – Ambient air temp sensor abnormality 1628
Wiring Diagram and monitoring screen for message DGE5MA 1629
DH2KKX – Return oil chamber press sensor abnormal 1630
Wiring Diagram and monitoring screen for message DH2KKX 1631
DH2LKX – Leak oil chamber press sensor abnormality 1632
Wiring Diagram and monitoring screen for message DH2LKX 1633
D5ZXMA – Impulse kWh-meter signal abnormality 1634
Wiring Diagram and monitoring screen for message D5ZXMA 1635
DJE5L4 – SLS sensor system abnormality 1636
Wiring Diagram and monitoring screen for message DJE5L4 1637
DJE6L4 – CLS sensor system abnormality 1638
Wiring Diagram and monitoring screen for message DJE6L4 1639
DBB3KK – Abnormality in VBAT voltage 1640
Wiring Diagram for message DBB3KK 1641
DBB0KK – KOMTRAX Plus source voltage Error 1642
Wiring Diagram for message DBB0KK 1643
DBB0KQ – KOMTRAX Plus Connector Mismatch 1644
Wiring Diagram for message DBB0KQ 1645
DBB5KP – 5V sensor1 power abnormality 1646
Wiring Diagram – 5V sensor1 power abnormality (DBB5KP) 1647
DBB6KP – 24V Sensor Power Abnormality 1648
Wiring Diagram – 24V sensor power abnormality (DBB6KP) 1649
DA2RKR – CAN1 Discon (Pump Con) 1650
Wiring Diagram for message DA2RKR 1651
DBWRKR – CAN1 Discon (Valve/M Con) 1652
Wiring Diagram for message DBWRKR 1653
DBXRKR – CAN1 Discon (Valve/S1 Con) 1654
Wiring Diagram for message DBXRKR 1655
DBYRKR – CAN1 Discon (Valve/S2 Con) 1656
Wiring Diagram for message DBYRKR 1657
DCPRKR – CAN1 Discon (Electric Con) 1658
Wiring Diagram for message DCPRKR 1659
DA2QKR – CAN2 Discon (Pump Con) 1660
Wiring Diagram for message DA2QKR 1661
DBWQKR – CAN2 Discon (Valve/M Con) 1662
Wiring Diagram for message DBWQKR 1663
DBXQKR – CAN2 Discon (Valve/S1 Con) 1664
Wiring Diagram for message DBXQKR 1665
DBYQKR – CAN2 Discon (Valve/S2 Con) 1666
Wiring Diagram for message DBYQKR 1667
DCPQKR – CAN2 Discon (Electric Con) 1668
Wiring Diagram for message DCPQKR 1669
DBBQKR – CAN2 Discon (KOMTRAX Plus) 1670
Wiring Diagram for message DBBQKR 1671
D19YKB – Emergency Lighting Ladder Relay Short Circuit 1672
Wiring Diagram and monitoring screen for message D19YKB 1673
DV00KB – Shutdown Buzzer Short Circuit 1674
Wiring Diagram and monitoring screen for message DV00KB 1675
7 Troubleshooting by Symptoms 1677
7 1 Symptoms of the E-motor(s) and related parts 1678
SEM001 – Starting the E-motor(s) is not possible 1678
SEM002 – Stopping the E-motor(s) is not possible 1679
SEM003 – E-motor has excessive vibration 1680
View onto the coupling for SEM003 1681
SEM004 – Abnormal noise coming from the E-motor(s) 1682
SEM005 – E-motor lacks output (low power) 1684
View onto the PM CLINIC sheet (power check) for SEM005 1685
SEM006 – Air-to-Air motor cooling system not sufficient 1686
Exemplary view onto the Air-to-Air motor cooling system for SEM006 1687
SEM007 – Motor shuts down during start 1688
Signal wiring for the phases (SEM007) 1689
SEM008 – Substation main circuit breaker tripped 1690
Net-line supply overview (SEM008) 1691
Electric energy consumption (SEM008) 1692
Motor current overview (SEM008) 1693
7 2 Symptoms of the Hydraulic System 1694
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function) 1694
SHY002 – No work equipment, travel, or swing movement 1696
SHY003 – Work equipment has too much hydraulic drift 1697
SHY004 – Work equipment has big time lag 1698
SHY005 – Machine deviates during travel movement 1699
SHY006 – Machine does not swing (or it swings very low) 1700
Slew brake block (SHY006) 1701
SHY007 – Swing acceleration is poor 1702
SHY008 – Excessive overrun when stopping swing 1704
SHY009 – Floating system without function 1706
SHY010 – Abnormal noise coming from SRV or MRV 1707
SHY011 – Track tensioning system without function 1708
Track tensioning – overview (SHY011) 1709
SHY012 – Ladder does not move, or slow movement 1710
SHY013 – The hydraulic driven grease pump does not move 1712
SHY014 – Abnormal track chain movement during digging 1714
SHY015 – Swing parking brake without function 1715
SHY016 – Travel parking brake without function 1716
7 3 Symptoms of the Mechanical System 1718
SME001 – Abnormal noise around the PTO / hydraulic pumps 1718
SME002 – There is a big shock when stopping swing 1719
SME003 – There is a big abnormal noise when moving/stopping swing 1720
SME004 – Abnormal noise coming from a travel gearbox 1722
SME005 – Abnormal noise coming from the work equipment (lack of grease) 1724
SME006 – Abnormal idler movement 1726
SME007 – Leak at the PTO shaft seal 1728
7 4 Symptoms of Additional Systems 1730
SAD001 – Air conditioner for the cabin does not work 1730
Exemplary view onto A/C test tools & A/C filling and service station 1731
SAD002 – Air conditioner LV cabinet does not work 1732
Exemplary view onto A/C test tools & A/C filling and service station 1733
SAD003 – Air conditioner HV cabinet does not work 1734
Exemplary view onto A/C test tools & A/C filling and service station 1735
50 DISASSEMBLY & ASSEMBLY 1737
TOC 1739
1 Superstructure 1747
1 1 Superstructure / machine house overview 1748
1 2 Batteries 1750
1 2 1 Removal of the batteries 1750
1 2 2 Replacement of the batteries 1752
1 3 Electric motor 1753
1 3 1 Removal of the electric motor 1753
1 3 2 Replacement of the electric motor 1758
1 3 3 Final alignment of the electric motor 1761
1 3 4 Capacitor assembly 1762
1 3 4 1 Removal of the capacitor assembly 1763
1 3 4 2 Replacement of the capacitor assembly 1765
1 4 Coupling assembly 1766
1 4 1 Vulkan coupling 1766
1 4 1 1 Removal of the Vulkan coupling 1768
1 4 1 2 Replacement of the Vulkan coupling 1770
1 5 PTO 1772
1 5 1 Overview of the PTO and the mounting of the pumps 1772
1 5 2 Main pumps 1774
1 5 2 1 Preparatory works for main pump removal 1774
1 5 2 2 Removal of main pump 1 1777
1 5 2 3 Replacement of main pump 1 1779
1 5 2 4 Removal of main pump 2 1780
1 5 2 5 Replacement of main pump 2 1782
1 5 2 6 Removal of main pump 3 1783
1 5 2 7 Replacement of main pump 3 1783
1 5 2 8 Removal of main pump 4 1783
1 5 2 9 Replacement of main pump 4 1783
1 5 3 PTO oil circulation pump (auxiliary pump) 1784
1 5 3 1 Removal of the oil circulation pump (auxiliary pump) 1784
1 5 3 2 Replacement of the oil circulation pump (auxiliary pump) 1786
1 5 4 Pilot oil pump 1787
1 5 4 1 Removal of the pilot oil pump 1787
1 5 4 2 Replacement of the pilot oil pump 1787
1 5 5 Hydraulic oil cooler fan drive pump 1789
1 5 5 1 Removal of the hydraulic oil cooler fan drive pump 1789
1 5 5 2 Replacement of the hydraulic oil cooler fan drive pump 1791
1 5 6 Pump distributor gearbox (PTO) 1792
1 5 6 1 Removal of the pump distributor gearbox (PTO) 1794
1 5 6 2 Replacement of the pump distributor gearbox (PTO) 1796
1 6 Hydraulics 1798
1 6 1 Hydraulic oil cooler assembly 1798
1 6 1 1 Removal of hydraulic cooler fan 1799
1 6 1 2 Replacement of hydraulic cooler fan 1800
1 6 1 3 Removal of hydraulic cooler fan bearings and motors 1801
1 6 1 4 Replacement of hydraulic cooler fan bearings and motors 1803
1 6 1 5 Removal of the hydraulic oil coolers 1804
1 6 1 6 Replacement of the hydraulic oil coolers 1807
1 6 1 7 Removal of the hydraulic oil cooler assembly 1808
1 6 1 8 Replacement of the hydraulic oil cooler assembly 1813
1 6 2 Main gate valve 1814
1 6 2 1 Removal of the main gate valve 1814
1 6 2 2 Replacement of the main gate valve 1815
1 6 3 Hydraulic oil reservoir 1816
1 6 3 1 Removal of the hydraulic oil reservoir 1817
1 6 3 2 Replacement of the hydraulic oil reservoir 1823
1 6 4 Main control valve blocks 1826
1 6 4 1 General information 1826
1 6 4 2 Removal of the main control valve blocks 1834
1 6 4 3 Replacement of the main control valve blocks 1838
1 6 5 Main relief valves (MRV) 1839
1 6 5 1 Removal of the MRV at the main control valve blocks 1839
1 6 5 2 Replacement of the MRV at the main control valve blocks 1840
1 6 6 Service line relief valves (SRV) 1842
1 6 6 1 Removal of SRV on main control valve block 1843
1 6 6 2 Replacement of SRV on main control valve blocks 1844
1 6 7 Anti-cavitation valves (ACV) 1845
1 6 7 1 Removal of single ACV at the manifold 1847
1 6 7 2 Replacement of single ACV at the manifold 1850
1 6 7 3 Removal of ACV with attached check valve at the manifold 1851
1 6 7 4 Replacement of ACV with attached check valve at the manifold 1853
1 6 7 5 Removal of ACV on main control valve blocks 1855
1 6 7 6 Replacement of ACV on main control valve blocks 1856
1 6 8 Throttle check valves 1858
1 6 8 1 Removal of throttle check valves 1861
1 6 8 2 Replacement of throttle check valves 1863
1 6 9 Diffuser block (FSA only) 1864
1 6 9 1 Removal of the Diffuser block at the manifold 1864
1 6 9 2 Replacement of the Diffuser block at the manifold 1866
1 6 10 Manifold 1867
1 6 10 1 Removal of the manifold 1867
1 6 10 2 Replacement of the manifold 1870
1 7 Slew system 1871
1 7 1 Slew gear 1871
1 7 1 1 Removal of the slew gear 1873
1 7 1 2 Replacement of the slew gear 1876
1 7 2 Swing motor 1878
1 7 2 1 Removal of the swing motor 1879
1 7 2 2 Replacement of the swing motor 1881
1 7 3 Slew parking brake 1882
1 7 3 1 Removal/disassembly of the slew parking brake (L&S) 1883
1 7 3 2 Replacement/assembly of the slew parking brake (L&S) 1886
1 7 3 3 Removal of the slew parking brake (siebenhaar) 1889
1 7 3 4 Replacement of the slew parking brake (Siebenhaar) 1892
1 7 4 Dynamic slew brake 1896
1 7 4 1 Removal of the slew brake valve 1899
1 7 4 2 Replacement of the slew brake valve 1901
1 7 5 Swing circle 1902
1 7 5 1 Removal of the swing circle 1903
1 7 5 2 Replacement of the swing circle 1906
1 7 6 Swing circle lubrication pinion (dummy wheel) 1910
1 7 6 1 Removal of the lubrication pinion assembly 1911
1 7 6 2 Replacement of the lubrication pinion assembly 1913
1 8 Lubrication pumps 1914
1 8 1 Removal of the lubrication pump 1914
1 8 2 Replacement of the lubricating pump 1916
1 9 Operatorโs cab 1918
1 9 1 Removal of the operatorโs cab 1920
1 9 2 Replacement of the operatorโs cab 1925
1 9 3 Cab-mounts 1926
1 9 3 1 Removal of the cab-mounts 1926
1 9 3 2 replacement of the cab-mounts 1928
1 9 4 Front window 1930
1 9 4 1 Removal of the front window 1930
1 9 4 2 Replacement of the front window 1931
1 9 5 Operatorโs seat 1932
1 9 5 1 Removal of the operatorโs seat 1932
1 9 5 2 Replacement of the operatorโs seat 1933
1 10 Cab base (medium voltage switch cabinet) 1934
1 10 1 Removal of the cab base 1934
1 10 2 Replacement of the cab base 1937
1 10 3 Pump controller 1939
1 10 3 1 Removal of the pump controller 1939
1 10 3 2 Replacement of the pump controller 1940
1 11 Access ladder 1942
1 11 1 Removal of the access ladder 1943
1 11 2 Replacement of the access ladder 1945
1 11 3 Removal of the access ladder cylinder 1947
1 11 4 Replacement of the access ladder cylinder 1949
1 12 Counterweight 1950
1 12 1 Removal of the counterweight 1951
1 12 2 Replacement of the counterweight 1953
1 13 Superstructure Lifting 1954
1 13 1 Remove the superstructure from the undercarriage 1954
1 13 2 Install the superstructure onto the undercarriage 1959
1 14 High voltage switch cabinet 1962
1 14 1 Removal of the high voltage switch cabinet 1962
1 14 2 Replacement of the high voltage switch cabinet 1967
1 15 Slip ring unit 1968
1 15 1 Removal of the slip ring unit 1969
1 15 2 Replacement of the slip ring unit 1972
2 Undercarriage 1973
2 1 Undercarriage overview 1974
2 2 Travel system 1976
2 2 1 Track group 1976
2 2 1 1 Changing of the track group 1976
2 2 2 Sprocket 1981
2 2 2 1 Removal of the sprocket 1981
2 2 2 2 Replacement of the sprocket 1986
2 2 3 Guide wheels 1988
2 2 3 1 Removal of the guide wheel assembly 1988
2 2 3 2 Replacement of the guide wheel assembly 1990
2 2 4 Track tensioning accumulators 1992
2 2 4 1 Removal of the low pressure accumulators 1992
2 2 4 2 Replacement of the low pressure accumulators 1993
2 2 4 3 Removal of the high pressure accumulators 1995
2 2 4 4 Replacement of the high pressure accumulators 1996
2 2 5 Track tension valve block 1997
2 2 5 1 Removal of the track tensioning valve block 1997
2 2 5 2 Replacement of the track tensioning valve block 1999
2 2 6 Track tensioning cylinders 2000
2 2 6 1 Removal of the track tensioning cylinders 2000
2 2 6 2 Replacement of the track tensioning cylinders 2002
2 2 7 Hydraulic hoses of the track tensioning system 2003
2 2 7 1 Precursory work 2003
2 2 7 2 Substitute the hydraulic hoses inside the car body 2005
2 2 7 3 Substitute the hydraulic hoses between car body and crawler frame 2005
2 2 7 4 Substitute the hydraulic hoses inside the crawler frame 2007
2 2 7 5 Subsequent work 2007
2 2 8 Travel brake valve block (overspeed valve) 2009
2 2 8 1 Removal of the travel brake valve block 2012
2 2 8 2 Replacement of the travel brake valve block 2013
2 2 9 Travel motors 2014
2 2 9 1 Removal of the travel motors 2014
2 2 9 2 Replacement of the travel motors 2016
2 2 10 Travel parking brake 2018
2 2 10 1 Travel parking brake overview 2018
2 2 10 2 Removal/disassembly of the travel parking brake (L&S) 2023
2 2 10 3 Replacement/assembly of the travel parking brake (L&S) 2026
2 2 10 4 Removal/disassembly of the travel parking brake (Zollern) 2029
2 2 10 5 Replacement/assembly of the travel parking brake (Zollern) 2032
2 2 11 Travel gear box 2034
2 2 11 1 Removal of the travel gear box 2035
2 2 11 2 Replacement of the travel gear box 2037
2 2 12 Carrier roller 2039
2 2 12 1 Removal of the carrier roller assembly 2039
2 2 12 2 Replacement of the carrier roller assembly 2042
2 2 13 Track roller 2043
2 2 13 1 Removal of the track roller assembly 2043
2 2 13 2 Replacement of the track roller assembly 2045
2 3 Car body 2046
2 3 1 Removal of the car body and the crawler carriers (type with mounting pins) 2046
2 3 2 Replacement of the car body and the crawler carriers (type with mounting pins) 2050
2 3 3 Removal of the car Body and the crawler carriers (type with bolted connection) 2054
2 3 4 Replacement of the car body and the crawler carriers (type with bolted connection) 2060
2 3 5 Rotary joint 2068
2 3 5 1 Removal of the rotary joint 2068
2 3 5 2 Replacement of the rotary joint 2071
2 4 Cable drum (optional) 2072
2 4 1 Preparatory work for the removal and replacement of the cable drum assembly 2073
2 4 2 Removal of the cable drum assembly 2074
2 4 3 Replacement of the cable drum assembly 2075
2 5 Cable supply 2078
2 5 1 Preparatory work for the removal and replacement of the cable supply 2079
2 5 2 Removal of the cable supply 2080
2 5 3 Replacement of the cable supply assembly 2082
3 Attachment 2085
3 1 Backhoe 2086
3 1 1 Boom 2087
3 1 1 1 Removal of the Boom 2087
3 1 1 2 Replacement of the boom 2090
3 1 1 3 Removal of the boom cylinders 2092
3 1 1 4 Replacement of the boom cylinders 2097
3 1 2 Stick 2102
3 1 2 1 Removal of the Stick 2102
3 1 2 2 Replacement of the Stick 2106
3 1 2 3 Removal of the Stick Cylinders 2108
3 1 2 4 Replacement of the Stick cylinders 2113
3 1 3 Bucket 2118
3 1 3 1 Removal of the bucket 2118
3 1 3 2 Replacement of the bucket 2121
3 1 3 3 Removal of the Bucket Cylinders 2122
3 1 3 4 Replacement of the Bucket Cylinders 2128
3 1 4 Bucket link rod and steering rods 2131
3 1 4 1 Removal of the bucket link rod 2131
3 1 4 2 Replacement of the bucket link rod 2133
3 1 4 3 Removal of the steering rods 2134
3 1 4 4 Replacement of the steering rods 2137
3 1 5 Ground engaging tools (GET) 2138
3 1 5 1 Removal and replacement of the GET 2138
3 1 6 Hydraulic hoses at the backhoe attachment 2140
3 1 6 1 Substitute the boom arc hoses 2140
3 1 6 2 Substitute the boom cylinder hoses 2146
3 1 6 3 Substitute the stick cylinder hoses 2150
3 1 6 4 Substitute the bucket cylinder hoses 2154
3 2 Faceshovel 2158
3 2 1 Using the installation tools for hydraulic cylinders 2159
3 2 2 Boom 2160
3 2 2 1 Removal of the boom 2160
3 2 2 2 Replacement of the boom 2167
3 2 2 3 Removal of the boom cylinders 2172
3 2 2 4 Replacement of the boom cylinders 2176
3 2 3 Stick 2180
3 2 3 1 Removal of the stick 2180
3 2 3 2 Replacement of the stick 2184
3 2 3 3 Removal of the stick cylinders 2188
3 2 3 4 Replacement of the stick cylinders 2192
3 2 4 Bull Clam bucket 2196
3 2 4 1 Removal of the bull clam bucket 2196
3 2 4 2 Replacement of the bull clam bucket 2202
3 2 4 3 Removal of the bucket cylinders 2204
3 2 4 4 Replacement of the bucket cylinders 2208
3 2 4 5 Removal of the clam cylinders 2212
3 2 4 6 Replacement of the clam cylinders 2216
3 2 5 Ground engaging tools (GET) 2219
3 2 5 1 Removal and replacement of the GET 2219
3 2 6 Hydraulic hoses at the Faceshovel attachment 2220
3 2 6 1 Substitute the boom arc hoses 2220
3 2 6 2 Substitute the boom cylinder hoses 2226
3 2 6 3 Substitute the stick arc hoses 2230
3 2 6 4 Substitute the stick cylinder hoses 2234
3 2 6 5 Substitute the bucket cylinder hoses 2238
3 2 6 6 Substitute the clam cylinder hoses 2242
3 3 Metering valves (grease injectors) at the attachment 2250
3 3 1 Operation test of the metering valves (grease injectors) 2251
3 3 2 Removal of the metering valves (grease injectors) 2252
3 3 3 Replacement of the metering valves (grease injectors) 2254
3 4 Cylinder bypass test 2255
4 Service Information 2257
4 1 Classification of Voltages for KMG Electric Shovels 2258
4 2 Fluids and lubricants 2258
4 3 Lifting Gears 2259
4 4 Safety hints for sling accessory 2261
4 5 Filling capacities 2262
4 6 Work instructions 2263
4 6 1 Remove / install the crawler carrier 2263
4 7 Weight tables 2264
4 7 1 Superstructure 2264
4 7 2 Undercarriage 2266
4 7 3 Backhoe attachment (BHA) 2267
4 7 4 Face shovel attachment (FSA) 2268
4 8 Torque charts according to KOMATSU company standard 2269
4 8 1 Metric standard thread 2269
4 8 2 Metric fine thread 2270
4 8 3 Cummins motor torques – metric 2271
4 8 4 Cummins motor torques – U S customary 2271
4 8 5 Flange connections 2272
4 9 Blind plugs 2273
4 9 1 Dummy plates for SAEโflanges 2273
4 9 2 Classification of threads to the nominal width 2275
4 9 3 Plugs and fittings according to DIN 2353 2276
4 10 Conversion table 2277
4 10 1 Method of using the conversion table 2277
4 10 2 Millimeter – inch & kilogram – pound 2278
4 10 3 Liter – U S gallon & liter – U K gallon 2279
4 10 4 Nm- ft lb 2280
4 10 5 Bar – PSI – kPa – MPa 2281
4 10 6 Temperature 2282
4 11 Tools 2283
4 11 1 Standard tool case 2283
4 11 2 Used special tools (Overview) 2285
5 Tools catalogue 2289
6 Parts & Service News 2291
6 1 List of the PARTS AND SERVICE NEWS 2292
7 Supplierโs documentation 2295
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