Komatsu PC5500-11 T4 Hydraulic Mining Shovel Shop Manual PDF

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Komatsu PC5500-11 T4 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD

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Komatsu PC5500-11 T4 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD 

Language : English
Pages : 2546
Downloadable : Yes
File Type : PDF

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Komatsu PC5500-11 T4 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD 

SHOP MANUAL PC5500-11 T4 1
00 FOREWORD & SAFETY 3
1 FOREWORD 5
1 1 BEFORE READING THIS MANUAL 6
1 1 1 CSA (Canadian Standards Association) 6
1 2 CONTENTS OF THIS BINDER 7
1 2 1 Contacting the Service 7
1 2 2 Guarantee 7
1 3 DIVISION OF THE BINDER 8
2 SAFETY 9
2 1 SAFETY INFORMATION 10
2 2 OVERVIEW 11
2 2 1 NORMAL OPERATIONS 11
2 2 2 REGULAR MAINTENANCE 11
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 11
2 2 4 ADDITIONAL SAFETY PRECAUTIONS 11
2 3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 12
2 3 1 SOUND 12
2 3 2 VIBRATION 13
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 14
2 4 1 UNDERSTANDING THE excavator 14
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 14
2 4 2 1 ENSURING SAFE OPERATION 14
2 4 3 PREPARATIONS FOR SAFE OPERATION 14
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 14
2 4 3 2 INSPECTING THE excavator 14
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 15
2 4 3 4 KEEP excavator CLEAN 15
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 15
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 16
2 4 3 7 IF A PROBLEM IS FOUND 16
2 4 4 FIRE PREVENTION 16
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 16
2 4 4 2 ACTION IF FIRE OCCURS ON PC3000 Tier 2 and Electro 17
2 4 4 3 ACTION IF FIRE OCCURS ON PC3000 Tier 4, PC4000, PC5500, PC7000, PC8000 18
2 4 4 4 EMERGENCY EXIT FROM OPERATOR’S CAB FOR PC3000 18
2 4 4 5 EMERGENCY EXIT FROM OPERATOR’S CAB FOR PC4000, PC5500, PC7000, PC8000 19
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR 19
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE excavator 19
2 4 5 2 NO JUMPING ON OR OFF THE excavator 19
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 19
2 4 5 4 WORKING IN HIGH PLACES 20
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 21
2 4 5 6 LEAVING THE excavator 21
2 4 6 BURN PREVENTION 21
2 4 6 1 Hot coolant 21
2 4 6 2 Hot oil 22
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 22
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 22
2 4 9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 23
2 4 9 1 UNAUTHORIZED MODIFICATION 23
2 4 9 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 23
2 4 10 ELECTROMAGNETIC COMPATIBILITY (EMC) 23
2 4 11 PRECAUTIONS AT JOBSITE 24
2 4 11 1 VISIBILITY FROM OPERATOR’S SEAT 25
2 4 11 2 CAMERA SYSTEM WITH MONITORS 25
2 4 11 3 ENSURE GOOD VISIBILITY 25
2 4 11 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 25
2 4 11 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 26
2 4 11 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 26
2 4 11 7 Lightning Strikes 27
2 4 11 8 WORKING ON LOOSE GROUND 27
2 4 11 9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 28
2 4 11 10 VENTILATION OF ENCLOSED AREAS 29
2 4 12 STARTING motor 30
2 4 12 1 WARNING TAG 30
2 4 12 2 CHECKS BEFORE STARTING motor 30
2 4 12 3 PRECAUTION WHEN STARTING motor 30
2 4 12 4 PRECAUTION IN COLD AREAS 31
2 4 13 OPERATION 31
2 4 13 1 CHECKS BEFORE OPERATION 31
2 4 13 2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 32
2 4 13 3 PRECAUTIONS WHEN traveling 33
2 4 13 4 TRAVELING ON SLOPES 34
2 4 13 5 OPERATIONS ON SLOPES 35
2 4 13 6 PROHIBITED OPERATIONS 35
2 4 13 7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 36
2 4 13 8 PARKING THE excavator 36
2 4 13 9 TRANSPORTATION 36
2 5 PRECAUTION FOR MAINTENANCE 37
2 5 1 GENERAL PRECAUTIONS 37
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 38
2 5 1 2 STOP motor FOR MAINTENANCE 39
2 5 1 3 WARNING TAG 39
2 5 1 4 Maintenance safety Switch 39
2 5 1 5 KEEP WORKPLACE CLEAN AND TIDY 40
2 5 1 6 APPOINT LEADER WHEN WORKING WITH OTHERS 41
2 5 1 7 TWO WORKERS FOR MAINTENANCE WHEN THE excavator IS RUNNING 41
2 5 1 8 INSTALLING, REMOVING OR STORING ATTACHMENTS 41
2 5 1 9 PRECAUTIONS WHEN WORKING UNDER THE excavator OR EQUIPMENT 42
2 5 1 10 NOISE 42
2 5 1 11 WHEN USING A HAMMER 42
2 5 1 12 PROPER TOOLS 43
2 5 1 13 ACCUMULATOR 43
2 5 1 14 PERSONNEL 43
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 44
2 5 2 1 PRECAUTION WHEN WELDING 44
2 5 2 2 BATTERY HANDLING 44
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 45
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 46
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 47
2 5 3 3 REPLACEMENT OF HOSE LINES 47
2 5 3 4 INSPECTION OF HOSE LINES 47
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 48
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 48
2 5 3 7 AIR CONDITIONING MAINTENANCE 48
2 5 3 8 COMPRESSED AIR 49
2 5 3 9 WASTE MATERIALS 49
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 50
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 50
2 6 2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS 50
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 50
2 7 SPECIAL SAFETY EQUIPMENT 51
2 7 1 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’S CAB 52
2 7 2 OBJECT HANDLING 52
2 7 3 LIGHTING 52
2 7 4 WARNING BEACON 52
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 52
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 52
2 7 5 2 INSTRUCTIONS FOR USE 53
2 7 5 3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 54
2 7 5 4 INSTRUCTIONS FOR USE 54
01 SPECIFICATION 57
PC5500-11 T4 59
10 STRUCTURE & FUNCTION 63
TOC 65
1 Introduction 79
1 1 Foreword 80
1 2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining excavators 81
1 3 Explanation of abbreviations 82
1 4 Diagrams and illustrations in this manual 83
2 Specifications 85
2 1 Lifting Gears 86
2 2 Safety hints for sling accessory 88
2 3 Standard Tightening Torque Chart 89
2 4 Conversion Table 90
2 5 Blind plugs 96
2 6 Classification of threads to the nominal width 98
2 7 Plugs & fittings according to ISO 8434-1 / DIN 2353 99
3 Main assembly groups 101
3 1 General layout 102
3 2 Superstructure 104
3 2 1 Side view 104
3 2 2 Superstructure top view 106
3 3 Machinery house 108
3 4 Hydraulic oil tank 110
3 5 Hydraulic oil cooler 112
3 6 Fuel tank with Wiggins service system VR300 114
3 7 Cab support 116
3 8 Operator’s cab 118
3 9 Air conditioner 120
3 10 Main control blocks (FSA) 122
3 11 Slew machinery 124
3 11 1 Slew gear type 632770 124
3 12 Undercarriage 126
3 13 Slew ring 128
3 14 Attachment 130
3 14 1 Front Shovel Attachment (FSA) 130
3 14 2 Backhoe Attachment (BHA) 132
3 15 Counterweight 134
3 16 KomVision camera system 136
3 17 PLM (Payload Management) 137
4 Drive 139
4 1 Prime drive assembly 140
4 2 Engine and PTO mounts 142
4 2 1 Checks and adjustments 143
4 3 Flexible coupling 144
4 3 1 Information for maintenance 146
4 3 2 Coupling elements 147
4 3 3 Separation and assembly of the coupling inner and outer part 148
4 3 4 Operation troubles, causes, and rectification 149
4 4 Radiator assembly and fan drive 150
4 4 1 Radiator assembly 150
4 4 2 Radiator fan drive 152
4 4 2 1 Hydraulic schematic of radiator fan drive 154
4 4 3 Fan pump type HP112 156
4 4 4 Radiator fan speed testing & adjustment 158
4 4 4 1 Testing & readjustment procedure 160
4 4 4 2 Basic adjustment procedure 161
4 5 Pump distributor gearbox (PTO) 162
4 5 1 Pump chamber ventilation, oil level, and oil drain 164
4 5 2 PTO gear oil standard 165
4 5 3 Pump spline lubrication 166
4 5 3 1 Oil level in main pump & gear oil pump drive shaft housing 167
4 5 4 PTO lubrication and cooling 168
4 5 4 1 Hydraulic components and schematic of cooling circuit-1 168
4 5 4 2 Schematic overview – PTO gear oil cooling circuit-1 170
4 5 4 3 Checks and adjustments 172
4 6 Hydraulic pumps – location, drive speed and flow rates 174
4 7 Air cleaner 178
4 8 Exhaust gas aftertreatment (T4 final) 180
4 8 1 DEF system layout 182
4 8 2 DEF tank – location & overview 184
4 8 3 Dosing pumps at DEF tank 186
4 8 4 Coolant supply for DEF tank heating circuit 188
4 8 5 Information on DEF (Diesel Exhaust Fluid) 190
4 8 5 1 DEF refilling line 190
4 8 5 2 DEF Maintenance information 191
4 8 5 3 Notes on DEF quality and temperature – Important 191
4 8 5 4 DEF storage 191
4 8 5 5 Common names used for DEF (Diesel Exhaust Fluid) 191
4 8 6 DEF tank level 192
4 8 7 SCR catalyst for exhaust gas aftertreatment 194
4 8 7 1 Dosing valve 197
4 8 8 Wiring between engine → DEF tank → SCR catalyst 198
4 9 Fuel cooling (T4 equipment) 200
5 Hydraulic oil tank 203
5 1 General layout 204
5 2 Hydraulic oil level definition 206
5 2 1 Oil level sight gauge for return oil chamber 207
5 2 2 View onto a return oil filter 209
5 3 Hydraulic oil tank, location of the electric equipment 210
5 4 Suction oil tank with strainers 212
5 5 Return oil collector pipe with strainer 214
5 6 Back pressure valve 216
5 7 Transfer pump 218
5 8 Return and leak oil filter 220
5 9 Breather filter 222
6 Hydraulic oil cooling 225
6 1 Overall view on the hydraulic oil cooling 226
6 1 1 Hydraulic oil cooling overview part 2 228
6 2 Function of the hydraulic oil cooling circuit 230
6 3 Adjustment of the back pressure valve 232
6 4 Stepless cooler fan RPM control 234
6 4 1 SRV 236
6 4 2 Components of the fan drive circuits 238
6 4 3 Fan pump type HPV112 240
6 5 Oil cooler fan speed 242
6 6 Oil cooler fan speed testing/adjustment 244
6 6 1 Testing & readjustment procedure via K+ 246
6 6 2 SRV adjustment procedure 247
6 7 Hydraulic oil temperature charts 248
7 Controlling 249
7 1 PPC safety circuit 250
7 2 General layout 254
7 3 Control and filter panels – location of components 256
7 3 1 Control and filter panel engine 1 (rear) 256
7 3 2 Valve cartridge block engine 1 (rear) 258
7 3 3 Control and filter panel engine 2 (front) 260
7 3 4 Static air bleeding from hydraulic pumps via transfer pump 262
7 4 Pilot pressure supply and adjustments 264
7 4 1 Pilot pressure control (PPC) circuit 264
7 4 2 Pilot pressure operating the main block spools 266
7 4 3 Checks and adjustment of pilot pressure 268
7 4 4 Remote control valves arrangement 270
7 5 Function of the electro hydraulic control system 272
7 5 1 Illustration of the joystick signal flow (example) 274
7 6 Hand lever (joystick) control 276
7 6 1 Voltage supply of LH hand lever 20S020 277
7 6 2 Direction signal course from hand lever to controllers 278
7 6 3 Double ratiometric* output diagram 279
7 7 Foot pedal control 280
7 7 1 Voltage supply of foot pedal 20S021a 282
7 7 2 Direction signal course from foot pedal to controllers 283
7 7 3 Double ratiometric* output diagram for 2 direction pedal 284
7 7 4 Single ratiometric* output diagram for 1 direction pedal 284
7 8 Hand lever & foot pedal monitoring 286
7 8 1 Lever monitoring screens (example) 288
7 8 2 Valve monitoring screen (example) 290
7 9 Valve solenoid adjustment 292
7 9 1 Overview sol min/max current & adjustment range 293
7 10 ACCEL & DECEL time adjustment 294
7 10 1 Accel & Decel times 294
8 Components 297
8 1 Main control blocks and high pressure screens (FSA) 298
8 2 Main control blocks with valves and HP screens (FSA) 300
8 3 Main control blocks with valves and HP screens (BHA) 302
8 4 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) 304
8 5 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) 306
8 6 Restrictor block with secondary relief valve 308
8 7 Anti-cavitation valve (ACV) block 310
8 7 1 Single ACV block on the manifold 310
8 7 2 Double ACV block on the manifold 312
8 8 Remote control valves 314
8 9 4/3 Directional solenoid valves 316
8 10 Proportional solenoid valves 318
8 11 High-pressure screen 320
8 12 Control blocks and valves 322
8 12 1 Main control blocks I, II, III (4 spool blocks) 322
8 12 1 1 Spin lock for valve blocks (ND52) 323
8 12 2 Hydraulic diagram of a 4-spool valve block 324
8 12 3 Spool types 325
8 12 4 Spool positions (control block) 328
8 12 5 MRV, SRV, and ACV 330
8 12 6 Load holding valve 332
8 12 7 Main control block IV (slew) 334
8 13 Travel brake valve 336
8 14 4/2 Directional valves 338
8 15 Pressure double stage valve 340
8 16 Hydraulic cylinder 342
8 16 1 Hydraulic cylinder – Chesterton® 11KE sealing 342
8 16 2 Cylinder data markings 344
9 Main hydraulic pumps & pump regulation system 345
9 1 General 346
9 1 1 Pump data 348
9 2 Main pumps 352
9 2 1 Hydraulic pump type HPV375 352
9 2 1 1 Main pump sectional drawings 354
9 2 2 Servo valve 356
9 2 2 1 VC valve  servo piston 357
9 2 3 EPC valve 362
9 3 Electronic pump regulation system 364
9 3 1 Cut-off function 366
9 3 2 Slew control 366
9 3 3 Temperature control 366
9 3 4 Hydraulic oil temperature charts 367
9 4 Pump & valve controllers 368
9 4 1 Service menu screen 370
9 4 2 Service ID 370
9 4 3 Service menu – 01 Monitoring 370
9 5 Monitoring PUMP 1 controller 371
9 5 1 Monitoring PUMP 2 controller 372
9 6 Using machine monitor functions for monitoring 373
9 7 Error indication of pump controllers 373
9 8 Adjustments for pump controllers 374
9 8 1 Adjustments for PUMP 1 controller 374
9 8 2 Adjustments for PUMP 2 controller 375
9 9 Details on adjustable parameters 376
9 9 1 PUMP1 controller 376
9 9 2 PUMP2 controller 378
9 9 3 Description of the primary p-factor 380
9 9 4 Pump sol min current values according to pump type plate 381
9 9 5 Pump sol max current values according to pump type plate 382
9 10 Checks and adjustments 384
9 10 1 Engine power check 384
9 10 2 Cut-off function check 386
9 10 2 1 Cut-off for clam close (FSA only) 387
9 11 Engine speed sensors (pick-up) 388
9 11 1 General 389
9 11 2 Engine speed sensor (pick-up) adjustment 389
9 11 3 In case of problems – when correct speed sensor adjustment is guaranteed 390
10 Operating hydraulics 393
10 1 General 394
10 1 1 Allocation of pumps and main valve blocks 396
10 2 Spool functions (FSA) 398
10 2 1 Floating function for boom and stick cylinders 398
10 2 2 Spool functions (BHA) 400
10 3 Hydraulics for the attachment cylinders 402
10 3 1 Electric / hydraulic flowchart “Boom UP” (FSA) 402
10 3 2 Electric / hydraulic flowchart “boom up” (BHA) 404
10 3 3 Electric / hydraulic flowchart “boom down” (FSA), single movement and Auto-float ON 406
10 3 4 Electric / hydraulic flowchart “boom down” (FSA), Auto-float OFF – button 20S095 pressed and single movement 408
10 3 5 Electric / hydraulic flowchart “Boom down” (BHA) 410
10 3 6 Electric / hydraulic flowchart “Stick out” (FSA) 412
10 3 7 Electric / hydraulic flowchart “Stick out” (BHA) 414
10 3 8 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float ON and single movement 416
10 3 9 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float OFF – 20S098 pressed & single movement 418
10 3 10 Electric / hydraulic flowchart “Stick in” (BHA) 420
10 3 11 Electric / hydraulic flowchart “Bucket fill” (FSA) 422
10 3 12 Electric / hydraulic flowchart “Bucket fill” (BHA) 424
10 3 13 Electric / hydraulic flowchart “Bucket dump” (FSA) 426
10 3 14 Electric / hydraulic flowchart “Bucket dump” (BHA) 428
10 3 15 Electric / hydraulic flowchart “Clam open” (FSA) 430
10 3 16 Electric / hydraulic flowchart “Clam close” (FSA) 432
10 3 17 Checks & adjustments of main relief valve (MRV) 434
10 3 18 Checks and adjustments of the secondary relief valves (SRV) 436
10 3 18 1 Boom cylinders, piston side (BHA & FSA), boom up 436
10 3 18 2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down 440
10 3 18 3 Stick cylinders, piston side (FSA), stick out 444
10 3 18 4 Stick cylinders, piston side (BHA), stick in 448
10 3 18 5 Stick cylinders, piston rod side (FSA), stick in 452
10 3 18 6 Stick cylinders, piston rod side (BHA), stick out 456
10 3 18 7 Bucket cylinders, piston side (FSA), bucket fill 460
10 3 18 8 Bucket cylinders, piston side (BHA), bucket fill 464
10 3 18 9 Bucket cylinders, piston rod side (FSA), bucket dump 468
10 3 18 10 Bucket cylinders, piston rod side (BHA), bucket dump 472
10 3 18 11 Clam cylinders, piston rod side (FSA), clam open 476
10 3 18 12 Clam cylinders, piston side (FSA), clam close 480
10 3 19 Checks and adjustments of cycle times 484
10 3 19 1 Checks and adjustments of boom lowering speed (FSA) 484
10 3 19 2 Checks and adjustments of boom lowering speed (BHA) 488
10 3 19 3 Checks and adjustments of stick retract speed (FSA) 492
10 3 19 4 Checks and adjustments of stick retract speed (BHA) 496
10 3 19 5 Checks and adjustments of bucket dump speed (FSA) 500
10 3 19 6 Checks and adjustments of bucket dump speed (BHA) 504
10 3 19 7 Checks and Adjustment of bucket Curl Speed (BHA) 508
10 3 19 8 Checks and adjustments of clam close speed (FSA) 512
10 4 Hydraulics for the slew circuit 514
10 4 1 Slew circuit with variable slew motors 514
10 4 2 Slew motor (variable displacement) 518
10 4 2 1 Hydraulic slew motor – displacement control 520
10 4 3 Slew gearbox type 2063 522
10 4 4 Slew gearbox type 632770 524
10 4 5 Slew parking brake (on slew gear type 2063) 526
10 4 6 Slew parking brake (on slew gear type 632770) 528
10 4 7 Slew brake valve 530
10 4 8 Flushing circuit 534
10 4 9 Electric / hydraulic flowchart “Slew left” FSA 536
10 4 10 Electric / hydraulic flowchart “Slew left” BHA 538
10 4 11 Electric / hydraulic flowchart “Slew right” FSA 540
10 4 12 Electric / hydraulic flowchart “Slew right” BHA 542
10 4 13 Checks and adjustments for the slew circuit 544
10 4 13 1 Pressure checks & adjustments – double stage valve (DSV) 545
10 4 13 2 Checks & adjustments – brake pilot pressure 547
10 4 13 3 Checks & adjustments – slew speed 548
10 4 14 Function check for hydraulic slew brake 550
10 4 15 Function check for slew parking brake 552
10 4 15 1 Slew parking brake release pressure check 552
10 5 Hydraulics for the travel circuit 554
10 5 1 Travel circuit 554
10 5 2 Travel motor 558
10 5 3 Rotary joint 560
10 5 4 Travel gearbox 562
10 5 4 1 Travel gearbox type 2063 562
10 5 4 2 Travel gearbox type 631053 564
10 5 5 Travel parking brake 566
10 5 5 1 Travel parking brake on travel gear type 2063 566
10 5 5 2 Travel parking brake on travel gear type 631053 567
10 5 5 3 Travel brake valve 568
10 5 6 Electric / hydraulic flowchart “travel forward” 570
10 5 7 Electric / hydraulic flowchart “travel backwards” 572
10 5 8 Checks and adjustments 574
10 5 8 1 Checks and adjustments for travel circuit 574
10 5 8 2 Function check for the travel parking brake 578
11 Hydraulic track tensioning system 581
11 1 General 582
11 2 Functional description 586
11 3 Double stage valve 588
11 4 Tensioning cylinder 590
11 5 Adjustments / checks 592
12 Access stairway, hydraulically operated 595
12 1 Overview 596
12 2 Function of the hydraulically operated access stairway 598
12 3 Adjustments / checks 602
13 Central refilling system (Service arm) 605
13 1 General 606
13 2 Function 608
14 Hints for reading the Hydraulic Diagram 611
14 1 General 612
14 2 Hydraulic symbols 614
14 2 1 Lines, unions 615
14 2 2 Components, valves 617
14 2 3 Sensors 617
14 2 4 Valves, valve components 618
14 2 5 Pump, motor, cylinder 622
15 Hints for reading the electric Wiring Diagram 625
15 1 General 626
15 2 Reference code of the electrical components 627
15 2 1 Area code 627
15 2 2 Component identifying letter 628
15 3 Graphical symbols 629
15 4 Concept of the Wiring Diagram 634
15 4 1 Cover page of the Komatsu W/D 634
15 4 2 Example 1 from the schematics in the W/D 636
15 4 3 Example 2 from the schematics in the W/D 638
15 4 4 Table of contents in the W/D 640
15 4 5 Location list 642
15 4 6 Cross reference list for electr components in the W/D 644
15 4 7 Cross reference list for terminals in the W/D 646
15 4 8 Cross reference list for connectors in the W/D 648
15 4 9 Cross reference list for terminal boards in the W/D 650
15 4 10 Connection table 652
15 5 Cable and connector marking 654
15 6 Cable color identification 656
16 Monitoring & Control System 657
16 1 Controller system overview 658
16 2 System layout 660
16 2 1 CAN #1 overview 660
16 2 2 CAN #2 overview 661
16 2 3 CAN #0 at 52K014-1/-2 662
16 2 4 CAN #0 overview 662
16 3 Interface connection 663
16 3 1 General description 664
16 4 Machine monitor – Operator level 665
16 5 Main gauge screens 666
16 6 Operator menu / Tabs / Function of keys F1 F6 670
16 6 1 Operator menu → Shovel payload 672
16 6 2 Operator menu → ECO Guidance – Operation Records 674
16 6 3 Operator menu → ECO Guidance – Average Fuel Consumption Logs 676
16 6 4 Operator menu → Machine Setting 678
16 6 5 Operator menu → Aftertreatment cleaning 680
16 6 6 List of engine fault codes for inducement 685
16 6 7 Operator menu → SCR Information 694
16 6 8 Operator menu → Maintenance 698
16 6 8 1 Reset of ’remaining time’ till next maintenance interval 700
16 6 8 2 Usage limitation 701
16 6 9 Operator menu → Monitor Setting – Screen Adjustment 703
16 6 10 Operator menu → Monitor Setting – Clock Adjustment – Calender 704
16 6 11 Operator menu → Monitor Setting – Clock Adjustment – Time 705
16 6 12 Operator menu → Monitor Setting – Clock Adjustment – 12h/24h Mode 706
16 6 13 Operator menu → Monitor Setting – Clock Adjustment – Daylight Saving Time 707
16 6 14 Operator menu → Monitor Setting – Language 708
16 6 15 Operator menu → Monitor Setting – ID Key Information 709
16 7 Status indication and errors on the operator level 710
16 7 1 Prompts (status indication) 710
16 7 2 Cautions 711
16 7 3 Emergency shutdown screen 712
16 7 4 Fault levels for error messages 714
16 7 5 Action code level L01 715
16 7 6 Action code level L02 716
16 7 7 Action code level L03 717
16 7 8 Action code level L04 718
16 7 9 Error list 719
16 8 Table of failure codes 720
16 8 1 Table of failure codes for Mechanical Systems PC5500-11 T4 720
16 8 2 Table of failure codes for Electrical Systems PC5500-11 T4 722
16 8 3 Failure codes without monitor indication 736
16 8 4 Additional text information for action codes 736
16 9 Table of C-codes – Diesel engines QSK38 T4 738
16 10 Flow charts of machine monitor screens 752
16 10 1 Flow chart Operator Level 752
16 10 2 Flow chart Service Level 753
16 11 Machine monitor – Service level 754
16 11 1 Entering the Service Level 754
16 11 2 Key symbols (F1 F6) on the Service Level 756
16 11 3 Service Menu selection screens 757
16 12 Service Menu – item 01 Monitoring / Custom 758
16 12 1 Monitoring list for: ENG1 controller 758
16 12 2 Monitoring list for: ENG2 controller 760
16 12 3 Monitoring list for: PUMP1 controller 762
16 12 4 Monitoring list for: PUMP2 controller 765
16 12 5 Monitoring list for: VALVE0 controller 768
16 12 6 Monitoring list for: VALVE1 controller 771
16 12 7 Monitoring list for: VALVE2 controller 774
16 12 8 Monitoring list for: MON (monitor) 776
16 12 9 Monitoring list for: KOM PLS (K+ controller) 778
16 12 10 How to perform the monitoring function 780
16 13 Service Menu – item 02 PM Clinic 782
16 13 1 PM Clinic (General) 782
16 13 2 PM Clinic (Power Check) 783
16 13 3 Functions of PM CLINIC (POWER CHECK) 784
16 14 Service Menu – item 03 Abnormality record 786
16 14 1 Reset error messages 787
16 15 Service Menu – item 04 Maintenance record 788
16 16 Service Menu – item 05 Maintenance Mode Setting 789
16 17 Service Menu – item 06 Snap Shot 790
16 18 Service Menu – item 07 Phone Number Entry 791
16 19 Service menu – item 08 Default 792
16 20 Service Menu – item 09 Unit 794
16 21 Service Menu – item 10 Adjustment 796
16 21 1 Adjustments for: PUMP1 controller 796
16 21 2 Adjustments for: PUMP2 controller 799
16 21 3 Pump sol ’min’ current values according to pump type plate 801
16 21 4 Pump sol ’max’ current values according to pump type plate 802
16 21 5 Adjustments for: VALVE0 controller 803
16 21 6 Accel & Decel times 809
16 21 7 Adjustments for: VALVE2 controller 810
16 21 8 Adjustments for: KOM PLS controller 811
16 21 9 Adjustments for: MON (Monitor) 812
16 21 9 1 Using the Idling Stop Timer 813
16 22 Service Menu – item 11 Machine Configuration 814
16 22 1 Details of Machine Configuration for PC7000-11 T4 815
16 22 2 Changing lever control from EURO to KMG 816
16 22 2 1 Changing lever control from KMG to EURO 816
16 22 3 Changing attachment type from FSA to BHA 818
16 22 3 1 Changing attachment type from BHA to FSA 818
16 22 4 In case of problems during changing procedure for lever control or attachment type 819
16 23 Service Menu – item 12 Abuse function setting 820
16 24 Automatic engine speed control 822
16 24 1 Auto-Deceleration mode 822
16 24 2 Auto Low Idle mode 822
16 24 3 Idling Stop Timer 823
16 25 KOMTRAX Plus controller (UM600) 824
16 26 CR720 controller 828
16 26 1 Location of CR720 controllers 828
16 27 Controller replacement procedure 830
16 27 1 Sequence of the controller replacement procedure 830
16 27 2 After controller replacement 831
17 Lubrication system 833
17 1 General overview SLS & CLS1 / 2 834
17 1 1 General description 835
17 2 Basic function of lubrication systems 836
17 3 Lubrication systems (SLS & CLS1/2) 838
17 3 1 Lubrication pump station 840
17 3 2 General Information on CLS1/2 842
17 3 3 General information on SLS 842
17 3 4 Manual lube activation 842
17 4 Lubrication cycle 843
17 4 1 Operation and control 843
17 4 2 Lubrication cycle – processing 844
17 4 3 Time segments & switch points of a lubrication cycle 845
17 4 4 Lubrication modes 846
17 4 4 1 Automatic lubrication mode 846
17 4 4 2 Manual lubrication mode 846
17 4 4 3 Reduced pause time for service 846
17 5 Hydraulically driven lube pump 848
17 5 1 Adjustment of lube pump speed 850
17 5 1 1 Stroke speed adjustment 851
17 5 1 2 Working pressure 851
17 6 Lubricant injectors 852
17 6 1 Tightening torques for fittings at grease injectors 853
17 6 2 Description 853
17 6 3 Adjustment of lubricant output 853
17 6 4 Operation principle of lubricant injectors 854
17 6 4 1 Function description 855
17 6 5 Connection of two or more injectors 856
17 7 Vent valve & grease outlet filter 858
17 7 1 Vent valve description 859
17 8 End-line switch 860
17 8 1 Description 861
17 8 2 CLS1/2 end-line switch adjustment 862
17 8 3 SLS end-line switch adjustment 864
17 9 Lubricant level sensors 866
17 9 1 Description 867
17 9 2 Checks 867
17 10 Commissioning 868
17 10 1 Commissioning of CLS 1/2 lubrication system 868
17 10 2 Fine adjustment 869
17 10 3 Commissioning of SLS lubrication system 870
18 Air conditioner 873
18 1 Large A/C Systems on Hydraulic Mining Excavators 874
18 2 Working on A/C systems 876
18 2 1 Refrigerant Recovery 876
18 2 2 Compressor oil procedures 876
18 3 Maintenance & preventive maintenance of A/C systems 877
18 4 Commissioning of A/C systems 878
18 5 Compressor oil – Lubrication chart 880
18 6 Standard Air Conditioning System Diesel Drive 882
18 6 1 A/C compressor type TM-16 884
18 6 2 A/C compressor type TM-21 885
18 6 3 Principle diagram of an electromagnetic clutch 886
18 6 4 Filter-drier 887
18 7 Air conditioner unit at operator’s cab 888
18 7 1 Shut-Off valves at dryer cartridge 889
18 8 A/C control panel 890
18 8 1 Button layout 891
18 8 2 Display/LEDs 892
18 9 Additional air conditioner 894
18 9 1 Top view 894
18 9 2 Side view 896
18 9 3 Air conditioner condenser unit 897
19 Deep temperature equipment (option) 899
19 1 General information 900
19 1 1 Introduction 900
19 1 2 Deep temperature components overview 900
19 1 3 Power supply preconditions for preheating 901
19 1 4 Power requirements for preheating systems 902
19 2 Preheating procedure 903
19 2 1 Global flow chart of the preheating procedure 903
19 2 2 Starting the preheating procedure 904
19 2 3 Preheating of operator’s cab and Diesel engine [coolant system] 905
19 2 4 Preheating of lubricants and superstructure (Diesel) [electric system] 906
19 3 Constant heating of travel motors (TTT equipment below-40°C only) 907
19 4 Component location 908
19 4 1 Electric heating elements for hydraulic & batteries [electric excavator] 908
19 4 2 Electric heating elements for hydraulics [Diesel excavator] 910
19 4 3 Electric heating elements for engines & batteries [Diesel excavator] 912
19 5 Components of TT equipment 914
19 5 1 Preheating components on a Diesel excavator 914
19 5 2 Preheating components on an electric excavator 915
19 5 3 Wiring Diagrams for preheating systems 916
19 5 3 1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 916
19 5 3 2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 917
19 5 3 3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 918
19 5 3 4 Wiring diagram “Suction Oil Manifold Preheating” 919
19 5 3 5 Wiring diagram “PTO Preheating” 920
19 5 3 6 Wiring diagram “Battery heater pads” 921
40 TROUBLESHOOTING 923
TOC 925
1 Introduction 953
1 1 Overview 954
1 1 1 General advice when using troubleshooting charts 954
1 2 General precautions 955
2 General Information for Troubleshooting 957
2 1 Preparations For Work 958
2 2 Precautions During Work 958
2 3 Precautions When Carrying Out Any Operation 959
2 3 1 Precautions when carrying out removal work 959
2 3 2 Precautions when carrying out installation work 959
2 3 3 Precautions when completing the operation 960
2 4 Fundamental Requirements for Trouble shooting 961
2 4 1 Technical documentation 961
2 4 2 Tools 961
2 4 2 1 Reference Guide for Deutsch Removal Tools 964
2 4 3 Personnel 965
2 5 Points To Remember When Trouble- shooting 965
2 6 Sequence Of Events In Troubleshooting 967
2 7 Checks Before Troubleshooting 968
2 8 Handling Of Electric Equipment And Hydraulic Components 969
2 8 1 Points to remember when handling electric equipment 969
2 8 2 Points To Remember When Handling Hydraulic Equipment 971
2 9 General working procedures 974
2 9 1 Air Bleeding of Various Hydraulic Parts 974
2 9 2 Air bleeding from hydraulic pumps 974
2 9 3 Air bleeding from hydraulic cylinders 974
2 10 Cylinder bypass test 975
2 11 Basics about “How to crimp” (with strain relief) 976
2 11 1 Crimp tool & repair kit 976
2 11 2 General 977
2 11 3 Select the required connector components 977
2 11 4 Stripping a wire 978
2 11 5 Crimping 979
2 11 6 Connector assembly after crimping 980
2 12 Cable Shielding 981
3 Mounting Locations and Connector Types 983
3 1 Superstructure 984
3 1 1 Superstructure side view 984
3 1 2 Superstructure top view 986
3 2 Machinery house 988
3 2 1 Location of engine remote oil tank sensors 990
3 3 Location of hydraulic components 992
3 3 1 Control and filter panel engine 1 (rear) 992
3 3 2 Valve cartridge block engine 1 (rear) 994
3 3 3 Control and filter panel engine 2 (front) 996
3 3 4 Remote control valves arrangement 998
3 4 View onto SLS or CLS1/2 grease container and lubrication cycle components 1000
3 5 Hydraulic oil tank & suction oil tank – Location of electrical components 1002
3 6 Hydraulically operated access stairway 1004
3 7 Refilling arm 1006
3 8 Connector Types Overview 1008
4 Standard Value Table for Electrical Components 1013
5 Tables for Testing and Troubleshooting 1027
5 1 Test Value Tables for Transducers 1028
5 1 1 Pump press transducers 1028
5 1 2 PLM pressure sensors 1029
5 1 3 Hydraulic oil pressure transducers 1030
5 1 4 Miscellaneous Pressure Transducers 1031
5 1 5 Temperature Transducers 1032
5 2 Hydraulic oil temperature charts 1033
5 3 PTO gear oil temperature charts 1033
5 4 Table of failure codes 1034
5 4 1 Table of failure codes for Mechanical Systems PC5500-11 T4 1034
5 4 2 Table of failure codes for Electrical Systems PC5500-11 T4 1036
5 5 Table of C-codes – Diesel engines QSK38 T4 1050
5 6 Table of PLM fault codes 1064
5 6 1 Note for troubleshooting of PLM fault codes 1065
5 7 Tables of Symptom Codes 1066
5 7 1 Symptoms of engines and Related electrical systems 1066
5 7 2 Symptoms of Hydraulic System 1066
5 7 3 Symptoms of Mechanical System 1067
5 7 4 Symptoms of Additional Systems 1067
5 8 Cable colour identification 1068
6 Troubleshooting by Trouble Code 1069
B@HANS – Hyd Oil Overheat 1070
Monitoring hydraulic oil temperature 1071
Hydraulic oil temperature charts 1072
6A1BMA – Trouble Shut-Off (gate) valve not open error 1073
View onto gap of proximity switch 40B031 1074
Wiring Diagram (40B031) for message 6A1BMA 1075
AA10NX – Air Cleaner1 Clogging 1076
AA1FNX – Air Cleaner2 Clogging 1076
View onto an engine air cleaner (AA10NX & AA1FNX) 1077
AB00KE – Charge Voltage Low 1078
AB0MKE – Charge Voltage2 Low 1078
Wiring Diagram (alternator) for message AB00KE or AB0MKE 1079
B@F0MA – CLS1 Lubrication System Error 1080
B@CPMA – SLS Lubrication System Error 1081
B@CNMA – CLS2 Lubrication System Error 1082
B@F0N9 – CLS1 pressure increase time too long 1084
B@CNN9 – CLS2 pressure increase time too long 1084
B@CPN9 – SLS pressure increase time too long 1084
Allocation of vent valves and end-of-line switches 1085
Vent valve (62Q507a & 62Q509a & 62Q642a) 1086
Wiring Diagram – lube pump solenoid & vent valve (CLS1/2 & SLS) 1087
B@F0N0 – CLS1 pressure decrease time too long 1088
B@CNN0 – CLS2 pressure decrease time too long 1088
B@CPN0 – SLS pressure decrease time too long 1088
Vent valve (62Q507a & 62Q509a & 62Q642a) 1089
B@F0ZK – CLS1 grease level too low 1090
B@CPZK – SLS grease level too low 1090
Wiring Diagram – grease level sensors (CLS1/2 & SLS) 1091
B@HAZK – Hydraulic oil level too low 1092
Hydraulic oil level in defined excavator position 1093
Wiring Diagram – hydraulic oil level sensor 40B004 1094
B@CBNS – PTO1 Gear Oil Temp High 1095
B@KCNS – PTO2 Gear Oil Temp High 1095
B@CBNS – PTO1 Gear Oil Temp High 1096
View onto pump distributor gearbox (PTO1/2) 1097
B@CBZG – PTO1 Gear Lubrication Error 1098
B@KCZG – PTO2 Gear Lubrication Error 1098
Monitoring PTO1/2 lube oil pressure 1099
Shutdown adjustment for PTO1/2 lube oil pressure 1099
B@H2NX – Breather Filter Clogging 1100
40B024 and indicator plate for definition of oil levels 1101
B@M9NX – PTO1 Gear Oil Filter Clogging 1102
B@N8NX – PTO2 Gear Oil Filter Clogging 1102
View onto PTO1/2 gear oil filter with pressure sensor 57B027-1/-2 1103
B@HBNX – Return Oil Filter Clogging 1104
B@L4NX – Leak Oil Filter Clogging 1105
B@L5N9 – Pilot Press X2 Too Low 1106
Valve cartridge block, location of components 1107
B@L5N0 – Pilot Press X2 Too High 1108
Valve cartridge block, location of components 1109
B@BKPQ – Eng Remote Oil Tank1 Empty 1110
B@BLPQ – Eng Remote Oil Tank2 Empty 1110
B@HANX – Screen At Hyd Cooler Entry Clogging 1112
Monitoring screens for 40B165 and 40B166 1112
Hydraulic oil tank & return oil collector pipe with strainer, location of components 1113
AB30MA – Starter Circuit Abnormality 1114
Wiring Diagram for AB30MA 1115
989HMA – Emergency stop line abnormality 1116
Monitoring screens and Wiring Diagram for 989HMA 1117
DGT3MA – PTO1 oil temperature sensor abnormality 1118
Wiring Diagram, monitoring screen, and location of 57B049-1 1119
DGH2MA – Hydraulic oil temp sensor abnormality 1120
Wiring Diagram, monitoring screen, and location of 59B015 1121
DHQ7MA – PTO1 lube pressure sensor abnormality 1122
Monitoring screen, Wiring Diagram, and location of 57B017-1 1123
D1E7KB – Starter cut relay short circuit 1124
Wiring Diagram and monitoring screen – Starter cut relay for message D1E7KB 1125
D1E7KY – Starter cut relay hot short circuit 1126
Wiring Diagram – Starter cut relay for message D1E7KY 1127
DHPEMA – Pump-1 pressure sensor abnormality 1128
DHPGMA – Pump-2 pressure sensor abnormality 1128
DHPJMA – Pump-3 pressure sensor abnormality 1128
DHPLMA – Pump-4 pressure sensor abnormality 1128
DHPNMA – Pump-5 pressure sensor abnormality 1128
DHPQMA – Pump-6 pressure sensor abnormality 1128
Main pumps 1 3 → Monitoring screen & Wiring Diagram – PWR & GND supply for pump pressure transducers 1130
Main pumps 4 6 → Monitoring screen & Wiring Diagram – PWR & GND supply for pump pressure transducers 1131
DLE2MA – Engine speed sensor abnormality 1132
Monitoring screen and Wiring Diagram 52B064 -1 for message DLE2MA 1133
DA27KP – 24V sensor power abnormality 1134
Wiring Diagram – 24V sensor power supply for DA27KP 1135
DA26KP – 5V sensor2 power abnormality 1136
Wiring Diagram – 5V sensor power supply for DA26KP 1137
DA2LKA – Operating Lamp Open Circuit(Pump Con) 1138
Wiring Diagram – Operating Lamp Open Circuit(Pump Con) 1139
DA2LKB – Operating Lamp Short Circuit(Pump Con) 1140
Wiring Diagram – Operating Lamp Short Circuit(Pump Con) 1141
DA22KK – Solenoid Power Low Error(Pump Con) 1142
DA22MA – Solenoid Power Circuit Abnormality 1143
Wiring Diagram 1 – monitoring safety power line for DA22MA 1144
Wiring Diagram 2 – 11Q044d for DA22MA 1145
DXAAKA – Pump1 Front Solenoid open circuit 1146
DXACKA – Pump2 Front Solenoid open circuit 1146
DXAEKA – Pump3 Front Solenoid open circuit 1146
Wiring Diagram – EPC valve control (PUMP1) 1147
DXAAKB – Pump1 Front Solenoid short circuit 1148
DXACKB – Pump2 Front Solenoid short circuit 1148
DXAEKB – Pump3 Front Solenoid short circuit 1148
Wiring Diagram – EPC valve control (PUMP1) 1149
DWA5KA – CLS pump solenoid open circuit 1150
DWA8KA – SLS pump solenoid open circuit 1150
Wiring Diagram – CLS1/SLS pump solenoid control 1151
DWA5KB – CLS pump solenoid short circuit 1152
DWA8KB – SLS pump solenoid short circuit 1152
Wiring Diagram – CLS1/SLS pump solenoid control 1153
DWA5KY – CLS pump solenoid hot short circuit 1154
DWA8KY – SLS pump solenoid hot short circuit 1154
Wiring Diagram – CLS/SLS pump solenoid / hot short circuit 1155
DWA7KA – CLS line release solenoid open circuit 1156
DWA9KA – SLS lube line release sol open circuit 1156
Wiring Diagram – CLS1/SLS lube line release solenoid control 1157
DWA7KB – CLS line release solenoid short circuit 1158
DWA9KB – SLS lube line release solenoid short circuit 1158
Wiring Diagram – CLS/SLS lube line release solenoid control 1159
DWA7KY – CLS line release sol hot short circuit 1160
DWA9KY – SLS lube line release sol hot short circuit 1160
Wiring Diagram – CLS/SLS lube line release solenoid / hot short circuit 1161
DWAAKA – PTO lube preload solenoid open circuit 1162
Wiring Diagram and monitoring screen for message DWAAKA 1163
DWAAKB – PTO lube preload solenoid short circuit 1164
Wiring Diagram and monitoring screen for message DWAAKB 1165
DWAAKY – PTO lube preload sol hot short circuit 1166
Wiring Diagram for message DWAAKY 1167
D168KB – Oil cooler preload sol relay short circuit 1168
Wiring Diagram and monitoring screen – Relay 11K070 (D168KB) 1169
D1E9KB – Wiper fast relay short circuit 1170
D1ETKB – Wiper slow relay short circuit 1170
D1EBKB – Wiper stop relay short circuit 1170
Wiring Diagram – wiper motor control 1171
D162KB – Horn relay short circuit 1172
Wiring Diagram and monitoring screen – signal horn control 1173
D1F0KB – Engine1/motor1 shutdown relay short circuit 1174
D1F4KB – Engine2/motor2 shutdown relay short circuit 1174
Wiring Diagram and monitoring screen – engine1/2 shutdown relay 11K064-1/2 1175
D1F0KY – Engine1/motor1 shutdown relay hot short 1176
D1F4KY – Engine2/motor2 shutdown relay hot short 1176
Wiring Diagram for D1F0KY / D1F4KY 1177
DWNCKA – Hyd Oil Cooler fan pump1 Sol open circuit 1178
DWNUKA – Hyd Oil Cooler fan pump2 Sol open circuit 1178
Wiring Diagram – Hyd oil cooler fan pump1/2 solenoid 1179
DWNCKB – Hyd Oil Cooler fan pump1 Sol short circuit 1180
DWNUKB – Hyd Oil Cooler fan pump2 Sol short circuit 1180
Wiring Diagram – Hyd oil cooler fan pump1/2 solenoid 1181
DXQ0KA – X1 pilot pressure pump1 Sol open circuit 1182
DXQ1KA – X1 pilot pressure pump2 Sol open circuit 1182
Wiring Diagram – X1 pilot pressure pump1/2 solenoid 1183
DXQ0KB – X1 pilot pressure pump1 Sol short circuit 1184
DXQ1KB – X1 pilot pressure pump2 Sol short circuit 1184
Wiring Diagram – X1 pilot pressure pump1/2 solenoid 1185
DWN5KA – Radiator fan pump1 Sol open circuit 1186
DWNTKA – Radiator fan pump2 Sol open circuit 1186
Wiring Diagram – Radiator fan pump1/2 solenoid 1187
DWN5KB – Radiator fan pump1 Sol short circuit 1188
DWNTKB – Radiator fan pump2 Sol short circuit 1188
Wiring Diagram – Radiator fan pump1/2 solenoid 1189
D110KA – Battery relay open circuit 1190
Wiring Diagram – battery relay 11Q044d 1191
D110KB – Battery relay short circuit 1192
Wiring Diagram – Battery relay 11Q044d 1193
DA29KQ – Model Selection Abnormality 1194
Wiring Diagram and monitoring screen – machine selection PUMP1 (DA29KQ) 1195
DA2YKQ – Motor/Engine Selection Abnormality 1196
Monitoring screen for motor/engine selection PUMP1 1196
DA20KQ – Pump Con Selection Abnormality 1197
Monitoring screen for PUMP1 controller selection 1197
DLM8MA – Oil cooler fan1 speed sensor abnormality 1198
Wiring Diagram and monitoring screen – Oil cooler fan1 speed sensor (DLM8MA) 1199
DXAGKA – Pump4 Front Solenoid open circuit 1200
DXAJKA – Pump5 Front Solenoid open circuit 1200
DXALKA – Pump6 Front Solenoid open circuit 1200
Wiring Diagram – EPC valve control (PUMP2) 1201
DXAGKB – Pump4 Front Solenoid short circuit 1202
DXAJKB – Pump5 Front Solenoid short circuit 1202
DXALKB – Pump6 Front Solenoid short circuit 1202
Wiring Diagram – EPC valve control (PUMP2) 1203
DWAEKA – CLS2 pump solenoid open circuit 1204
Wiring Diagram and monitoring screen – CLS2 pump solenoid control 1205
DWAEKB – CLS2 pump solenoid short circuit 1206
Wiring Diagram and monitoring screen – CLS2 pump solenoid control 1207
DWAEKY – CLS2 pump solenoid hot short circuit 1208
Wiring Diagram and monitoring screen – CLS2 pump solenoid / hot short circuit 1209
DWAFKA – CLS2 line release solenoid open circuit 1210
Wiring Diagram and monitoring screen – CLS2 lube line release solenoid control 1211
DWAFKB – CLS2 line release solenoid short circuit 1212
Wiring Diagram and monitoring screen – CLS2 lube line release solenoid control 1213
DWAFKY – CLS2 line release sol hot short circuit 1214
Wiring Diagram & monitoring screen – CLS2 lube line release solenoid / hot short circuit 1215
DWABKA – PTO2 lube preload solenoid open circuit 1216
Wiring Diagram and monitoring screen for message DWABKA 1217
DWABKB – PTO2 lube preload solenoid short circuit 1218
Wiring Diagram and monitoring screen for message DWABKB 1219
DWABKY – PTO lube preload sol hot short circuit 1220
Wiring Diagram for message DWABKY 1221
DGT8MA – PTO2 oil temperature sensor abnormality 1222
Wiring Diagram, monitoring screen, and location of 57B049-2 1223
DGE5MA – Ambient air temp sensor abnormality 1224
Wiring Diagram and monitoring screen for message DGE5MA 1225
DHQ8MA – PTO2 lube pressure sensor abnormality 1226
Monitoring screen, Wiring Diagram, and location of 57B017-2 1227
AB3EMA – Starter Circuit Abnormality 1228
Wiring Diagram for AB3EMA 1229
D1EEKB – Starter cut relay short circuit 1230
Wiring Diagram and monitoring screen – Starter cut relay for message D1EEKB 1231
D1EEKY – Starter cut relay hot short circuit 1232
Wiring Diagram – Starter cut relay for message D1EEKY 1233
FF11KB – Starter power cut relay1 short circuit 1234
Wiring Diagram and monitoring screen – Starter power cut relay for message FF11KB 1235
FF11KY – Starter power cut relay1 hot short circuit 1236
Wiring Diagram – Starter power cut relay1 hot short circuit for message FF11KY 1237
FF11LK – Starter power cut relay1 abnormality 1238
FF12LK – Starter power cut relay2 abnormality 1239
DBZ7KP – 24V sensor power abnormality 1240
Wiring Diagram – 24V sensor power supply for DBZ7KP 1241
DBZ6KP – 5V sensor2 power abnormality 1242
Wiring Diagram – 5V sensor power supply for DBZ6KP 1243
DBZLKA – Operating Lamp Open Circuit(Pump2 Con) 1244
Wiring Diagram – Operating Lamp Open Circuit(Pump2 Con) 1245
DBZLKB – Operating Lamp Short Circuit(Pump2 Con) 1246
Wiring Diagram – Operating Lamp Short Circuit(Pump2 Con) 1247
DBZ2KK – Solenoid Power Low Error(Pump2 Con) 1248
DLE6MA – Engine2 speed sensor abnormality 1250
Monitoring screen and Wiring Diagram – 52B064-2 for message DLE6MA 1251
DBZ9KQ – Model Selection Abnormality 1252
Wiring Diagram and monitoring screen – machine selection PUMP2 (DBZ9KQ) 1253
DBZWKQ – Motor/Engine Selection Abnormality 1254
Monitoring screen for motor/engine selection PUMP2 1254
DBZ0KQ – Pump2 Con Selection Abnormality 1255
Monitoring screen for PUMP2 controller selection 1255
DLMAMA – Oil cooler fan2 speed sensor abnormality 1256
Wiring Diagram and monitoring screen – Oil cooler fan2 speed sensor (DLMAMA) 1257
DDABL4 – Lock lever switch mismatch 1258
DDXAL4 – Ladder up position proximity switch mismatch 1259
DDXBL4 – Service arm upper position proximity switch mismatch 1260
DKURMA – R lever right-left potentio abnormality 1262
Wiring Diagram – right lever right-left potentiometer input (DKURMA) 1263
DKUSMA – R lever right-left redu pot abnorm(VALVE/M) 1264
Wiring Diagram – right lever redundant right-left potentiometer input (DKUSMA) 1265
DKUQL8 – R lever right-left potentio error 1266
Wiring Diagram – right lever main + redundant right-left signal voltage (DKUQL8) 1267
DKUQL4 – R lever right-left sig mismatch(VALVE/M) 1268
Wiring Diagram – R lever right-left redundant signal input at VALVE0 and VALVE1 1269
DKUNMA – R lever front-back potentio abnormality 1270
Wiring Diagram – right lever front-back potentiometer input (DKUNMA) 1271
DKUPMA – R lever front-back redu pot abnorm(VALVE/M) 1272
Wiring Diagram – right lever redundant front-back potentiometer input (DKUPMA) 1273
DKUML8 – R lever front-back potentio error 1274
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8) 1275
DKUML4 – R lever front-back sig mismatch(VALVE/M) 1276
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1 1277
DKUXMA – Left lever right-left potentio abnormality 1278
Wiring Diagram – left lever right-left potentiometer input (DKUXMA) 1279
DKUYMA – L lever right-left redu pot abnorm(VALVE/M) 1280
Wiring Diagram – left lever redundant right-left potentiometer input (DKUYMA) 1281
DKUWL8 – L lever right-left potentio error 1282
Wiring Diagram – left lever main + redundant right-left signal voltage (DKUWL8) 1283
DKUWL4 – L lever right-left sig mismatch(VALVE/M) 1284
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1 1285
DKUUMA – L lever front-back potentio abnormality 1286
Wiring Diagram – left lever front-back potentiometer input (DKUUMA) 1287
DKUVMA – L lever front-back redu pot abnorm(VALVE/M) 1288
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/M) for DKUVMA 1289
DKUTL8 – L lever front-back potentio error 1290
Wiring Diagram – L lever front-back potentio error (DKUTL8) 1291
DKUTL4 – L lever front-back sig mismatch(VALVE/M) 1292
Wiring Diagram – L lever front-back sig mismatch(VALVE/M) for DKUTL4 1293
DKW1MA – R pedal potentio abnormality 1294
Wiring Diagram – R pedal potentio abnormality (DKW1MA) 1295
DKW2MA – R pedal redundant pot abnormality(VALVE/M) 1296
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA 1297
DKW0L8 – R pedal potentio error 1298
Wiring Diagram – R pedal potentio error (DKW0L8) 1299
DKW0L4 – R pedal signal mismatch(VALVE/M Con) 1300
Wiring Diagram – R pedal signal mismatch(VALVE/M Con) for DKW0L4 1301
DKW4MA – L pedal potentio abnormality 1302
Wiring Diagram – L pedal potentio abnormality (DKW4MA) 1303
DKW5MA – L pedal redundant pot abnormality(VALVE/M) 1304
Wiring Diagram – L pedal redundant pot abnormality(VALVE/M) for DKW5MA 1305
DKW3L8 – L pedal potentio error 1306
Wiring Diagram – L pedal potentio error (DKW3L8) 1307
DKW3L4 – L pedal signal mismatch(VALVE/M Con) 1308
Wiring Diagram – L pedal signal mismatch(VALVE/M Con) for DKW3L4 1309
DKW7MA – Clam open potentio abnormality 1310
Wiring Diagram – Clam open potentio abnormality (DKW7MA) 1311
DKW8MA – Clam open redu pot abnormality(VALVE/M) 1312
Wiring Diagram – Clam open redu pot abnormality(VALVE/M) for DKW8MA 1313
DKW6L8 – Clam open potentio error 1314
Wiring Diagram – Clam open potentio error (DKW6L8) 1315
DKW6L4 – Clam open signal mismatch(VALVE/M Con) 1316
Wiring Diagram – Clam open signal mismatch(VALVE/M Con) for DKW6L4 1317
DKWAMA – Clam close potentio abnormality 1318
Wiring Diagram – Clam close potentio abnormality (DKWAMA) 1319
DKWBMA – Clam close redundant pot abnorm(VALVE/M) 1320
Wiring Diagram – Clam close redundant pot abnorm(VALVE/M) for DKWBMA 1321
DKW9L8 – Clam close potentio error 1322
Wiring Diagram – Clam close potentio error (DKW9L8) 1323
DKW9L4 – Clam close signal mismatch(VALVE/M Con) 1324
Wiring Diagram – Clam close signal mismatch(VALVE/M Con) for DKW9L4 1325
DKWDMA – Hydraulic slew brake potentio abnormality 1326
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA) 1327
DKWEMA – Hyd slew brake redu pot abnorm(VALVE/M) 1328
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/M) for DKWEMA 1329
DKWCL8 – Hydraulic slew brake potentio error 1330
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8) 1331
DKWCL4 – Hyd slew brake sig mismatch(VALVE/M) 1332
Wiring Diagram – Hyd slew brake sig mismatch(VALVE/M) for DKWCL4 1333
DBWLKA – Operating Lamp Open Circuit(VALVE/M Con) 1334
Wiring Diagram – Operating Lamp Open Circuit(VALVE/M Con) 1335
DBWLKB – Operating Lamp Short Circuit(VALVE/M Con) 1336
Wiring Diagram – Operating Lamp Short Circuit(VALVE/M Con) 1337
DWNPKA – Service arm up solenoid open circuit 1338
Wiring Diagram and monitoring screen for message DWNPKA 1339
DWNPKB – Service arm up solenoid short circuit 1340
Wiring Diagram and monitoring screen for message DWNPKB 1341
DWNPKY – Service arm up solenoid hot short circuit 1342
Wiring Diagram and monitoring screen for message DWNPKY 1343
DWNQKA – Service arm down solenoid open circuit 1344
Wiring Diagram and monitoring screen for message DWNQKA 1345
DWNQKB – Service arm down solenoid short circuit 1346
Wiring Diagram and monitoring screen for message DWNQKB 1347
DWNQKY – Service arm down solenoid hot short circuit 1348
Wiring Diagram and monitoring screen for message DWNQKY 1349
DW4BKA – Travel parking brake solenoid open circuit 1350
Wiring Diagram and monitoring screen for message DW4BKA 1351
DW4BKB – Travel parking brake sol short circuit 1352
Wiring Diagram and monitoring screen for message DW4BKB 1353
DW4BKY – Travel parking brake sol hot short circuit 1354
Wiring Diagram and monitoring screen for message DW4BKY 1355
DW4BMA – Travel parking brake solenoid circuit abnormality 1356
Wiring Diagram and monitoring screen for DW4BMA 1357
DW45KA – Slew parking brake solenoid open circuit 1358
Wiring Diagram and monitoring screen for message DW45KA 1359
DW45KB – Slew parking brake solenoid short circuit 1360
Wiring Diagram and monitoring screen for message DW45KB 1361
DW45KY – Slew parking brake sol hot short circuit 1362
Wiring Diagram and monitoring screen for message DW45KY 1363
DW45MA – Slew parking brake solenoid circuit abnormality 1364
Wiring Diagram and monitoring screen for DW45MA 1365
DXN2KA – Boom1 epc solenoid open circuit 1366
DXN3KA – Stick1 epc solenoid open circuit 1366
DXNJKA – Bucket1 epc solenoid open circuit 1366
DXNHKA – Travel1 left epc solenoid open circuit 1366
DXN4KA – Boom2 epc solenoid open circuit 1366
DXN5KA – Clam2 epc solenoid open circuit 1366
DXN6KA – Stick2 epc solenoid open circuit 1366
DXN8KA – Bucket2 epc solenoid open circuit 1366
DXNBKA – Bucket3 epc solenoid open circuit 1366
DXNCKA – Boom3 epc solenoid open circuit 1366
DXNLKA – Stick3 epc solenoid open circuit 1366
DXNKKA – Travel3 right epc solenoid open circuit 1366
DXNMKA – Slew4 epc solenoid open circuit 1366
Details of above 6-digit failure codes (FSA & BHA) 1367
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623 1368
Wiring Diagram for EPC 61K624 – 61K625 1369
Wiring Diagram for EPC 61K626 – 61K627 – 61K628 – 61K629 1370
Wiring Diagram for EPC 61K630 – 61K631 – 61K632 1371
Monitoring screens as an example 1372
DXN2KB – Boom1 epc solenoid short circuit (BHA) 1374
DXN3KB – Stick1 epc solenoid short circuit 1374
DXNJKB – Bucket1 epc solenoid short circuit 1374
DXNHKB – Travel1 left epc solenoid short circuit 1374
DXN4KB – Boom2 epc solenoid short circuit 1374
DXN5KB – Clam2 epc solenoid short circuit (FSA) 1374
DXN6KB – Stick2 epc solenoid short circuit (BHA) 1374
DXN8KB – Bucket2 epc solenoid short circuit 1374
DXNBKB – Bucket3 epc solenoid short circuit 1374
DXNCKB – Boom3 epc solenoid short circuit 1374
DXNLKB – Stick3 epc solenoid short circuit 1374
DXNKKB – Travel3 right epc solenoid short circuit 1374
DXNMKB – Slew4 epc solenoid short circuit 1374
Details of above 6-digit failure codes (FSA & BHA) 1375
DXN2KY – Boom1 epc solenoid hot short circuit (BHA) 1376
DXN3KY – Stick1 epc solenoid hot short circuit 1376
DXNJKY – Bucket1 epc solenoid hot short circuit 1376
DXNHKY – Travel1 left epc solenoid hot short circuit 1376
DXN4KY – Boom2 epc solenoid hot short circuit 1376
DXN5KY – Clam2 epc solenoid hot short circuit (FSA) 1376
DXN6KY – Stick2 epc solenoid hot short circuit (BHA) 1376
DXN8KY – Bucket2 epc solenoid hot short circuit 1376
DXNBKY – Bucket3 epc solenoid hot short circuit 1376
DXNCKY – Boom3 epc solenoid hot short circuit 1376
DXNLKY – Stick3 epc solenoid hot short circuit 1376
DXNKKY – Travel3 right epc solenoid hot short circuit 1376
DXNMKY – Slew4 epc solenoid hot short circuit 1376
Details of above 6-digit failure codes (FSA & BHA) 1377
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623 1378
Wiring Diagram for EPC 61K624 – 61K625 1379
Wiring Diagram for EPC 61K626 – 61K627 – 61K628 – 61K629 1380
Wiring Diagram for EPC 61K630 – 61K631 – 61K632 1381
DWACKA – Service arm check valve sol open circuit 1382
Wiring Diagram and monitoring screen for message DWACKA 1383
DWACKB – Service arm check valve sol short circuit 1384
Wiring Diagram and monitoring screen for message DWACKB 1385
DWACKY – Service arm check valveSol hotShortCircuit 1386
Wiring Diagram and monitoring screen for message DWACKY 1387
DWADKA – Ladder speed control solenoid open circuit 1388
Wiring Diagram and monitoring screen for message DWADKA 1389
DWADKB – Ladder speed control sol short circuit 1390
Wiring Diagram and monitoring screen for message DWADKB 1391
DWADKY – Ladder speed control sol hot short circuit 1392
Wiring Diagram – Ladder speed control sol hot short circuit (DWADKY) 1393
DBW5MA – 5V sensor1 power abnormality 1394
DBW6MA – 5V sensor2 power abnormality 1394
Wiring Diagram – 5V power supply and GND output at VALVE0 1398
DBW9KQ – Model Selection Abnormality 1400
Monitoring screen and Wiring Diagram – model selection abnormality (DBW9KQ) 1401
DBWZKQ – Lever control selection abnormality 1402
Monitoring screen & Wiring Diagram – Lever control selection abnormality (DBWZKQ) 1403
DBWYKQ – Attachment selection abnormality 1404
Monitoring screen & Wiring Diagram – Attachment selection abnormality (DBWYKQ) 1405
DBW2KK – Solenoid Power Low Error(VALVE/M Con) 1406
Wiring Diagram 1 for message DBW2KK 1408
Wiring Diagram 2 for message DBW2KK 1409
DBW0KQ – VALVE/M Con Selection Abnormality 1410
Monitoring screen and Wiring Diagram for message DBW0KQ 1411
DDDWMC – Ladder operation switch abnormality 1412
Wiring Diagram and monitoring screen for message DDDWMC 1413
DKWHMA – R lever right-left redu pot abnorm(VLV/S1) 1414
Wiring Diagram – right lever redundant right-left potentiometer input (DKWHMA) 1415
DKWFL4 – R lever right-left sig mismatch(VALVE/S1) 1416
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1 1417
DKWLMA – R lever front-back redu pot abnorm(VLV/S1) 1418
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA) 1419
DKWJL4 – R lever front-back sig mismatch(VALVE/S1) 1420
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1 1421
DKWPMA – L lever right-left redu pot abnorm(VLV/S1) 1422
Wiring Diagram – left lever redundant right-left potentiometer input (DKWPMA) 1423
DKWML4 – L lever right-left sig mismatch(VALVE/S1) 1424
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1 1425
DKWSMA – L lever front-back redu pot abnorm(VLV/S1) 1426
Wiring Diagram – L lever front-back redu pot abnorm(VLV/S1) for DKWSMA 1427
DKWQL4 – L lever front-back sig mismatch(VALVE/S1) 1428
Wiring Diagram – L lever front-back sig mismatch(VALVE/S1) for DKWQL4 1429
DKWVMA – R pedal red pot abnormality(VALVE/S1) 1430
Wiring Diagram – R pedal red pot abnormality(VALVE/S1) for DKWVMA 1431
DKWTL4 – R pedal signal mismatch(VALVE/S1 Con) 1432
Wiring Diagram – R pedal signal mismatch(VALVE/S1 Con) for DKWTL4 1433
DKWYMA – L pedal red pot abnormality(VALVE/S1) 1434
Wiring Diagram – L pedal red pot abnormality(VALVE/S1) for DKWYMA 1435
DKWWL4 – L pedal signal mismatch(VALVE/S1 Con) 1436
Wiring Diagram – L pedal signal mismatch(VALVE/S1 Con) for DKWWL4 1437
DKX2MA – Clam open redu pot abnormality(VALVE/S1) 1438
Wiring Diagram – Clam open redu pot abnormality(VALVE/S1) for DKX2MA 1439
DKX0L4 – Clam open signal mismatch(VALVE/S1 Con) 1440
Wiring Diagram – Clam open signal mismatch(VALVE/S1 Con) for DKX0L4 1441
DKX5MA – Clam close redu pot abnormality(VALVE/S1) 1442
Wiring Diagram – Clam close redu pot abnormality(VALVE/S1) for DKX5MA 1443
DKX3L4 – Clam close signal mismatch(VALVE/S1 Con) 1444
Wiring Diagram – Clam close signal mismatch(VALVE/S1 Con) for DKX3L4 1445
DKX8MA – Hyd slew brake redu pot abnorm(VALVE/S1) 1446
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/S1) for DKX8MA 1447
DKX6L4 – Hyd slew brake signal mismatch(VALVE/S1) 1448
Wiring Diagram – Hyd slew brake signal mismatch(VALVE/S1) for DKX6L4 1449
DBXLKA – Operating Lamp Open Circuit(VALVE/S1 Con) 1450
Wiring Diagram – Operating Lamp Open Circuit((VALVE/S1 Con) 1451
DBXLKB – Operating Lamp Short Circuit(VALVE/S1 Con) 1452
Wiring Diagram – Operating Lamp Short Circuit(VALVE/S1 Con) 1453
DWNRKB – Ladder up solenoid short circuit 1454
Wiring Diagram and monitoring screen for message DWNRKB 1455
DWNRKY – Ladder up solenoid hot short circuit 1456
Wiring Diagram – Ladder up solenoid hot short circuit (DWNRKY) 1457
DWNRMA – Ladder up solenoid circuit abnormality 1458
Wiring Diagram and monitoring screen for DWNRMA 1459
DW7RKA – Hydraulic slew brake solenoid open circuit 1460
Wiring Diagram and monitoring screen for message DW7RKA 1461
DW7RKB – Hydraulic slew brake sol short circuit 1462
Wiring Diagram and monitoring screen for message DW7RKB 1463
DW7RKY – Hyd slew brake sol hot short circuit 1464
Wiring Diagram – Hyd slew brake sol hot short circuit (DW7RKY) 1465
DWASKA – Bucket1 fill solenoid open circuit 1466
Wiring Diagram and monitoring screen for message DWASKA 1467
DWASKB – Bucket1 fill solenoid short circuit 1468
Wiring Diagram and monitoring screen for message DWASKB 1469
DWASKY – Bucket1 fill solenoid hot short circuit 1470
Wiring Diagram and monitoring screen for message DWASKY 1471
DWAWKA – Bucket1 dump solenoid open circuit 1472
Wiring Diagram and monitoring screen for message DWAWKA 1473
DWAWKB – Bucket1 dump solenoid short circuit 1474
Wiring Diagram and monitoring screen for message DWAWKB 1475
DWAWKY – Bucket1 dump solenoid hot short circuit 1476
Wiring Diagram and monitoring screen for message DWAWKY 1477
DWKAKA – Travel1 left forward sol open circuit 1478
Wiring Diagram and monitoring screen for message DWKAKA 1479
DWKAKB – Travel1 left forward sol short circuit 1480
Wiring Diagram and monitoring screen for message DWKAKB 1481
DWKAKY – Travel1 left forward sol hot short circuit 1482
Wiring Diagram and monitoring screen for message DWKAKY 1483
DWKEKA – Travel1 left backward sol open circuit 1484
Wiring Diagram and monitoring screen for message DWKEKA 1485
DWKEKB – Travel1 left backward sol short circuit 1486
Wiring Diagram and monitoring screen for message DWKEKB 1487
DWKEKY – Travel1 left backward sol hot short circuit 1488
Wiring Diagram and monitoring screen for message DWKEKY 1489
DWBEKA – Boom1 down solenoid open circuit 1490
Wiring Diagram and monitoring screen for message DWBEKA 1491
DWBEKB – Boom1 down solenoid short circuit 1492
Wiring Diagram and monitoring screen for message DWBEKB 1493
DWBEKY – Boom1 down solenoid hot short circuit 1494
Wiring Diagram and monitoring screen for message DWBEKY 1495
DWBAKA – Boom1 up solenoid open circuit 1496
Wiring Diagram and monitoring screen for message DWBAKA 1497
DWBAKB – Boom1 up solenoid short circuit 1498
Wiring Diagram and monitoring screen for message DWBAKB 1499
DWBAKY – Boom1 up solenoid hot short circuit 1500
Wiring Diagram and monitoring screen for message DWBAKY 1501
DWBJKA – Stick1 out solenoid open circuit 1502
Wiring Diagram and monitoring screen for message DWBJKA 1503
DWBJKB – Stick1 out solenoid short circuit 1504
Wiring Diagram and monitoring screen for message DWBJKB 1505
DWBJKY – Stick1 out solenoid hot short circuit 1506
Wiring Diagram and monitoring screen for message DWBJKY 1507
DWBNKA – Stick1 in solenoid open circuit 1508
Wiring Diagram and monitoring screen for message DWBNKA 1509
DWBNKB – Stick1 in solenoid short circuit 1510
Wiring Diagram and monitoring screen for message DWBNKB 1511
DWBNKY – Stick1 in solenoid hot short circuit 1512
Wiring Diagram and monitoring screen for message DWBNKY 1513
DWBBKA – Boom2 up solenoid open circuit 1514
Wiring Diagram (BHA) and monitoring screen for message DWBBKA 1515
Wiring Diagram (FSA) and monitoring screen for message DWBBKA 1516
DWBBKB – Boom2 up solenoid short circuit 1517
Wiring Diagram (BHA) and monitoring screen for message DWBBKB 1518
Wiring Diagram (FSA) and monitoring screen for message DWBBKB 1519
DWBBKY – Boom2 up solenoid hot short circuit 1520
Wiring Diagram for message DWBBKY 1521
DWBFKA – Boom2 down solenoid open circuit 1522
Wiring Diagram (BHA) and monitoring screen for message DWBFKA 1523
Wiring Diagram (FSA) and monitoring screen for message DWBFKA 1524
DWBFKB – Boom2 down solenoid short circuit 1525
Wiring Diagram (BHA) and monitoring screen for message DWBFKB 1526
Wiring Diagram (FSA) and monitoring screen for message DWBFKB 1527
DWBFKY – Boom2 down solenoid hot short circuit 1528
Wiring Diagram for message DWBFKY 1529
DWBXKA – Clam2 close solenoid open circuit 1530
Wiring Diagram and monitoring screen for message DWBXKA 1531
DWBXKB – Clam2 close solenoid short circuit 1532
Wiring Diagram and monitoring screen for message DWBXKB 1533
DWBXKY – Clam2 close solenoid hot short circuit 1534
Wiring Diagram and monitoring screen for message DWBXKY 1535
DWBKKA – Stick2 out solenoid open circuit 1536
Wiring Diagram and monitoring screen for message DWBKKA 1537
DWBKKB – Stick2 out solenoid short circuit 1538
Wiring Diagram and monitoring screen for message DWBKKB 1539
DWBKKY – Stick2 out solenoid hot short circuit 1540
Wiring Diagram and monitoring screen for message DWBKKY 1541
DWBTKA – Clam2 open solenoid open circuit 1542
Wiring Diagram and monitoring screen for message DWBTKA 1543
DWBTKB – Clam2 open solenoid short circuit 1544
Wiring Diagram and monitoring screen for message DWBTKB 1545
DWBTKY – Clam2 open solenoid hot short circuit 1546
Wiring Diagram and monitoring screen for message DWBTKY 1547
DWBPKA – Stick2 in solenoid open circuit 1548
Wiring Diagram and monitoring screen for message DWBPKA 1549
DWBPKB – Stick2 in solenoid short circuit 1550
Wiring Diagram and monitoring screen for message DWBPKB 1551
DWBPKY – Stick2 in solenoid hot short circuit 1552
Wiring Diagram and monitoring screen for message DWBPKY 1553
DWATKA – Bucket2 fill solenoid open circuit 1554
Wiring Diagram (BHA) and monitoring screen for message DWATKA 1555
Wiring Diagram (FSA) and monitoring screen for message DWATKA 1556
DWATKB – Bucket2 fill solenoid short circuit 1557
Wiring Diagram (BHA) and monitoring screen for message DWATKB 1558
Wiring Diagram (FSA) and monitoring screen for message DWATKB 1559
DWATKY – Bucket2 fill solenoid hot short circuit 1560
Wiring Diagram for message DWATKY 1561
DWAXKA – Bucket2 dump solenoid open circuit 1562
Wiring Diagram (BHA) and monitoring screen for message DWAXKA 1563
Wiring Diagram (FSA) and monitoring screen for message DWAXKA 1564
DWAXKB – Bucket2 dump solenoid short circuit 1565
Wiring Diagram (BHA) and monitoring screen for message DWAXKB 1566
Wiring Diagram (FSA) and monitoring screen for message DWAXKB 1567
DWAXKY – Bucket2 dump solenoid hot short circuit 1568
Wiring Diagram and monitoring screen for message DWAXKY 1569
D5ZWKB – Travel hour meter short circuit 1570
Wiring Diagram and monitoring screen for message D5ZWKB 1571
D1EUKB – Travel alarm relay short circuit 1572
Wiring Diagram and monitoring screen for message D1EUKB 1573
DBX9KQ – Model Selection Abnormality 1574
Wiring Diagram and monitoring screen for message DBX9KQ 1575
DBXZKQ – Lever Control Selection Abnormality 1576
Wiring Diagram and monitoring screen for message DBXZKQ 1577
DBXYKQ – Attachment selection abnormality 1578
Wiring Diagram – Attachment selection abnormality (DBXYKQ) 1579
D561MA – Lock lever sol power cut abnorm(VALVE/S1) 1580
Wiring Diagram 1 for message D561MA 1582
Monitoring screens and Wiring Diagram 2 for message D561MA 1583
D563MA – Ladder up sensor sol cut abnorm(VLV/S1) 1584
Wiring Diagram 1 for message D563MA 1586
Monitoring screens and Wiring Diagram 2 for message D563MA 1587
D565MA – Service arm (up) sensor sol cut abnorm(VLV/S1) 1588
Wiring Diagram 1 for message D565MA 1590
Wiring Diagram 2 and monitoring screens for message D565MA 1591
DBX2KK – Solenoid Power Low Error(VALVE/S1 Con) 1592
Monitoring screen and Wiring Diagram 1 for message DBX2KK 1593
Wiring Diagram 2 for message DBX2KK – PPC safety circuit 1594
DBX0KQ – VALVE/S1 Con Selection Abnormality 1596
Wiring Diagram and monitoring screen for message DBX0KQ 1597
DBYLKA – Operating Lamp Open Circuit(VALVE/S2 Con) 1598
Wiring Diagram – Operating Lamp Open Circuit(VALVE/S2 Con) 1599
DBYLKB – Operating Lamp Short Circuit(VALVE/S2 Con) 1600
Wiring Diagram – Operating Lamp Short Circuit(VALVE/S2 Con) 1601
DWAUKA – Bucket3 fill solenoid open circuit 1602
Wiring Diagram and monitoring screen for message DWAUKA 1603
DWAUKB – Bucket3 fill solenoid short circuit 1604
Wiring Diagram and monitoring screen for message DWAUKB 1605
DWAUKY – Bucket3 fill solenoid hot short circuit 1606
Wiring Diagram and monitoring screen for message DWAUKY 1607
DWAYKA – Bucket3 dump solenoid open circuit 1608
Wiring Diagram and monitoring screen for message DWAYKA 1609
DWAYKB – Bucket3 dump solenoid short circuit 1610
Wiring Diagram and monitoring screen for message DWAYKB 1611
DWAYKY – Bucket3 dump solenoid hot short circuit 1612
Wiring Diagram and monitoring screen for message DWAYKY 1613
DWBCKA – Boom3 up solenoid open circuit 1614
Wiring Diagram and monitoring screen for message DWBCKA 1615
DWBCKB – Boom3 up solenoid short circuit 1616
Wiring Diagram and monitoring screen for message DWBCKB 1617
DWBCKY – Boom3 up solenoid hot short circuit 1618
Wiring Diagram and monitoring screen for message DWBCKY 1619
DWBGKA – Boom3 down solenoid open circuit 1620
Wiring Diagram and monitoring screen for message DWBGKA 1621
DWBGKB – Boom3 down solenoid short circuit 1622
Wiring Diagram and monitoring screen for message DWBGKB 1623
DWBGKY – Boom3 down solenoid hot short circuit 1624
Wiring Diagram and monitoring screen for message DWBGKY 1625
DWBLKA – Stick3 out solenoid open circuit 1626
Wiring Diagram (BHA) and monitoring screen for message DWBLKA 1627
Wiring Diagram (FSA) and monitoring screen for message DWBLKA 1628
DWBLKB – Stick3 out solenoid short circuit 1629
Wiring Diagram (BHA) and monitoring screen for message DWBLKB 1630
Wiring Diagram (FSA) and monitoring screen for message DWBLKB 1631
DWBLKY – Stick3 out solenoid hot short circuit 1632
Wiring Diagram and monitoring screen for message DWBLKY 1633
DWBQKA – Stick3 in solenoid open circuit 1634
Wiring Diagram (BHA) and monitoring screen for message DWBQKA 1635
Wiring Diagram (FSA) and monitoring screen for message DWBQKA 1636
DWBQKB – Stick3 in solenoid short circuit 1637
Wiring Diagram (BHA) and monitoring screen for message DWBQKB 1638
Wiring Diagram (FSA) and monitoring screen for message DWBQKB 1639
DWBQKY – Stick3 in solenoid hot short circuit 1640
Wiring Diagram and monitoring screen for message DWBQKY 1641
DWKQKA – Travel3 right backward sol open circuit 1642
Wiring Diagram and monitoring screen for message DWKQKA 1643
DWKQKB – Travel3 right backward sol short circuit 1644
Wiring Diagram and monitoring screen for message DWKQKB 1645
DWKQKY – Travel3 right backward sol hot short 1646
Wiring Diagram and monitoring screen for message DWKQKY 1647
DWKLKA – Travel3 right forward sol open circuit 1648
Wiring Diagram and monitoring screen for message DWKLKA 1649
DWKLKB – Travel3 right forward sol short circuit 1650
Wiring Diagram and monitoring screen for message DWKLKB 1651
DWKLKY – Travel3 right forward sol hot short 1652
Wiring Diagram and monitoring screen for message DWKLKY 1653
DWARKA – Slew4 right solenoid open circuit 1654
Wiring Diagram and monitoring screen for message DWARKA 1655
DWARKB – Slew4 right solenoid short circuit 1656
Wiring Diagram and monitoring screen for message DWARKB 1657
DWARKY – Slew4 right solenoid hot short circuit 1658
Wiring Diagram and monitoring screen for message DWARKY 1659
DWAMKA – Slew4 left solenoid open circuit 1660
Wiring Diagram and monitoring screen for message DWAMKA 1661
DWAMKB – Slew4 left solenoid short circuit 1662
Wiring Diagram and monitoring screen for message DWAMKB 1663
DWAMKY – Slew4 left solenoid hot short circuit 1664
Wiring Diagram and monitoring screen for message DWAMKY 1665
DXEDKA – Hydraulic slew brake epc sol open circuit 1666
Wiring Diagram and monitoring screen for message DXEDKA 1667
DXEDKB – Hyd slew brake epc sol short circuit 1668
Wiring Diagram and monitoring screen for message DXEDKB 1669
DXEDKY – Hyd slew brake epc sol hot short circuit 1670
Wiring Diagram and monitoring screen for message DXEDKY 1671
DBY9KQ – Model Selection Abnormality 1672
Wiring Diagram and monitoring screen for message DBY9KQ 1673
DBYZKQ – Lever Control Selection Abnormality 1674
Wiring Diagram and monitoring screen for message DBYZKQ 1675
DBYYKQ – Attachment selection abnormality 1676
Wiring Diagram – Attachment selection abnormality (DBYYKQ) 1677
D562MA – Lock lever sol power cut abnorm(VALVE/S2) 1678
Wiring Diagram 1 for message D562MA 1680
Monitoring screens and Wiring Diagram 2 for message D562MA 1681
D564MA – Ladder up sensor sol cut abnorm(VLV/S2) 1682
Wiring Diagram 1 for message D564MA 1684
Monitoring screens and Wiring Diagram 2 for message D564MA 1685
D566MA – Service arm sensor sol cut abnorm(VALV/S2) 1686
Wiring Diagram 1 for message D566MA 1688
Monitoring screens and Wiring Diagram 2 for message D566MA 1689
DBY2KK – Solenoid Power Low Error(VALVE/S2 Con) 1690
Monitoring screen and Wiring Diagram 1 for message DBY2KK 1691
Wiring Diagram 2 for message DBY2KK – PPC safety circuit 1692
DBY0KQ – VALVE/S2 Con Selection Abnormality 1694
Wiring Diagram and monitoring screen for message DBY0KQ 1695
DJH2KX – Hydraulic oil level sensor abnormality 1696
Wiring Diagram and monitoring screen for message DJH2KX 1697
DJE3KX – Remote engine oil level1 sens abnormality 1698
DJE4KX – Remote engine oil level2 sens abnormality 1698
Wiring Diagram and monitoring screen for message DJE3KX & DJE4KX 1699
B@NHKX – Hydraulic oil tank air filter sensor abnormality 1700
Wiring Diagram and monitoring screen for message B@NHKX 1701
DH2GKX – Suction tank pressure sensor abnormality 1702
Wiring Diagram and monitoring screen for message DH2GKX 1703
DH2HKX – Oil cooler pressure sensor abnormality 1704
Wiring Diagram and monitoring screen for message DH2HKX 1705
DH2JKX – Preload valve return oil press abnormality 1706
Wiring Diagram and monitoring screen for message DH2JKX 1707
DHSUKX – X2 pressure sensor abnormality 1708
Wiring Diagram and monitoring screen for message DHSUKX 1709
DJF1KX – Fuel level sensor abnormality 1710
Wiring Diagram and monitoring screen for message DJF1KX 1711
DH2KKX – Return oil chamber press sensor abnormal 1712
Wiring Diagram and monitoring screen for message DH2KKX 1713
DH2LKX – Leak oil chamber press sensor abnormality 1714
Wiring Diagram and monitoring screen for message DH2LKX 1715
DJE5L4 – SLS sensor system abnormality 1716
Wiring Diagram and monitoring screen for message DJE5L4 1717
DJE6L4 – CLS sensor system abnormality 1718
Wiring Diagram and monitoring screen for message DJE6L4 1719
DBVLKA – Operating Lamp Open Circuit(KOMTRAX) 1720
Wiring Diagram for message DBVLKA 1721
DBVLKB – Operating Lamp Short Circuit(KOMTRAX) 1722
Wiring Diagram for message DBVLKB 1723
DBV1KK – KOMTRAX Plus source voltage Error 1724
Wiring Diagram for message DBV1KK 1725
DBV5KB – 5V sensor1 power abnormality 1726
Wiring Diagram 1 and monitoring screen for message DBV5KB 1727
DBV6KB – 24V Sensor Power Abnormality 1728
Wiring Diagram 1 and monitoring screen for message DBV6KB 1729
DAFGMC – GPS Module Error 1730
Wiring Diagram for message DAFGMC 1731
D862KA – GPS Antenna Open Circuit 1732
DBVVKR – Ethernet 1 Disconnection 1733
DBVWKR – Ethernet 2 Disconnection 1734
DA2RKR – CAN1 Discon (Pump Con) 1736
CAN1 overview for message DA2RKR 1737
DBZRKR – CAN1 Discon (Pump2 Con) 1738
CAN1 overview for message DBZRKR 1739
DBWRKR – CAN1 Discon (Valve/M Con) 1740
CAN1 overview for message DBWRKR 1741
DBXRKR – CAN1 Discon (Valve/S1 Con) 1742
CAN1 overview for message DBXRKR 1743
DBYRKR – CAN1 Discon (Valve/S2 Con) 1744
CAN1 overview for message DBYRKR 1745
DB2QKR – CAN2 Discon (Engine Con) 1746
CAN2 overview for message DB2QKR 1747
Wiring Diagram for PWR supply at 52K014-1 (DB2QKR) 1748
F72QKR – CAN2 Discon (Engine2 Con) 1749
CAN2 overview for message F72QKR 1750
Wiring Diagram for PWR supply at 52K014-2 (F72QKR) 1751
DA2QKR – CAN2 Discon (Pump Con) 1752
CAN2 overview for message DA2QKR 1753
DBZQKR – CAN2 Discon (Pump2 Con) 1754
CAN2 overview for message DBZQKR 1755
DBWQKR – CAN2 Discon (Valve/M Con) 1756
CAN2 overview for message DBWQKR 1757
DBXQKR – CAN2 Discon (Valve/S1 Con) 1758
CAN2 overview for message DBXQKR 1759
DBYQKR – CAN2 Discon (Valve/S2 Con) 1760
CAN2 overview for message DBYQKR 1761
DBVRKR – CAN1 Discon (KOMTRAX Plus) 1762
CAN1 overview for message DBVRKR 1763
DBVQKR – CAN2 Discon (KOMTRAX Plus) 1764
CAN2 overview for message DBVQKR 1765
DBPRKR – CAN1 Discon (KomVision) 1766
Wiring Diagram for DBPRKR 1767
DBPQKR – CAN2 Discon (KomVision) 1768
Wiring Diagram for DBPQKR 1769
DAFLKA – Operating Lamp Open Circuit(Monitor) 1770
Wiring Diagram for message DAFLKA 1771
DAFLKB – Operating Lamp Short Circuit(Monitor) 1772
Wiring Diagram for message DAFLKB 1773
DBSSKR – PLM Discon (Shovel PLM) 1774
Wiring Diagram for message DBSSKR 1775
DBSSKT – Shovel PLM Internal Error 1776
Wiring Diagram – PLM components for message DBSSKT 1777
D19YKB – Emergency Lighting Ladder Relay Short Circuit 1778
Wiring Diagram and monitoring screen for message D19YKB 1779
DV00KB – Shutdown Buzzer Short Circuit 1780
Wiring Diagram and monitoring screen for message DV00KB 1781
DAF0KM – Inconsistency of KomVision Setting 1782
DBP5KP – Camera Power Output Voltage Low 1784
Wiring Diagram for message DBP5KP 1785
DBP0NR – KomVision Controller High Temperature Error 1786
DPQ4KB – Short Circuit of KomVision Monitor ON/OFF Signal 1788
Wiring Diagram for message DPQ4KB 1789
DBP0KT – KomVision Controller Internal Error 1790
DBP0KM – KomVision Controller Setting Error 1791
DR10KA – Disconnection of Camera 1 NTSC Input 1792
DR20KA – Disconnection of Camera 2 NTSC Input 1792
DR30KA – Disconnection of Camera 3 NTSC Input 1792
DR40KA – Disconnection of Camera 4 NTSC Input 1792
DR50KA – Disconnection of Camera 5 NTSC Input 1792
DR60KA – Disconnection of Camera 6 NTSC Input 1792
DR90KA – Disconnection of Camera 7 NTSC Input 1792
Wiring Diagram for message DR10KA DR90KA 1793
DPQ4KT – KomVision Monitor Internal Error 1794
DBPLKA – Operating Lamp Open Circuit (KomVision) 1796
Wiring Diagram for message DBPLKA 1797
DBPLKB – Operating Lamp Short Circuit (KomVision) 1798
Wiring Diagram for message DBPLKB 1799
DBPWKR – Ethernet 1 Discon (KomVision) 1800
DBPXKR – Ethernet 2 Discon (KomVision) 1800
7 Troubleshooting by Symptoms 1801
7 1 Symptoms of engines and related electrical systems 1802
SEL001 – Engine does not start (engine does not rotate) 1802
Wiring Diagram 1 (batteries) for symptom code SEL001 1804
Wiring Diagram 2 (20S030 & 20S105a/b) for symptom code SEL001 1805
Wiring Diagram 3 (engine enable) for symptom code SEL001 1806
Wiring Diagram 4 (starter motors) for symptom code SEL001 (engine 1 as example) 1807
SEL002 – Engine stops while in operation 1808
Wiggins Service System VR300 1809
SEL003 – Engine speed is hunting during boom-up movement 1810
SEL004 – Engine does not stop 1812
SEL005 – Engine lacks output (no power) 1813
Judgment Table for SEL005 1814
SEL006 – Engine does not start (Pre-lube does not stop) 1815
SEL007 – Oil consumption is excessive 1816
Judgment Table for SEL007 1817
SEL008 – Oil becomes contaminated quickly 1818
Judgment Table for SEL008 1819
SEL009 – Fuel consumption is excessive 1820
Judgment Table for SEL009 1821
SEL010 – Oil is in engine coolant 1822
Judgment Table for SEL010 1823
SEL011 – Oil level rises 1824
Judgment Table for SEL011 1825
SEL012 – Coolant temperature becomes too high (overheating) 1826
Judgment Table for SEL012 1827
7 2 Symptoms of Hydraulic System 1828
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function) 1828
SHY002 – Engine speed sharply drops or engine stalls too much 1830
SHY003 – No work equipment, travel, or slew movement 1831
SHY004 – Work equipment has too much hydraulic drift 1832
SHY005 – Work equipment has big time lag 1833
SHY006 – Excavator deviates during travel movement 1834
SHY007 – Hydraulic system has lack of power 1836
Servo valve (SHY007) 1837
SHY008 – Excavator does not slew 1838
Slew brake block (SHY008) 1839
SHY009 – Slew acceleration is poor 1840
SHY010 – Excessive overrun when stopping slew movement 1842
SHY011 – Floating system without function (FSA only) 1844
SHY012 – Abnormal noise coming from SRV or MRV 1845
SHY013 – Track tensioning system without function 1846
Track tensioning – overview (SHY013) 1847
SHY014 – Stairway does not move, or slow movement 1848
SHY015 – Refilling arm does not move, or slow movement 1850
SHY016 – Hydraulic driven grease pump does not move 1852
SHY017 – Abnormal track chain movement during digging 1854
SHY018 – Slew parking brake without function 1855
SHY019 – Travel parking brake without function 1856
7 3 Symptoms of Mechanical System 1858
SME001 – Abnormal noise is made 1858
Judgment Table for SME001 1859
SME002 – Abnormal noise around PTOs / hydraulic pumps 1860
SME003 – Vibration is excessive (engine mountings) 1862
Judgment Table for SME003 1863
SME004 – Vibration is excessive (engine torsion) 1864
SME005 – There is a big shock when stopping slew movement 1865
SME006 – There is a big abnormal noise when moving/stopping slew movement 1866
SME007 – Fan blades make abnormal noise 1868
SME008 – Abnormal noise coming from a travel gearbox 1870
SME009 – Abnormal noise coming from work equipment (lack of grease) 1872
SME010 – Abnormal idler movement 1874
SME011 – Leak at PTO drive shaft seal 1876
7 4 Symptoms of Additional Systems 1878
SAD001 – Air conditioner for cabin does not work 1878
View onto A/C unit (SAD001) 1879
SAD002 – Air conditioner compressor clutch is burnt 1880
View onto A/C compressor and its mounting (SAD002) 1881
SAD003 – Air conditioning system defective (pipes and hoses full of moisture) 1882
View onto A/C filling and service station 1883
50 DISASSEMBLY & ASSEMBLY 1885
TOC 1887
1 Introduction 1895
1 1 Foreword 1896
1 2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 1897
1 3 Diagrams and illustrations in this manual 1897
1 4 Procedures for disassembling and assembling in this manual 1898
1 5 Explanation of abbreviations 1899
2 Safety 1901
2 1 Overview 1903
2 1 1 Method of using this manual 1903
2 2 General precautions 1905
2 2 1 General 1905
2 2 2 Personal protective clothing 1905
2 2 3 When using a hammer 1906
2 2 4 Proper tools 1906
2 2 5 Personnel 1906
2 2 6 Fire prevention 1907
2 2 7 Unauthorized modification 1907
2 3 Precautions for maintenance and repair 1908
2 3 1 General precautions 1908
2 3 2 Keep work place clean and tidy 1908
2 3 3 Precautions when welding 1909
2 3 4 Precaution with high pressure fluids 1909
2 3 4 1 Handling high pressure hoses and pipes 1909
2 3 5 Compressed air 1909
2 3 6 Waste materials 1910
2 3 7 Isolate the excavator using the transfer pump 1911
2 3 8 Isolate the excavator 1911
2 3 9 De-isolate the excavator 1912
3 Superstructure 1913
3 1 Superstructure 1914
3 2 Machinery House 1916
3 2 1 Machinery House roof 1918
3 2 1 1 Disassembling of the machinery house roof cover plates 1920
3 2 1 2 assembling of the machinery house roof cover plates 1925
3 2 1 3 Disassembling of the traverse with SCR catalysts (t4 equipment) 1930
3 2 1 4 Assembling of the traverse with SCR catalysts (t4 equipment) 1937
3 2 1 5 Disassembling of the traverse with DEF tanks (t4 equipment) 1942
3 2 1 6 Assembling of the traverse with DEF tanks (T4 equipment) 1944
3 2 2 Air intake system 1948
3 2 2 1 Disassembling of the air intake system 1948
3 2 2 2 Assembling of the air intake system 1950
3 2 3 Lubrication pump station 1952
3 2 3 1 Disassembling of the lubrication pump station 1952
3 2 4 assembling of the lubrication pump station 1954
3 2 5 Diesel engine 1956
3 2 5 1 Disassembling of the diesel engine (engine 1 or 2) 1956
3 2 5 2 Assembling of the Diesel engine (engine 1 or 2) 1962
3 2 6 Alternator 1968
3 2 6 1 Disassembling of the alternator 1968
3 2 6 2 Assembling of the alternator 1969
3 2 6 3 Disassembling of the starter motor 1970
3 2 6 4 Assembling of the starter motor 1971
3 2 7 Batteries 1972
3 2 7 1 Disassembling of the batteries 1972
3 2 8 Assembling of the batteries 1974
3 2 9 Engine cooling system 1976
3 2 9 1 Disassembling of the radiator fan assembly 1977
3 2 9 2 Assembling of the radiator fan assembly 1978
3 2 9 3 Disassembling of the radiator fan 1980
3 2 9 4 Assembling of the radiator fan 1982
3 2 9 5 Disassembling of the radiator assembly 1983
3 2 9 6 Assembling of the radiator assembly 1986
3 2 10 Flexible drive coupling 1988
3 2 10 1 Disassembling of the CentaFlex coupling assembly 1988
3 2 10 2 Assembling of the centaflex coupling assembly 1991
3 2 10 3 Replacing the rubber rollers of the CentaFlex coupling 1993
3 2 11 Main pump assemblies 1995
3 2 11 1 Disassembling of the main pump 1996
3 2 11 2 Assembling of the main pumps 2000
3 2 12 Pump distributor gearbox (PTO) 2003
3 2 12 1 Disassembling of the pump distributor gearbox (PTO) 2004
3 2 12 2 Assembling of the pump distributor gearbox (PTO) 2006
3 2 12 3 Disassembling of the control and filter plate 2008
3 2 12 4 Assembling of the control and filter plate 2013
3 2 12 5 Disassembling of the PTO gear oil pump 2017
3 2 12 6 Assembling of the PTO gear oil pump 2019
3 3 Hydraulic System 2020
3 3 1 Hydraulic oil cooler assembly 2020
3 3 1 1 Disassembling of the hydraulic cooler fan and motor 2020
3 3 1 2 Assembling of the hydraulic cooler fan and motor 2023
3 3 1 3 Disassembling of the hydraulic oil coolers 2025
3 3 1 4 Assembling of the hydraulic oil coolers 2028
3 3 1 5 Disassembling of the hydraulic oil cooler Assembly 2031
3 3 1 6 Assembling of the hydraulic oil cooler frame 2034
3 3 2 Hydraulic oil Tank 2038
3 3 2 1 Disassembling of the main gate valve 2039
3 3 2 2 Assembling of the main gate valve 2042
3 3 2 3 Disassembling of the hydraulic oil tank 2044
3 3 2 4 assembling of the hydraulic oil tank 2050
3 3 3 Main control valve blocks 2055
3 3 3 1 Disassembling of the main control valve blocks I and III 2055
3 3 3 2 Assembling of the main control valve blocks I and III 2059
3 3 3 3 Disassembling of the main control valve blocks II 2062
3 3 3 4 Assembling of the main control valve blocks II 2064
3 3 3 5 Disassembling of the main control valve blocks IV 2066
3 3 3 6 Assembling of the main control valve blocks IV 2068
3 3 3 7 DISASSEMBLING OF THE HIGH PRESSURE FILTERS AT THE MAIN CONTROL VALVE BLOCKS 2070
3 3 3 8 Assembling of the high pressure filters at the main control valve blocks 2073
3 3 3 9 Disassembling of the MRV at the main control valve blocks 2076
3 3 3 10 Assembling of the MRV at the main control valve blocks 2077
3 3 3 11 Disassembling of SRV on main control valve block 2078
3 3 3 12 Assembling of SRV on main control valve blocks 2079
3 3 3 13 Disassembling of ACV-/SRV-block on main control valve blocks 2080
3 3 3 14 Assembling of ACV-/SRV-block on main control valve blocks 2082
3 3 4 Distributor manifold 2084
3 3 4 1 Disassembling of the throttle check valves at the distributor manifold 2084
3 3 4 2 Assembling of the throttle check valves at the distributor manifold 2086
3 3 4 3 Disassembling of anti cavitation valves at the distributor manifold 2088
3 3 4 4 Assembling of anti cavitation valves at the distributor manifold 2091
3 3 4 5 Disassembling of the distributor manifold 2094
3 3 4 6 Assembling of the distributor manifold 2097
3 4 Slew system 2100
3 4 1 Slew gear 2101
3 4 1 1 Disassembling of the slew gear 2101
3 4 1 2 Assembling of the slew gear 2104
3 4 1 3 Slew brake valve block 2107
3 4 1 4 Disassembling of the slew brake valve block 2107
3 4 1 5 assembling of the slew brake valve block 2109
3 4 2 Slew motor 2110
3 4 2 1 Disassemble of the slew motor 2111
3 4 2 2 Assembling of the slew motor 2113
3 4 3 Slew parking brake 2116
3 4 3 1 disassembly of the slew parking brake of slew gear type 2063 2117
3 4 3 2 Assembly of the slew parking brake of SLEW GEAR type 2063 2120
3 4 3 3 Disassembling of the slew parking brake of SLEW GEAR type 632770 2123
3 4 3 4 assembling of the slew parking brake of SLEW GEAR type 632770 2126
3 4 4 Slew circle 2128
3 4 4 1 Disassembling of the Slew circle 2129
3 4 4 2 Assembling of the Slew circle 2132
3 4 4 3 Disassembling of the lubrication pinion assembly 2134
3 4 4 4 Assembling of the lubrication pinion assembly 2135
3 5 Operator’s cab 2136
3 5 0 1 Disassembling of the operator’s cab 2137
3 5 0 2 Assembling of the operator’s cab 2141
3 5 1 Cab-mounts 2145
3 5 1 1 Disassembling of the cab-mounts 2145
3 5 1 2 Assembling of the cab-mounts 2147
3 5 2 Front window 2149
3 5 2 1 Disassembling of the front window 2149
3 5 2 2 Assembling of the front window 2150
3 5 3 Operator’s seat 2152
3 5 3 1 Disassembling of the operator’s seat 2152
3 5 3 2 Assembling of the operator’s seat 2153
3 6 Cab base 2154
3 6 1 Disassembling of the cab support frame 2155
3 6 2 Assembling of the cab support frame 2157
3 6 3 Disassembling of the cab base 2159
3 6 4 Assembling of the cab base 2162
3 7 Handrails, Grids, Stairways, ladders and platforms 2165
3 7 1 Handrails 2165
3 7 1 1 Disassembling of the handrails 2165
3 7 1 2 assembling of the handrails 2166
3 7 2 Grids 2168
3 7 2 1 Disassembling of the Grids 2168
3 7 2 2 assembling of the Grids 2169
3 7 3 Hydraulic access Stairway 2170
3 7 3 1 Disassembling of the access stairway 2170
3 7 3 2 Assembling of the access Stairway 2172
3 7 3 3 Disassembling of the access stairway cylinder 2174
3 7 3 4 Assembling of the access Stairway cylinder 2176
3 7 4 Steps 2177
3 7 4 1 Disassembling of the fuel tank step 2177
3 7 4 2 Assembling of the fuel tank step 2178
3 7 5 Platforms 2179
3 7 5 1 Disassembling of the access platform 2179
3 7 5 2 assembling of the access platform 2180
3 7 6 Emergency escape ladders 2181
3 7 6 1 Disassembling of the emergency escape ladder assembly at the cab base 2181
3 7 6 2 Assembling of the emergency escape ladder assembly at the cab base 2183
3 7 6 3 Disassembling of the emergency escape ladder assembly at the machinery house 2184
3 7 6 4 Assembling of the emergency escape ladder assembly at the machinery house 2186
3 8 Counterweight 2188
3 8 1 Disassembling of the counterweight 2189
3 8 2 Assembling of the counterweight 2190
3 9 Fuel tank 2192
3 9 1 Disassembling of the fuel tank 2193
3 9 2 Assembling of the fuel tank 2197
3 10 Superstructure lifting 2201
3 10 1 Disassembling the superstructure from the undercarriage 2201
3 10 2 Assembling the superstructure onto the undercarriage 2204
4 1 Undercarriage overview 2208
4 2 Travel system 2210
4 2 1 Crawler track group 2210
4 2 1 1 Changing of the crawler track 2210
4 2 2 Sprocket 2216
4 2 2 1 Disassembling of the sprocket assembly 2216
4 2 2 2 Assembling of the sprocket assembly 2221
4 2 3 Guide wheels 2224
4 2 3 1 Disassembling of the guide wheel assembly 2224
4 2 3 2 Assembling of the guide wheel assembly 2226
4 2 4 Track tensioning accumulators 2229
4 2 4 1 Disassembling of the low pressure accumulators 2229
4 2 4 2 Assembling of the low pressure accumulators 2231
4 2 4 3 Disassembling of the high pressure accumulators 2233
4 2 4 4 Assembling of the high pressure accumulators 2235
4 2 5 Track tension valve block 2236
4 2 5 1 Disassembling of the track tensioning valve block 2236
4 2 5 2 Assembling of the track tensioning valve block 2238
4 2 6 Track tensioning cylinders 2239
4 2 6 1 Disassembling of the track tensioning cylinders 2239
4 2 6 2 Assembling of the track tensioning cylinders 2241
4 2 7 Hydraulic hoses of the track tensioning system 2243
4 2 7 1 Replace the hydraulic hoses inside the center body 2245
4 2 7 2 Replace the hydraulic hoses between center body and crawler frame 2245
4 2 7 3 Replace the hydraulic hoses inside the crawler frame 2247
4 2 7 4 Subsequent work 2247
4 2 8 Travel brake valve block (overspeed valve) 2248
4 2 8 1 Disassembling of the travel brake valve block 2249
4 2 8 2 Assembling of the travel brake valve block 2251
4 2 9 Travel motor 2253
4 2 9 1 Disassembling of the travel motors 2253
4 2 9 2 Assembling of the travel motors 2255
4 2 10 Travel parking brake 2258
4 2 10 1 Travel parking brake overview 2258
4 2 10 2 Disassembling of the travel parking brake type 2063 2262
4 2 10 3 Assembling of the travel parking brake of type 2063 2265
4 2 10 4 Disassembling of the travel parking brake of type 631053 2268
4 2 10 5 Assembling of the travel parking brake of type 631053 2271
4 2 11 Travel gearbox 2274
4 2 11 1 Disassembling of the travel gearbox 2275
4 2 11 2 Assembling of the travel gearbox 2277
4 2 12 Carrier roller 2279
4 2 12 1 Disassembling of the carrier roller assembly 2279
4 2 12 2 Assembling of the carrier roller assembly 2281
4 2 13 Track roller 2283
4 2 13 1 Disassembling of the track roller assembly 2283
4 2 13 2 Assembling of the track roller assembly 2285
4 3 Car body 2287
4 3 1 Disassembling of the car body and the crawler carriers 2287
4 3 2 Assembling of the car body and the crawler carriers 2292
4 3 2 1 Tightening torque for the crawler carrier mounting bolts 2298
4 3 3 Rotary joint 2300
4 3 3 1 Removal of the rotary joint 2300
4 3 3 2 Assembling of the rotary joint 2303
5 Attachment 2307
5 1 Repair procedures 2308
5 1 1 Replacement of bushings at the attachment 2308
5 1 1 1 Disassembling of the bushings 2308
5 1 1 2 Installation of the bushings 2309
5 1 2 General installation instructions for attachment pins 2310
5 2 Backhoe Attachment (BHA) 2312
5 2 1 Overview 2312
5 2 2 Pin Sealing bucket – Steering Rod – bucket link rod 2314
5 2 3 Boom assembly 2316
5 2 3 1 Disassembling of the Boom 2316
5 2 3 2 Assembling of the boom 2318
5 2 3 3 Disassembling of the boom cylinders 2322
5 2 3 4 Assembling of the boom cylinders 2326
5 2 4 Stick assembly 2330
5 2 4 1 Disassembling of the Stick 2331
5 2 4 2 Assembling of the Stick 2336
5 2 4 3 Disassembling of the Stick Cylinders 2340
5 2 4 4 Assembling of the Stick cylinders 2344
5 2 5 Bucket and steering 2348
5 2 5 1 Disassembling of the bucket 2348
5 2 5 2 Assembling of the bucket 2352
5 2 5 3 Disassembling of the Bucket Cylinders 2355
5 2 5 4 Assembling of the Bucket Cylinders 2362
5 2 5 5 Disassembling of the bucket link rod 2370
5 2 5 6 Assembling of the bucket link rod 2373
5 2 5 7 Disassembling of the steering rods 2376
5 2 5 8 Assembling of the steering rods 2382
5 2 6 Hydraulic hoses at the backhoe attachment 2386
5 2 6 1 Replacing of the boom arc hoses 2386
5 2 6 2 Replacing of the lubrication hoses 2389
5 2 6 3 Replacing of the boom cylinder hoses 2390
5 2 6 4 Replacing of the stick cylinder hoses 2393
5 2 6 5 Replacing of the bucket cylinder hoses 2396
5 3 Front Shovel Attachment (FSA) 2399
5 3 1 Overview 2399
5 3 2 Using the Cylinder Mounting Device for Front shovel attachments (PN 967 000 40) 2400
5 3 2 1 Designated usage 2401
5 3 2 2 Non-designated usage 2401
5 3 3 Boom assembly 2402
5 3 3 1 Disassembling of the boom 2402
5 3 3 2 Assembling of the boom 2405
5 3 3 3 Disassembling of the boom cylinders 2408
5 3 3 4 Assembling of the boom cylinders 2413
5 3 4 Stick assembly 2419
5 3 4 1 Disassembling of the stick 2419
5 3 4 2 Assembling of the stick 2424
5 3 4 3 Disassembling of the stick cylinders 2428
5 3 4 4 Assembling of the stick cylinders 2432
5 3 5 Bull Clam bucket 2436
5 3 5 1 Disassembling of the bull clam bucket 2436
5 3 5 2 Assembling of the bull clam bucket 2440
5 3 5 3 Disassembling of the bucket cylinders 2444
5 3 5 4 Assembling of the bucket cylinders 2450
5 3 5 5 Disassembling of the clam cylinders 2456
5 3 5 6 Assembling of the clam cylinders 2461
5 3 5 7 Disassembling of the clam 2466
5 3 5 8 Assembling of the clam 2470
5 3 6 Hydraulic hoses at the Faceshovel attachment 2472
5 3 6 1 Replacing of the boom arc hoses 2472
5 3 6 2 Replacing of the lubrication hoses 2475
5 3 6 3 Replacing of the boom cylinder hoses 2477
5 3 6 4 Replacing of the stick arc hoses 2480
5 3 6 5 Replacing of the stick cylinder hoses 2483
5 3 6 6 Replacing of the bucket cylinder hoses 2486
5 3 6 7 Replacing of the clam cylinder hoses 2488
5 4 Metering valves (grease injectors) at the attachment 2494
5 4 1 Disassembling of the metering valves (grease injectors) 2494
5 4 2 Assembling of the metering valves (grease injectors) 2496
5 5 Ground engaging tools (GET) 2497
5 5 1 Disassembling and assembling of the GET 2497
5 6 Cylinder bypass test 2499
6 Service Information 2501
6 1 Fluids and lubricants 2502
6 2 Lifting Gears 2502
6 3 Safety hints for sling accessory 2504
6 4 Weight tables 2505
6 4 1 Superstructure 2505
6 4 2 Undercarriage 2508
6 4 3 Backhoe attachment (BHA) 2509
6 4 4 Face shovel attachment (FSA) 2510
6 5 Filling capacities 2511
6 6 Torque charts according to KOMATSU company standard 2514
6 6 1 Metric standard thread 2514
6 6 2 Metric fine thread 2515
6 6 3 Cummins motor torques – metric 2516
6 6 4 Cummins motor torques – U S customary 2516
6 6 5 Torque Charts for Flange Joints 2518
6 6 6 Tightening Torque for hydraulic hose connecting nut 2520
6 7 Blind plugs 2521
6 7 1 Dummy plates for hydraulic–flanges 2521
6 7 2 Classification of threads to the nominal width 2523
6 7 3 Plugs and fittings according to DIN 2353 2524
6 8 Conversion table 2525
6 8 1 Method of using the conversion table 2525
6 8 2 Millimeter – inch & kilogram – pound 2526
6 8 3 Liter – U S gallon & liter – U K gallon 2527
6 8 4 Nm- ft lb 2528
6 8 5 Bar – PSI – kPa – MPa 2529
6 8 6 Temperature 2530
6 9 Tools 2531
6 9 1 Standard tool case 2531
6 9 2 Used special tools (Overview) 2533
6 10 Work instructions 2536
6 10 1 Bleeding the track tensioning system 2536
6 10 2 Hints for hydraulic hose installation 2538
6 10 3 Remove / install the crawler carrier 2541
6 10 4 Repair procedure for the radiator assembly 2542
6 10 5 Using the installation tools for hydraulic cylinders 2543
7 Parts & Service News 2545
7 1 List of the parts and service news 2546

DESCRIPTION:

Komatsu PC5500-11 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.

S.V 11/12/24