Komatsu PC7000-11 T2 Hydraulic Mining Excavator Shop Manual PDF

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Komatsu PC7000-11 T2 Hydraulic Mining Excavator Shop Manual – PDF DOWNLOAD

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Komatsu PC7000-11 T2 Hydraulic Mining Excavator Shop Manual – PDF DOWNLOAD 

Language : English
Pages : 2556
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC7000-11 T2 Hydraulic Mining Excavator Shop Manual – PDF DOWNLOAD 

SN 35006 and up

SHOP MANUAL PC7000-11 T2 1
00 FORWORD & 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 12
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 13
2 4 1 UNDERSTANDING THE excavator 13
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 13
2 4 2 1 ENSURING SAFE OPERATION 13
2 4 3 PREPARATIONS FOR SAFE OPERATION 13
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 13
2 4 3 2 INSPECTING THE excavator 13
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 14
2 4 3 4 KEEP excavator CLEAN 14
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 14
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 15
2 4 3 7 IF A PROBLEM IS FOUND 15
2 4 4 FIRE PREVENTION 15
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 15
2 4 4 2 ACTION IF FIRE OCCURS ON PC3000 16
2 4 4 3 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000 17
2 4 4 4 EMERGENCY EXIT FROM OPERATOR’S CAB 17
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR 18
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE excavator 18
2 4 5 2 NO JUMPING ON OR OFF THE excavator 18
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 18
2 4 5 4 WORKING IN HIGH PLACES 18
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 19
2 4 5 6 LEAVING THE excavator 19
2 4 6 BURN PREVENTION 19
2 4 6 1 Hot coolant 19
2 4 6 2 Hot oil 20
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 20
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 20
2 4 9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 21
2 4 9 1 UNAUTHORIZED MODIFICATION 21
2 4 9 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 21
2 4 10 ELECTROMAGNETIC COMPATIBILITY (EMC) 21
2 4 11 PRECAUTIONS AT JOBSITE 22
2 4 11 1 VISIBILITY FROM OPERATOR’S SEAT 23
2 4 11 2 CAMERA SYSTEM WITH MONITORS 23
2 4 11 3 ENSURE GOOD VISIBILITY 23
2 4 11 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 23
2 4 11 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 24
2 4 11 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 24
2 4 11 7 Lightning Strikes 25
2 4 11 8 WORKING ON LOOSE GROUND 25
2 4 11 9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 26
2 4 11 10 VENTILATION OF ENCLOSED AREAS 27
2 4 12 STARTING motor 28
2 4 12 1 WARNING TAG 28
2 4 12 2 CHECKS BEFORE STARTING motor 28
2 4 12 3 PRECAUTION WHEN STARTING motor 28
2 4 12 4 PRECAUTION IN COLD AREAS 29
2 4 13 OPERATION 29
2 4 13 1 CHECKS BEFORE OPERATION 29
2 4 13 2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 30
2 4 13 3 PRECAUTIONS WHEN traveling 31
2 4 13 4 TRAVELING ON SLOPES 32
2 4 13 5 OPERATIONS ON SLOPES 33
2 4 13 6 PROHIBITED OPERATIONS 33
2 4 13 7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 34
2 4 13 8 PARKING THE excavator 34
2 4 13 9 TRANSPORTATION 34
2 5 PRECAUTION FOR MAINTENANCE 35
2 5 1 GENERAL PRECAUTIONS 35
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 36
2 5 1 2 STOP motor FOR MAINTENANCE 37
2 5 1 3 WARNING TAG 38
2 5 1 4 Maintenance safety Switch 39
2 5 1 5 KEEP WORKPLACE CLEAN AND TIDY 39
2 5 1 6 APPOINT LEADER WHEN WORKING WITH OTHERS 39
2 5 1 7 TWO WORKERS FOR MAINTENANCE WHEN THE excavator IS RUNNING 40
2 5 1 8 INSTALLING, REMOVING OR STORING ATTACHMENTS 40
2 5 1 9 PRECAUTIONS WHEN WORKING UNDER THE excavator OR EQUIPMENT 41
2 5 1 10 NOISE 41
2 5 1 11 WHEN USING A HAMMER 41
2 5 1 12 PROPER TOOLS 42
2 5 1 13 ACCUMULATOR 42
2 5 1 14 PERSONNEL 42
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 43
2 5 2 1 PRECAUTION WHEN WELDING 43
2 5 2 2 BATTERY HANDLING 43
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 44
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 45
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 46
2 5 3 3 REPLACEMENT OF HOSE LINES 46
2 5 3 4 INSPECTION OF HOSE LINES 46
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 47
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 47
2 5 3 7 AIR CONDITIONING MAINTENANCE 47
2 5 3 8 COMPRESSED AIR 48
2 5 3 9 WASTE MATERIALS 48
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 49
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 49
2 6 2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS 49
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 49
2 7 SPECIAL SAFETY EQUIPMENT 50
2 7 1 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB 51
2 7 2 OBJECT HANDLING 51
2 7 3 LIGHTING 51
2 7 4 WARNING BEACON 51
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 51
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 51
2 7 5 2 INSTRUCTIONS FOR USE 53
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 55
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 55
2 7 5 5 INSTRUCTIONS FOR USE 57
01 SPECIFICATION 59
SPECS PC7000-11 61
10 STRUCTURE & FUNCTION 69
TOC 71
1 Introduction 83
1 1 Foreword 84
1 2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining excavators 85
1 3 Explanation of abbreviations 86
1 4 Diagrams and illustrations in this manual 87
2 Specifications 89
2 1 Lifting Gears 90
2 2 Safety hints for sling accessory 92
2 3 Standard Tightening Torque Chart 93
2 4 Conversion Table 94
2 5 Blind plugs 100
2 6 Classification of threads to the nominal width 102
2 7 Plugs and fittings according to ISO 8434-1 / DIN 2353 103
3 Main assembly groups 105
3 1 General layout 106
3 2 Superstructure 108
3 2 1 Side view 108
3 2 2 Superstructure top view 110
3 3 Machinery house 112
3 4 Hydraulic oil tank 114
3 5 Hydraulic oil cooler 116
3 6 Fuel tank with Wiggins service system VR300 118
3 7 Cab support 120
3 8 Operator’s cab 122
3 9 Main control blocks (FSA) 124
3 10 Slew machinery 126
3 10 1 Slew gear type 2063 126
3 10 2 Slew gear type 632770 128
3 11 Undercarriage 130
3 12 Slew ring 132
3 13 Attachment 134
3 13 1 Front Shovel Attachment (FSA) 134
3 13 2 Backhoe Attachment (BHA) 136
3 14 Counterweight 138
3 15 PPC safety circuit 140
3 16 KomVision camera system 143
4 Drive 145
4 1 Prime drive assembly 146
4 2 Engine and PTO mounts 148
4 2 1 Checks and adjustments 149
4 3 Flexible coupling 150
4 3 1 Information for maintenance 152
4 3 2 Coupling elements 153
4 3 3 Separation and assembly of the coupling inner and outer part 154
4 3 4 Operation troubles, causes, and rectification 155
4 4 Radiator assembly and fan drive 156
4 4 1 Radiator assembly 156
4 4 2 Fan motor 158
4 4 3 Expansion tanks 159
4 4 4 Radiator fan drive 160
4 4 4 1 Hydraulic schematic of radiator fan drive 162
4 4 5 Fan pump type HPV190 164
4 4 6 Radiator fan speed testing & adjustment 166
4 4 6 1 Testing & readjustment procedure 168
4 4 6 2 Basic adjustment procedure 169
4 5 Pump distributor gearbox (PTO) 170
4 5 1 PTO oil filling, oil level, and ventilation 172
4 5 2 Pump spline lubrication 174
4 5 2 1 Oil level in main pump & gear oil pump drive shaft housing 175
4 5 3 PTO lubrication and cooling 176
4 5 3 1 Hydraulic components and schematic of cooling circuit-1 176
4 5 3 2 Schematic overview – PTO gear oil cooling circuit-1 178
4 5 3 3 Checks and adjustments 180
4 6 Hydraulic pumps – location, drive speed and flow rates 182
4 7 Air cleaner 186
4 8 Fuel filtration system stage 1 (HYDAC) 188
4 8 1 Status light & flash lights for fuel filtration 190
5 Hydraulic oil tank 193
5 1 General layout 194
5 1 1 Hydraulic oil level definition 196
5 2 Hydraulic oil tank, location of the electric equipment 198
5 3 Suction oil tank with strainers 200
5 4 Return oil collector pipe with strainer 202
5 5 Back pressure valve 204
5 6 Transfer pump 206
5 7 Return and leak oil filter 208
5 8 Breather filter 210
6 Hydraulic oil cooling 213
6 1 Overall view on the hydraulic oil cooling 214
6 2 Function of the hydraulic oil cooling circuit 216
6 3 Adjustment of the back pressure valve 218
6 4 Stepless cooler fan RPM control 220
6 4 1 Pressure limiting valves 222
6 4 2 Components of the fan drive circuits 224
6 4 3 Fan pump type HPV190 226
6 5 Oil cooler fan speed 228
6 6 OC fan resonance speed 230
6 7 Basic adjustment procedure for pressure limiting valves 232
6 8 Hydraulic oil temperature charts 233
7 Controlling 235
7 1 General layout 236
7 2 Control and filter panels – location of components 238
7 2 1 Control and filter panel engine 1 (rear) 238
7 2 2 Valve cartridge block engine 1 (rear) 240
7 2 3 Control and filter panel engine 2 (front) 242
7 3 Pilot pressure supply and adjustments 244
7 3 1 Pilot pressure control (PPC) circuit 244
7 3 2 Pilot pressure operating the main block spools 246
7 3 3 Checks and adjustment of pilot pressure 248
7 3 4 Remote control valves arrangement 250
7 4 Function of the electro hydraulic control system 252
7 4 1 Illustration of the joystick signal flow (example) 254
7 5 Hand lever (joystick) control 256
7 5 1 Voltage supply of LH hand lever 20S020 257
7 5 2 Direction signal course from hand lever to controllers 258
7 5 3 Double ratiometric* output diagram 259
7 6 Foot pedal control 260
7 6 1 Voltage supply of foot pedal 20S021a 262
7 6 2 Direction signal course from foot pedal to controllers 263
7 6 3 Double ratiometric* output diagram for 2 direction pedal 264
7 6 4 Single ratiometric* output diagram for 1 direction pedal 265
7 7 Hand lever & foot pedal monitoring 266
7 7 1 Lever monitoring screens (example) 267
7 7 2 Valve monitoring screen (example) 270
7 8 Valve solenoid adjustment 272
7 8 1 Overview sol min/max current & adjustment range 273
7 9 ACCEL & DECEL time adjustment 274
7 9 1 Accel & Decel times 274
8 Components 277
8 1 Main control blocks and high pressure screens (FSA) 278
8 2 Main control blocks with valves and hp screens (FSA) 280
8 3 Main control blocks with valves and hp screens (BHA) 282
8 4 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) 284
8 5 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) 286
8 6 Restrictor block with secondary relief valve 288
8 7 Anti-cavitation valve (ACV) block 290
8 7 1 Single ACV block on the manifold 290
8 7 2 Double ACV block on the manifold 292
8 8 Remote control valves 294
8 9 4/3 Directional solenoid valves 296
8 10 Proportional solenoid valves 298
8 11 High-pressure screen 300
8 12 Control blocks and valves 302
8 12 1 Main control blocks I, II, III (4 spool blocks) 302
8 12 1 1 Spin lock for valve blocks (ND52) 303
8 12 2 Hydraulic diagram of a 4-spool valve block 304
8 12 3 Spool types 305
8 12 4 Spool positions (control block) 308
8 12 5 MRV, SRV, and ACV 310
8 12 6 Load holding valve 312
8 12 7 Main control block IV (slew) 314
8 13 Travel brake valve 316
8 14 Pressure reducing valve 318
8 15 4/2 Directional valves 320
8 16 Pressure double stage valve 322
8 17 Hydraulic cylinder 324
8 17 1 Hydraulic cylinder – Chevron® sealing 324
8 17 2 Hydraulic cylinder – Chesterton® 11KE sealing 326
8 17 3 Cylinder data markings 328
9 Main hydraulic pumps, pump regulation, valve control & monitoring system 329
9 1 General 330
9 1 1 Pump data 332
9 2 Main pumps 336
9 2 1 Hydraulic pump type HPV375+375 336
9 2 1 1 Main pump sectional drawings 338
9 2 2 Servo valve 340
9 2 2 1 VC valve  servo piston 341
9 2 3 EPC valve 346
9 3 Electronic pump regulation system 348
9 3 1 Cut-off function 350
9 3 2 Slew control 351
9 3 3 Temperature control 351
9 3 3 1 Hydraulic oil temperature charts 352
9 4 Pump & valve controllers 354
9 4 1 Service menu screen 356
9 4 2 Service ID 356
9 4 3 Service menu – 01 Monitoring 356
9 5 Monitoring PUMP 1 controller 357
9 5 1 Monitoring PUMP 2 controller 358
9 6 Monitoring VALVE 0 controller 359
9 7 Monitoring VALVE 1 controller 360
9 8 Monitoring VALVE 2 controller 361
9 9 Using machine monitor functions for monitoring 362
9 10 Error indication of pump controllers 362
9 11 Adjustments for pump controllers 363
9 11 1 Adjustments for PUMP 1 controller 363
9 11 2 Adjustments for PUMP 2 controller 364
9 12 Details on adjustable parameters 365
9 12 1 PUMP1 controller 365
9 12 2 PUMP2 controller 367
9 12 3 Description of the primary p-factor 369
9 12 4 Pump sol min current values according to pump type plate 370
9 12 5 Pump sol max current values according to pump type plate 371
9 13 Checks and adjustments 372
9 13 1 Engine power check 372
9 13 2 Cut-off function check 374
9 13 2 1 Cut-off for clam close (FSA only) 375
9 14 Engine speed sensors (pick-up) 376
9 14 1 General 377
9 14 2 Engine speed sensor (pick-up) adjustment 377
9 14 3 In case of problems – when correct speed sensor adjustment is guaranteed 378
10 Operating hydraulics 381
10 1 General 382
10 1 1 Allocation of pumps and main valve blocks 384
10 2 Spool functions (FSA) 386
10 2 1 Floating function for boom and stick cylinders 386
10 2 2 Spool functions (BHA) 388
10 3 Hydraulics for the attachment cylinders 390
10 3 1 Electric / hydraulic flowchart “Boom UP” (FSA) 390
10 3 2 Electric / hydraulic flowchart “boom up” (BHA) 392
10 3 3 Electric / hydraulic flowchart “boom down” (FSA), single movement and Auto-float ON 394
10 3 4 Electric / hydraulic flowchart “boom down” (FSA), Auto-float OFF – button 20S095 pressed and single movement 396
10 3 5 Electric / hydraulic flowchart “Boom down” (BHA) 398
10 3 6 Electric / hydraulic flowchart “Stick out” (FSA) 400
10 3 7 Electric / hydraulic flowchart “Stick out” (BHA) 402
10 3 8 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float ON and single movement 404
10 3 9 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float OFF – 20S098 pressed & single movement 406
10 3 10 Electric / hydraulic flowchart “Stick in” (BHA) 408
10 3 11 Electric / hydraulic flowchart “Bucket fill” (FSA) 410
10 3 12 Electric / hydraulic flowchart “Bucket fill” (BHA) 412
10 3 13 Electric / hydraulic flowchart “Bucket dump” (FSA) 414
10 3 14 Electric / hydraulic flowchart “Bucket dump” (BHA) 416
10 3 15 Electric / hydraulic flowchart “Clam open” (FSA) 418
10 3 16 Electric / hydraulic flowchart “Clam close” (FSA) 420
10 3 17 Checks & adjustments of main relief valve (MRV) 422
10 3 18 Checks and adjustments of the secondary relief valves (SRV) 424
10 3 18 1 Boom cylinders, piston side (BHA & FSA), boom up 424
10 3 18 2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down 428
10 3 18 3 Stick cylinders, piston side (FSA), stick out 432
10 3 18 4 Stick cylinders, piston side (BHA), stick in 436
10 3 18 5 Stick cylinders, piston rod side (FSA), stick in 440
10 3 18 6 Stick cylinders, piston rod side (BHA), stick out 444
10 3 18 7 Bucket cylinders, piston side (FSA), bucket fill 448
10 3 18 8 Bucket cylinders, piston side (BHA), bucket fill 452
10 3 18 9 Bucket cylinders, piston rod side (FSA), bucket dump 456
10 3 18 10 Bucket cylinders, piston rod side (BHA), bucket dump 460
10 3 18 11 Clam cylinders, piston rod side (FSA), clam open 464
10 3 18 12 Clam cylinders, piston side (FSA), clam close 468
10 3 19 Checks and adjustments of cycle times 472
10 3 19 1 Checks and adjustments of boom lowering speed (FSA) 472
10 3 19 2 Checks and adjustments of boom lowering speed (BHA) 476
10 3 19 3 Checks and adjustments of stick retract speed (FSA) 480
10 3 19 4 Checks and adjustments of stick retract speed (BHA) 484
10 3 19 5 Checks and adjustments of bucket dump speed (FSA) 488
10 3 19 6 Checks and adjustments of bucket dump speed (BHA) 492
10 3 19 7 Checks and Adjustment of bucket Curl Speed (BHA) 496
10 3 19 8 Checks and adjustments of clam close speed (FSA) 500
10 4 Hydraulics for the slew circuit 502
10 4 1 Slew circuit with variable slew motors 502
10 4 2 Slew motor (variable displacement) 506
10 4 2 1 Hydraulic slew motor – displacement control 508
10 4 3 Slew gearbox type 2063 510
10 4 4 Slew gearbox type 632770 512
10 4 5 Slew parking brake (on slew gear type 2063) 514
10 4 6 Slew parking brake (on slew gear type 632770) 516
10 4 7 Slew brake valve 518
10 4 8 Flushing circuit 522
10 4 9 Electric / hydraulic flowchart “Slew left” FSA 524
10 4 10 Electric / hydraulic flowchart “Slew left” BHA 526
10 4 11 Electric / hydraulic flowchart “Slew right” FSA 528
10 4 12 Electric / hydraulic flowchart “Slew right” BHA 530
10 4 13 Checks and adjustments for the slew circuit 532
10 4 13 1 Pressure checks & adjustments – double stage valve (DSV) 533
10 4 13 2 Checks & adjustments – brake pilot pressure 535
10 4 13 3 Checks & adjustments – slew speed 536
10 4 14 Function check for hydraulic slew brake 538
10 4 15 Function check for slew parking brake 540
10 4 15 1 Slew parking brake release pressure check 540
10 5 Hydraulics for the travel circuit 542
10 5 1 Travel circuit 542
10 5 2 Travel motor 546
10 5 3 Rotary joint 548
10 5 4 Travel gearbox 550
10 5 4 1 Travel gearbox type 2063 550
10 5 4 2 Travel gearbox type 631053 552
10 5 5 Travel parking brake 554
10 5 5 1 Travel parking brake on travel gear type 2063 554
10 5 5 2 Travel parking brake on travel gear type 631053 555
10 5 5 3 Travel brake valve 556
10 5 6 Electric / hydraulic flowchart “travel forward” 558
10 5 7 Electric / hydraulic flowchart “travel backwards” 560
10 5 8 Checks and adjustments 562
10 5 8 1 Checks and adjustments for travel circuit 562
10 5 8 2 Function check for the travel parking brake 565
11 Hydraulic track tensioning system 567
11 1 General 568
11 2 Functional description 572
11 3 Double stage valve 574
11 4 Tensioning cylinder 576
11 5 Adjustments / checks 578
12 Access stairway, hydraulically operated 581
12 1 Overview 582
12 2 Function of the hydraulically operated access stairway 584
12 3 Adjustments / checks 588
13 Central refilling system (Service arm) 591
13 1 Refilling arm location 592
13 2 Function 594
14 Hints for reading the Hydraulic Diagram 597
14 1 General 598
14 2 Hydraulic symbols 600
14 2 1 Lines, unions 601
14 2 2 Components, valves 603
14 2 3 Sensors 603
14 2 4 Valves, valve components 604
14 2 5 Pump, motor, cylinder 608
15 Hints for reading the electric Wiring Diagram 611
15 1 General 612
15 2 Reference code of the electrical components 613
15 2 1 Area code 613
15 2 2 Component identifying letter 614
15 3 Graphical symbols 615
15 4 Concept of the Wiring Diagram 620
15 4 1 Cover page of the Komatsu W/D 620
15 4 2 Example 1 from the schematics in the W/D 622
15 4 3 Example 2 from the schematics in the W/D 624
15 4 4 Table of contents in the W/D (page 1 of 2) 626
15 4 5 Location list 628
15 4 6 Cross reference list for electr components in the W/D 630
15 4 7 Cross reference list for terminals in the W/D 632
15 4 8 Cross reference list for connectors in the W/D 634
15 4 9 Cross reference list for terminal boards in the W/D 636
15 4 10 Connection table 638
15 5 Cable and connector marking 640
15 6 Cable color identification 642
16 Monitoring & Control System 643
16 1 Controller system overview 644
16 2 System layout 646
16 2 1 CAN #1 overview 646
16 2 2 CAN #2 overview 647
16 2 3 CAN #0 overview 648
16 3 Interface connection 649
16 3 1 General description 650
16 4 Machine monitor – Operator level 651
16 5 Main gauge screens 652
16 6 Operator menus 656
16 6 1 Operator menu → ECO Guidance – Operation Records 658
16 6 2 Operator menu → ECO Guidance – Average Fuel Consumption Logs 660
16 6 3 Operator menu → Machine Setting 662
16 6 4 Operator menu → Maintenance 664
16 6 4 1 Reset of ’remaining time’ till next maintenance interval 666
16 6 4 2 Usage limitation 667
16 6 5 Operator menu → Monitor Setting – Screen Adjustment 669
16 6 6 Operator menu → Monitor Setting – Clock Adjustment – Calender 670
16 6 7 Operator menu → Monitor Setting – Clock Adjustment – Time 671
16 6 8 Operator menu → Monitor Setting – Clock Adjustment – 12h/24h Mode 672
16 6 9 Operator menu → Monitor Setting – Clock Adjustment – Daylight Saving Time 673
16 6 10 Operator menu → Monitor Setting – Language 674
16 7 Status indication and errors on the operator level 675
16 7 1 Prompts (status indication) 675
16 7 2 Cautions 676
16 7 3 Emergency shutdown screen 678
16 7 4 Fault levels for error messages 680
16 7 5 Action code level L01 681
16 7 6 Action code level L02 682
16 7 7 Action code level L03 683
16 7 8 Action code level L04 684
16 7 9 Error list 685
16 8 Table of failure codes 686
16 8 1 Table of failure codes for Mechanical Systems PC7000-11 T2 686
16 8 2 Table of failure codes for Electrical Systems PC7000-11 T2 688
16 8 3 Failure codes without monitor indication 702
16 8 4 Additional text information for action codes 702
16 9 Table of C-codes – Diesel engines QSK50 T2 704
16 10 Flow charts of machine monitor screens 712
16 10 1 Flow chart Operator Level 712
16 10 2 Flow chart Service Level 713
16 11 Machine monitor – Service level 714
16 11 1 Entering the Service Level 714
16 11 2 Key symbols (F1 F6) on the Service Level 716
16 11 3 Service Menu selection screens 717
16 12 Service Menu – item 01 Monitoring / Custom 718
16 12 1 Monitoring list for: ENG1 controller 718
16 12 2 Monitoring list for: ENG2 controller 720
16 12 3 Monitoring list for: PUMP1 controller 722
16 12 4 Monitoring list for: PUMP2 controller 725
16 12 5 Monitoring list for: VALVE0 controller 728
16 12 6 Monitoring list for: VALVE1 controller 731
16 12 7 Monitoring list for: VALVE2 controller 734
16 12 8 Monitoring list for: MON (monitor) 736
16 12 9 Monitoring list for: KOM PLS (K+ controller) 738
16 12 10 How to perform the monitoring function 740
16 13 Service Menu – item 02 PM Clinic 742
16 13 1 PM Clinic (General) 742
16 13 2 PM Clinic (Power Check) 743
16 13 3 Functions of PM CLINIC (POWER CHECK) 744
16 14 Service Menu – item 04 Abnormality record 746
16 14 1 Reset error messages 747
16 15 Service Menu – item 05 Maintenance record 748
16 16 Service Menu – item 06 Maintenance Mode Setting 749
16 17 Service Menu – item 07 Snap Shot 750
16 18 Service Menu – item 08 Phone Number Entry 751
16 19 Service menu – item 09 Default 752
16 20 Service Menu – item 10 Unit 754
16 21 Service Menu – item 11 Adjustment 756
16 21 1 Adjustments for: PUMP1 controller 756
16 21 2 Adjustments for: PUMP2 controller 759
16 21 3 Pump sol ’min’ current values according to pump type plate 761
16 21 4 Pump sol ’max’ current values according to pump type plate 762
16 21 5 Adjustments for: VALVE0 controller 763
16 21 6 Accel & Decel times 769
16 21 7 Adjustments for: VALVE2 controller 770
16 21 8 Adjustments for: KOM PLS controller 771
16 21 9 Adjustments for: MON (Monitor) 772
16 21 9 1 Using the Idling Stop Timer 773
16 22 Service Menu – item 12 Machine Configuration 774
16 22 1 Details of Machine Configuration for PC7000-11 T2 775
16 22 2 Changing lever control from EURO to KMG 776
16 22 2 1 Changing lever control from KMG to EURO 776
16 22 3 Changing attachment type from FSA to BHA 778
16 22 3 1 Changing attachment type from BHA to FSA 778
16 22 4 In case of problems during changing procedure for lever control or attachment type 779
16 22 5 Hydraulic Oil & PTO Gear Oil Definition Tables 780
16 22 5 1 Hydraulic oil temperature charts 780
16 22 5 2 PTO gear oil temperature charts 781
16 23 Service Menu – item 13 Abuse function setting 782
16 24 Automatic engine speed control 783
16 24 1 Auto-Deceleration mode 783
16 24 2 Auto Low Idle mode 783
16 24 3 Idling Stop Timer 783
16 25 KOMTRAX Plus controller (UM600) 784
16 26 CR720 controller 788
16 26 1 Location of CR720 controllers 788
16 27 Controller replacement procedure 790
16 27 1 Sequence of the controller replacement procedure 790
16 27 2 After controller replacement 791
17 Lubrication system 793
17 1 General overview SLS & CLS1 / 2 794
17 1 1 General description 795
17 2 Basic function of lubrication systems 796
17 3 Lubrication systems (SLS & CLS1/2) 798
17 3 1 Lubrication pump station 800
17 3 2 General Information on CLS1/2 802
17 3 3 General information on SLS 802
17 3 4 Manual lube activation 802
17 4 Lubrication cycle 803
17 4 1 Operation and control 803
17 4 2 Lubrication cycle – processing 804
17 4 3 Time segments & switch points of a lubrication cycle 805
17 4 4 Lubrication modes 806
17 4 4 1 Automatic lubrication mode 806
17 4 4 2 Manual lubrication mode 806
17 4 4 3 Reduced pause time for service 806
17 5 Hydraulically driven lube pump 808
17 5 1 Adjustment of lube pump speed 810
17 5 1 1 Stroke speed adjustment 811
17 5 1 2 Working pressure 811
17 6 Lubricant injectors 812
17 6 1 Tightening torques for fittings at grease injectors 813
17 6 2 Description 813
17 6 3 Adjustment of lubricant output 814
17 6 4 Operation principle of lubricant injectors 816
17 6 4 1 Function description 817
17 6 5 Connection of two or more injectors 818
17 7 Vent valve & grease outlet filter 820
17 7 1 Vent valve description 821
17 8 End-line switch 822
17 8 1 Description 823
17 8 2 CLS1/2 end-line switch adjustment 824
17 8 3 SLS end-line switch adjustment 826
17 9 Lubricant level sensors 828
17 9 1 Description 829
17 9 2 Checks 829
17 10 Commissioning 830
17 10 1 Commissioning of CLS 1/2 lubrication system 830
17 10 2 Fine adjustment 831
17 10 3 Commissioning of SLS lubrication system 832
18 Deep temperature equipment (option) 835
18 1 General information 836
18 1 1 Introduction 836
18 1 2 Deep temperature components overview 836
18 1 3 Power supply preconditions for preheating 837
18 1 4 Power requirements for preheating systems 838
18 2 Preheating procedure 839
18 2 1 Global flow chart of the preheating procedure 839
18 2 2 Starting the preheating procedure 840
18 2 3 Preheating of operator’s cab and Diesel engine [coolant system] 841
18 2 4 Preheating of lubricants and superstructure (Diesel) [electric system] 842
18 3 Constant heating of travel motors (TTT equipment below-40°C only) 843
18 4 Component location 844
18 4 1 Electric heating elements for hydraulic & batteries [electric excavator] 844
18 4 2 Electric heating elements for hydraulics [Diesel excavator] 846
18 4 3 Electric heating elements for engines & batteries [Diesel excavator] 848
18 5 Components of TT equipment 850
18 5 1 Preheating components on a Diesel excavator 850
18 5 2 Preheating components on an electric excavator 851
18 5 3 Wiring Diagrams for preheating systems 852
18 5 3 1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 852
18 5 3 2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 853
18 5 3 3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 854
18 5 3 4 Wiring diagram “Suction Oil Manifold Preheating” 855
18 5 3 5 Wiring diagram “PTO Preheating” 856
18 5 3 6 Wiring diagram “Battery heater pads” 857
40 TROUBLESHOOTING 859
1 Introduction 891
1 1 Overview 892
1 1 1 General advice when using troubleshooting charts 892
1 2 General precautions 893
2 General Information for Troubleshooting 895
2 1 Preparations For Work 896
2 2 Precautions During Work 896
2 3 Precautions When Carrying Out Any Operation 897
2 3 1 Precautions when carrying out removal work 897
2 3 2 Precautions when carrying out installation work 897
2 3 3 Precautions when completing the operation 898
2 4 Fundamental Requirements for Trouble shooting 899
2 4 1 Technical documentation 899
2 4 2 Tools 899
2 4 2 1 Reference Guide for Deutsch Removal Tools 902
2 4 3 Personnel 903
2 5 Points To Remember When Trouble- shooting 903
2 6 Sequence Of Events In Troubleshooting 905
2 7 Checks Before Troubleshooting 906
2 8 Handling Of Electric Equipment And Hydraulic Components 907
2 8 1 Points to remember when handling electric equipment 907
2 8 2 Points To Remember When Handling Hydraulic Equipment 909
2 9 General working procedures 912
2 9 1 Air Bleeding of Various Hydraulic Parts 912
2 9 2 Air bleeding from hydraulic pumps 912
2 9 3 Air bleeding from hydraulic cylinders 912
2 10 Cylinder bypass test 913
2 11 Basics about “How to crimp” (with strain relief) 914
2 11 1 Crimp tool & repair kit 914
2 11 2 General 915
2 11 3 Select the required connector components 915
2 11 4 Stripping a wire 916
2 11 5 Crimping 917
2 11 6 Connector assembly after crimping 918
2 12 Cable Shielding 919
3 Mounting Locations and Connector Types 921
3 1 Superstructure 922
3 1 1 Superstructure side view 922
3 1 2 Superstructure top view 924
3 2 Location of engine electrical parts 926
3 2 1 Engine side view 926
3 2 2 Engine top view 927
3 2 3 Location of engine remote oil tank sensors 929
3 3 Location of hydraulic components 930
3 3 1 Control and filter panel engine 1 (rear) 930
3 3 2 Valve cartridge block engine 1 (rear) 932
3 3 3 Control and filter panel engine 2 (front) 934
3 3 4 Remote control valves arrangement 936
3 4 View onto SLS or CLS1/2 grease container and lubrication cycle components 938
3 5 Hydraulic oil tank & suction oil tank – Location of electrical components 940
3 6 Hydraulically operated access stairway 942
3 7 Refilling arm 944
3 8 Connector Types Overview 946
4 Standard Value Table for Electrical Components 951
5 Tables for Testing and Troubleshooting 965
5 1 Test Value Tables for Transducers 966
5 1 1 Pump press transducers 966
5 1 2 Hydraulic oil pressure transducers 967
5 1 3 Miscellaneous Pressure Transducers 968
5 1 4 Temperature Transducers 969
5 2 Hydraulic oil temperature charts 970
5 3 PTO gear oil temperature charts 971
5 4 Table of failure codes 972
5 4 1 Table of failure codes for Mechanical Systems PC7000-11 T2 972
5 4 2 Table of failure codes for Electrical Systems PC7000-11 T2 974
5 5 Table of C-codes – Diesel engines QSK50 T2 988
5 6 Tables of Symptom Codes 996
5 6 1 Symptoms of engines and Related electrical systems 996
5 6 2 Symptoms of Hydraulic System 996
5 6 3 Symptoms of Mechanical System 997
5 6 4 Symptoms of Additional Systems 997
5 7 Cable colour identification 998
6 Troubleshooting by Trouble Code 999
B@HANS – Hyd Oil Overheat 1000
Monitoring hydraulic oil temperature 1001
Hydraulic oil temperature charts for message B@HANS 1002
6A1BMA – Trouble Shut-Off (gate) valve not open error 1004
View onto gap of proximity switch 40B031 1005
Wiring Diagram (40B031) for message 6A1BMA 1006
AA10NX – Air Cleaner1 Clogging 1008
AA1FNX – Air Cleaner2 Clogging 1008
View onto engine air cleaner (AA10NX & AA1FNX) 1009
AB00KE – Charge Voltage Low 1010
AB0MKE – Charge Voltage2 Low 1010
Wiring Diagram (alternator) for message AB00KE or AB0MKE 1011
K@3A00 – Fire In System 1012
Configuration information for Fire Suppression System Machinery House 1013
Monitoring information for Fire Suppression System Machinery House 1013
Wiring Diagram (FSS) for message K@3A00 1014
B@F0MA – CLS1 Lubrication System Error 1015
B@CPMA – SLS Lubrication System Error 1016
B@CNMA – CLS2 Lubrication System Error 1017
B@F0N9 – CLS1 pressure increase time too long 1018
B@CNN9 – CLS2 pressure increase time too long 1018
B@CPN9 – SLS pressure increase time too long 1018
Allocation of vent valves and end-of-line switches 1019
Vent valve (62Q507a & 62Q509a & 62Q642a) 1020
Wiring Diagram – lube pump solenoid & vent valve (CLS1/2 & SLS) 1021
B@F0N0 – CLS1 pressure decrease time too long 1022
B@CNN0 – CLS2 pressure decrease time too long 1022
B@CPN0 – SLS pressure decrease time too long 1022
Vent valve (62Q507a & 62Q509a & 62Q642a) 1023
B@F0ZK – CLS1 grease level too low 1024
B@CPZK – SLS grease level too low 1024
Wiring Diagram – grease level sensors (CLS1/2 & SLS) 1025
B@HAZK – Hydraulic oil level too low 1026
Hydraulic oil level in defined excavator position 1027
Wiring Diagram – hydraulic oil level sensor 40B004 1028
B@CBNS – PTO1 Gear Oil Temp High 1029
B@KCNS – PTO2 Gear Oil Temp High 1029
B@CBNS – PTO1 Gear Oil Temp High 1030
View onto the universal pump distributor gearbox (PTO1/2) 1031
B@CBZG – PTO1 Gear Lubrication Error 1032
B@KCZG – PTO2 Gear Lubrication Error 1032
Monitoring PTO1/2 lube oil pressure 1033
Shutdown adjustment for PTO1/2 lube oil pressure 1033
B@H2NX – Breather Filter Clogging 1034
Location of 40B024 and hydraulic oil level definitions 1035
B@M9NX – PTO1 Gear Oil Filter Clogging 1036
B@N8NX – PTO2 Gear Oil Filter Clogging 1036
View onto PTO1/2 gear oil filter with pressure sensor 57B027-1/-2 1037
B@HBNX – Return Oil Filter Clogging 1038
B@L4NX – Leak Oil Filter Clogging 1039
B@L5N9 – Pilot Press X2 Too Low 1040
Valve cartridge block, location of components 1041
B@L5N0 – Pilot Press X2 Too High 1042
Valve cartridge block, location of components 1043
B@BKPQ – Eng Remote Oil Tank1 Empty 1044
B@BLPQ – Eng Remote Oil Tank2 Empty 1044
B@HANX – Screen At Hyd Cooler Entry Clogging 1046
Monitoring screens for 40B165 and 40B166 1046
Hydraulic oil tank & return oil collector pipe with strainer, location of components 1047
AB30MA – Starter Circuit Abnormality 1048
Wiring Diagram for AB30MA 1049
989HMA – Emergency stop line abnormality 1050
Monitoring screens and Wiring Diagram for 989HMA 1051
DGT3MA – PTO1 oil temperature sensor abnormality 1052
Wiring Diagram, monitoring screen, and location of 57B049-1 1053
DGH2MA – Hydraulic oil temp sensor abnormality 1054
Wiring Diagram, monitoring screen, and location of 59B015 1055
DHQ7MA – PTO1 lube pressure sensor abnormality 1056
Monitoring screen, Wiring Diagram, and location of 57B017-1 1057
D1E7KB – Starter cut relay short circuit 1058
Wiring Diagram and monitoring screen – Starter cut relay for message D1E7KB 1059
D1E7KY – Starter cut relay hot short circuit 1060
Wiring Diagram – Starter cut relay for message D1E7KY 1061
DHPEMA – Pump-1/2 pressure sensor abnormality 1062
DHPGMA – Pump-3/4 pressure sensor abnormality 1062
DHPJMA – Pump-5/6 pressure sensor abnormality 1062
Monitoring screen & Wiring Diagram – PWR & GND supply for pump pressure transducers (main pumps 1 3) 1064
DLE2MA – Engine speed sensor abnormality 1066
Monitoring screen and Wiring Diagram – 52B064 -1 for message DLE2MA 1067
DA27KP – 24V sensor power abnormality 1068
Wiring Diagram – 24V sensor power supply for DA27KP 1069
DA26KP – 5V sensor2 power abnormality 1070
Wiring Diagram – 5V sensor power supply for DA26KP 1071
DA2LKA – Operating Lamp Open Circuit(Pump Con) 1072
Wiring Diagram – Operating Lamp Open Circuit(Pump Con) 1073
DA2LKB – Operating Lamp Short Circuit(Pump Con) 1074
Wiring Diagram – Operating Lamp Short Circuit(Pump Con) 1075
DA22KK – Solenoid Power Low Error(Pump Con) 1076
DA22MA – Solenoid Power Circuit Abnormality 1077
Wiring Diagram 1 – monitoring safety power line for DA22MA 1078
Wiring Diagram 2 – 11Q044d for DA22MA 1079
DXAAKA – Pump1 Solenoid open circuit 1080
DXABKA – Pump2 Solenoid open circuit 1080
DXACKA – Pump3 Solenoid open circuit 1080
DXADKA – Pump4 Solenoid open circuit 1080
DXAEKA – Pump5 Solenoid open circuit 1080
DXAFKA – Pump6 Solenoid open circuit 1080
Wiring Diagram – EPC valve control (PUMP1) 1081
DXAAKB – Pump1 Solenoid short circuit 1082
DXABKB – Pump2 Solenoid short circuit 1082
DXACKB – Pump3 Solenoid short circuit 1082
DXADKB – Pump4 Solenoid short circuit 1082
DXAEKB – Pump5 Solenoid short circuit 1082
DXAFKB – Pump6 Solenoid short circuit 1082
Wiring Diagram – EPC valve control (PUMP1) 1083
DWA5KA – CLS pump solenoid open circuit 1084
DWA8KA – SLS pump solenoid open circuit 1084
Wiring Diagram – CLS1/SLS pump solenoid control 1085
DWA5KB – CLS pump solenoid short circuit 1086
DWA8KB – SLS pump solenoid short circuit 1086
Wiring Diagram – CLS1/SLS pump solenoid control 1087
DWA5KY – CLS pump solenoid hot short circuit 1088
DWA8KY – SLS pump solenoid hot short circuit 1088
Wiring Diagram – CLS/SLS pump solenoid / hot short circuit 1089
DWA7KA – CLS line release solenoid open circuit 1090
DWA9KA – SLS lube line release sol open circuit 1090
Wiring Diagram – CLS1/SLS lube line release solenoid control 1091
DWA7KB – CLS line release solenoid short circuit 1092
DWA9KB – SLS lube line release solenoid short circuit 1092
Wiring Diagram – CLS/SLS lube line release solenoid control 1093
DWA7KY – CLS line release sol hot short circuit 1094
DWA9KY – SLS lube line release sol hot short circuit 1094
Wiring Diagram – CLS/SLS lube line release solenoid / hot short circuit 1095
DWAAKA – PTO lube preload solenoid open circuit 1096
Wiring Diagram and monitoring screen for message DWAAKA 1097
DWAAKB – PTO lube preload solenoid short circuit 1098
Wiring Diagram and monitoring screen for message DWAAKB 1099
DWAAKY – PTO lube preload sol hot short circuit 1100
Wiring Diagram for message DWAAKY 1101
D168KB – Oil cooler preload sol relay short circuit 1102
Wiring Diagram and monitoring screen – Relay 11K070 (D168KB) 1103
D1E9KB – Wiper fast relay short circuit 1104
D1ETKB – Wiper slow relay short circuit 1104
D1EBKB – Wiper stop relay short circuit 1104
Wiring Diagram – wiper motor control 1105
D162KB – Horn relay short circuit 1106
Wiring Diagram and monitoring screen – signal horn control 1107
D1F0KB – Engine1/motor1 shutdown relay short circuit 1108
D1F4KB – Engine2/motor2 shutdown relay short circuit 1108
Wiring Diagram and monitoring screen – engine1/2 shutdown relay 11K064-1/2 1109
D1F0KY – Engine1/motor1 shutdown relay hot short 1110
D1F4KY – Engine2/motor2 shutdown relay hot short 1110
Wiring Diagram for D1F0KY / D1F4KY 1111
DWNCKA – Hyd Oil Cooler fan pump1 Sol open circuit 1112
DWNUKA – Hyd Oil Cooler fan pump2 Sol open circuit 1112
Wiring Diagram – Hyd oil cooler fan pump1/2 solenoid 1113
DWNCKB – Hyd Oil Cooler fan pump1 Sol short circuit 1114
DWNUKB – Hyd Oil Cooler fan pump2 Sol short circuit 1114
Wiring Diagram – Hyd oil cooler fan pump1/2 solenoid 1115
DXQ0KA – X1 pilot pressure pump1 Sol open circuit 1116
DXQ1KA – X1 pilot pressure pump2 Sol open circuit 1116
Wiring Diagram – X1 pilot pressure pump1/2 solenoid 1117
DXQ0KB – X1 pilot pressure pump1 Sol short circuit 1118
DXQ1KB – X1 pilot pressure pump2 Sol short circuit 1118
Wiring Diagram – X1 pilot pressure pump1/2 solenoid 1119
DWN5KA – Radiator fan pump1 Sol open circuit 1120
DWNTKA – Radiator fan pump2 Sol open circuit 1120
Wiring Diagram – Radiator fan pump1/2 solenoid 1121
DWN5KB – Radiator fan pump1 Sol short circuit 1122
DWNTKB – Radiator fan pump2 Sol short circuit 1122
Wiring Diagram – Radiator fan pump1/2 solenoid 1123
D110KA – Battery relay open circuit 1124
Wiring Diagram – battery relay 11Q044d 1125
D110KB – Battery relay short circuit 1126
Wiring Diagram – Battery relay 11Q044d 1127
DA29KQ – Model Selection Abnormality 1128
Wiring Diagram and monitoring screen – machine selection PUMP1 (DA29KQ) 1129
DA2YKQ – Motor/Engine Selection Abnormality 1130
Monitoring screen for motor/engine selection PUMP1 1130
DA20KQ – Pump Con Selection Abnormality 1131
Monitoring screen for PUMP1 controller selection 1131
DA20MC – Pump Con Error 1132
DLM8MA – Oil cooler fan1 speed sensor abnormality 1134
Wiring Diagram and monitoring screen – Oil cooler fan1 speed sensor (DLM8MA) 1135
DXAGKA – Pump7 Solenoid open circuit 1136
DXAHKA – Pump8 Solenoid open circuit 1136
DXAJKA – Pump9 Solenoid open circuit 1136
DXAKKA – Pump10 Solenoid open circuit 1136
DXALKA – Pump11 Solenoid open circuit 1136
DXAMKA – Pump12 Solenoid open circuit 1136
Wiring Diagram – EPC valve control (PUMP2) 1137
DXAGKB – Pump7 Solenoid short circuit 1138
DXAHKB – Pump8 Solenoid short circuit 1138
DXAJKB – Pump9 Solenoid short circuit 1138
DXAKKB – Pump10 Solenoid short circuit 1138
DXALKB – Pump11 Solenoid short circuit 1138
DXAMKB – Pump12 Solenoid short circuit 1138
Wiring Diagram – EPC valve control (PUMP2) 1139
DWAEKA – CLS2 pump solenoid open circuit 1140
Wiring Diagram and monitoring screen – CLS2 pump solenoid control 1141
DWAEKB – CLS2 pump solenoid short circuit 1142
Wiring Diagram and monitoring screen – CLS2 pump solenoid control 1143
DWAEKY – CLS2 pump solenoid hot short circuit 1144
Wiring Diagram – CLS2 pump solenoid / hot short circuit 1145
DWAFKA – CLS2 line release solenoid open circuit 1146
Wiring Diagram – CLS2 lube line release solenoid control 1147
DWAFKB – CLS2 line release solenoid short circuit 1148
Wiring Diagram – CLS2 lube line release solenoid control 1149
DWAFKY – CLS2 line release sol hot short circuit 1150
Wiring Diagram – CLS2 lube line release solenoid / hot short circuit 1151
DWABKA – PTO2 lube preload solenoid open circuit 1152
Wiring Diagram and monitoring screen for message DWABKA 1153
DWABKB – PTO2 lube preload solenoid short circuit 1154
Wiring Diagram and monitoring screen for message DWABKB 1155
DWABKY – PTO lube preload sol hot short circuit 1156
Wiring Diagram for message DWABKY 1157
DGT8MA – PTO2 oil temperature sensor abnormality 1158
Wiring Diagram, monitoring screen, and location of 57B049-2 1159
DGE5MA – Ambient air temp sensor abnormality 1160
Wiring Diagram and monitoring screen for message DGE5MA 1161
DHQ8MA – PTO2 lube pressure sensor abnormality 1162
Monitoring screen, Wiring Diagram, and location of 57B017-2 1163
DCH3KB – Fuel filter heating short circuit 1164
Wiring Diagram and monitoring screen for message DCH3KB 1165
DCH3KY – Fuel filter heating hot short circuit 1166
Wiring Diagram for message DCH3KY 1167
DCH4KB – Fuel filter drain pipe heating short 1168
Wiring Diagram and monitoring screen for message DCH4KB 1169
DCH4KY – Fuel filter drain pipe heating hot short 1170
Wiring Diagram for message DCH4KY 1171
AB3EMA – Starter Circuit Abnormality 1172
Wiring Diagram for AB3EMA 1173
D1EEKB – Starter cut relay short circuit 1174
Wiring Diagram and monitoring screen – Starter cut relay for message D1EEKB 1175
D1EEKY – Starter cut relay hot short circuit 1176
Wiring Diagram – Starter cut relay for message D1EEKY 1177
FF11KB – Starter power cut relay1 short circuit 1178
Wiring Diagram and monitoring screen – Starter power cut relay for message FF11KB 1179
FF11KY – Starter power cut relay1 hot short circuit 1180
Wiring Diagram – Starter power cut relay1 hot short circuit for message FF11KY 1181
FF11LK – Starter power cut relay1 abnormality 1182
FF12LK – Starter power cut relay2 abnormality 1184
DBZ7KP – 24V sensor power abnormality 1186
Wiring Diagram – 24V sensor power supply for DBZ7KP 1187
DBZ6KP – 5V sensor2 power abnormality 1188
Wiring Diagram – 5V sensor power supply for DBZ6KP 1189
DBZLKA – Operating Lamp Open Circuit(Pump2 Con) 1190
Wiring Diagram – Operating Lamp Open Circuit(Pump2 Con) 1191
DBZLKB – Operating Lamp Short Circuit(Pump2 Con) 1192
Wiring Diagram – Operating Lamp Short Circuit(Pump2 Con) 1193
DHPLMA – Pump-7/8 pressure sensor abnormality 1194
DHPNMA – Pump-9/10 pressure sensor abnormality 1194
DHPQMA – Pump-11/12 pressure sensor abnormality 1194
Monitoring screen & Wiring Diagram – PWR & GND supply for pump pressure transducers (main pumps 4 6) 1196
DBZ2KK – Solenoid Power Low Error(Pump2 Con) 1197
DLE6MA – Engine2 speed sensor abnormality 1198
Monitoring screen and Wiring Diagram – 52B064-2 for message DLE6MA 1199
DBZ9KQ – Model Selection Abnormality 1200
Wiring Diagram and monitoring screen – machine selection PUMP2 (DBZ9KQ) 1201
DBZWKQ – Motor/Engine Selection Abnormality 1202
Monitoring screen for motor/engine selection PUMP2 1202
DBZ0KQ – Pump2 Con Selection Abnormality 1203
Monitoring screen for PUMP2 controller selection 1203
DBZ0MC – Pump2 Con Error 1204
DLMAMA – Oil cooler fan2 speed sensor abnormality 1206
Wiring Diagram and monitoring screen – Oil cooler fan2 speed sensor (DLMAMA) 1207
DDABL4 – Lock lever switch mismatch 1208
DDXAL4 – Ladder up position proximity switch mismatch 1209
DDXBL4 – Service arm upper position proximity switch mismatch 1210
DKURMA – R lever right-left potentio abnormality 1212
Wiring Diagram – right lever right-left potentiometer input (DKURMA) 1213
DKUSMA – R lever right-left redu pot abnorm(VALVE/M) 1214
Wiring Diagram – right lever redundant right-left potentiometer input (DKUSMA) 1215
DKUQL8 – R lever right-left potentio error 1216
Wiring Diagram – right lever main + redundant right-left signal voltage (DKUQL8) 1217
DKUQL4 – R lever right-left sig mismatch(VALVE/M) 1218
Wiring Diagram – R lever right-left redundant signal input at VALVE0 and VALVE1 1219
DKUNMA – R lever front-back potentio abnormality 1220
Wiring Diagram – right lever front-back potentiometer input (DKUNMA) 1221
DKUPMA – R lever front-back redu pot abnorm(VALVE/M) 1222
Wiring Diagram – right lever redundant front-back potentiometer input (DKUPMA) 1223
DKUML8 – R lever front-back potentio error 1224
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8) 1225
DKUML4 – R lever front-back sig mismatch(VALVE/M) 1226
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1 1227
DKUXMA – Left lever right-left potentio abnormality 1228
Wiring Diagram – left lever right-left potentiometer input (DKUXMA) 1229
DKUYMA – L lever right-left redu pot abnorm(VALVE/M) 1230
Wiring Diagram – left lever redundant right-left potentiometer input (DKUYMA) 1231
DKUWL8 – L lever right-left potentio error 1232
Wiring Diagram – left lever main + redundant right-left signal voltage (DKUWL8) 1233
DKUWL4 – L lever right-left sig mismatch(VALVE/M) 1234
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1 1235
DKUUMA – L lever front-back potentio abnormality 1236
Wiring Diagram – left lever front-back potentiometer input (DKUUMA) 1237
DKUVMA – L lever front-back redu pot abnorm(VALVE/M) 1238
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/M) for DKUVMA 1239
DKUTL8 – L lever front-back potentio error 1240
Wiring Diagram – L lever front-back potentio error (DKUTL8) 1241
DKUTL4 – L lever front-back sig mismatch(VALVE/M) 1242
Wiring Diagram – L lever front-back sig mismatch(VALVE/M) for DKUTL4 1243
DKW1MA – R pedal potentio abnormality 1244
Wiring Diagram – R pedal potentio abnormality (DKW1MA) 1245
DKW2MA – R pedal redundant pot abnormality(VALVE/M) 1246
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA 1247
DKW0L8 – R pedal potentio error 1248
Wiring Diagram – R pedal potentio error (DKW0L8) 1249
DKW0L4 – R pedal signal mismatch(VALVE/M Con) 1250
Wiring Diagram – R pedal signal mismatch(VALVE/M Con) for DKW0L4 1251
DKW4MA – L pedal potentio abnormality 1252
Wiring Diagram – L pedal potentio abnormality (DKW4MA) 1253
DKW5MA – L pedal redundant pot abnormality(VALVE/M) 1254
Wiring Diagram – L pedal redundant pot abnormality(VALVE/M) for DKW5MA 1255
DKW3L8 – L pedal potentio error 1256
Wiring Diagram – L pedal potentio error (DKW3L8) 1257
DKW3L4 – L pedal signal mismatch(VALVE/M Con) 1258
Wiring Diagram – L pedal signal mismatch(VALVE/M Con) for DKW3L4 1259
DKW7MA – Clam open potentio abnormality 1260
Wiring Diagram – Clam open potentio abnormality (DKW7MA) 1261
DKW8MA – Clam open redu pot abnormality(VALVE/M) 1262
Wiring Diagram – Clam open redu pot abnormality(VALVE/M) for DKW8MA 1263
DKW6L8 – Clam open potentio error 1264
Wiring Diagram – Clam open potentio error (DKW6L8) 1265
DKW6L4 – Clam open signal mismatch(VALVE/M Con) 1266
Wiring Diagram – Clam open signal mismatch(VALVE/M Con) for DKW6L4 1267
DKWAMA – Clam close potentio abnormality 1268
Wiring Diagram – Clam close potentio abnormality (DKWAMA) 1269
DKWBMA – Clam close redundant pot abnorm(VALVE/M) 1270
Wiring Diagram – Clam close redundant pot abnorm(VALVE/M) for DKWBMA 1271
DKW9L8 – Clam close potentio error 1272
Wiring Diagram – Clam close potentio error (DKW9L8) 1273
DKW9L4 – Clam close signal mismatch(VALVE/M Con) 1274
Wiring Diagram – Clam close signal mismatch(VALVE/M Con) for DKW9L4 1275
DKWDMA – Hydraulic slew brake potentio abnormality 1276
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA) 1277
DKWEMA – Hyd slew brake redu pot abnorm(VALVE/M) 1278
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/M) for DKWEMA 1279
DKWCL8 – Hydraulic slew brake potentio error 1280
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8) 1281
DKWCL4 – Hyd slew brake sig mismatch(VALVE/M) 1282
Wiring Diagram – Hyd slew brake sig mismatch(VALVE/M) for DKWCL4 1283
DBWLKA – Operating Lamp Open Circuit(VALVE/M Con) 1284
Wiring Diagram – Operating Lamp Open Circuit(VALVE/M Con) 1285
DBWLKB – Operating Lamp Short Circuit(VALVE/M Con) 1286
Wiring Diagram – Operating Lamp Short Circuit(VALVE/M Con) 1287
DWNPKA – Service arm up solenoid open circuit 1288
Wiring Diagram and monitoring screen for message DWNPKA 1289
DWNPKB – Service arm up solenoid short circuit 1290
Wiring Diagram and monitoring screen for message DWNPKB 1291
DWNPKY – Service arm up solenoid hot short circuit 1292
Wiring Diagram and monitoring screen for message DWNPKY 1293
DWNQKA – Service arm down solenoid open circuit 1294
Wiring Diagram and monitoring screen for message DWNQKA 1295
DWNQKB – Service arm down solenoid short circuit 1296
Wiring Diagram and monitoring screen for message DWNQKB 1297
DWNQKY – Service arm down solenoid hot short circuit 1298
Wiring Diagram and monitoring screen for message DWNQKY 1299
DW4BKA – Travel parking brake solenoid open circuit 1300
Wiring Diagram and monitoring screen for message DW4BKA 1301
DW4BKB – Travel parking brake sol short circuit 1302
Wiring Diagram and monitoring screen for message DW4BKB 1303
DW4BKY – Travel parking brake sol hot short circuit 1304
Wiring Diagram and monitoring screen for message DW4BKY 1305
DW4BMA – Travel parking brake solenoid circuit abnormality 1306
Wiring Diagram and monitoring screen for DW4BMA 1307
DW45KA – Slew parking brake solenoid open circuit 1308
Wiring Diagram and monitoring screen for message DW45KA 1309
DW45KB – Slew parking brake solenoid short circuit 1310
Wiring Diagram and monitoring screen for message DW45KB 1311
DW45KY – Slew parking brake sol hot short circuit 1312
Wiring Diagram and monitoring screen for message DW45KY 1313
DW45MA – Slew parking brake solenoid circuit abnormality 1314
Wiring Diagram and monitoring screen for DW45MA 1315
DXN2KA – Boom1 epc solenoid open circuit (BHA) 1316
DXN3KA – Stick1 epc solenoid open circuit 1316
DXNJKA – Bucket1 epc solenoid open circuit 1316
DXNHKA – Travel1 left epc solenoid open circuit 1316
DXN4KA – Boom2 epc solenoid open circuit 1316
DXN5KA – Clam2 epc solenoid open circuit (FSA) 1316
DXN6KA – Stick2 epc solenoid open circuit (BHA) 1316
DXN8KA – Bucket2 epc solenoid open circuit 1316
DXNBKA – Bucket3 epc solenoid open circuit 1316
DXNCKA – Boom3 epc solenoid open circuit 1316
DXNLKA – Stick3 epc solenoid open circuit 1316
DXNKKA – Travel3 right epc solenoid open circuit 1316
DXNMKA – Slew4 epc solenoid open circuit 1316
Details of above 6-digit failure codes (FSA & BHA) 1317
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623 1318
Wiring Diagram for EPC 61K624 – 61K625 1319
Wiring Diagram for EPC 61K626 – 61K627 – 61K628 – 61K629 1320
Wiring Diagram for EPC 61K630 – 61K631 – 61K632 1321
Monitoring screens as an example 1322
DXN2KB – Boom1 epc solenoid short circuit (BHA) 1324
DXN3KB – Stick1 epc solenoid short circuit 1324
DXNJKB – Bucket1 epc solenoid short circuit 1324
DXNHKB – Travel1 left epc solenoid short circuit 1324
DXN4KB – Boom2 epc solenoid short circuit 1324
DXN5KB – Clam2 epc solenoid short circuit (FSA) 1324
DXN6KB – Stick2 epc solenoid short circuit (BHA) 1324
DXN8KB – Bucket2 epc solenoid short circuit 1324
DXNBKB – Bucket3 epc solenoid short circuit 1324
DXNCKB – Boom3 epc solenoid short circuit 1324
DXNLKB – Stick3 epc solenoid short circuit 1324
DXNKKB – Travel3 right epc solenoid short circuit 1324
DXNMKB – Slew4 epc solenoid short circuit 1324
Details of above 6-digit failure codes (FSA & BHA) 1325
DXN2KY – Boom1 epc solenoid hot short circuit (BHA) 1326
DXN3KY – Stick1 epc solenoid hot short circuit 1326
DXNJKY – Bucket1 epc solenoid hot short circuit 1326
DXNHKY – Travel1 left epc solenoid hot short circuit 1326
DXN4KY – Boom2 epc solenoid hot short circuit 1326
DXN5KY – Clam2 epc solenoid hot short circuit (FSA) 1326
DXN6KY – Stick2 epc solenoid hot short circuit (BHA) 1326
DXN8KY – Bucket2 epc solenoid hot short circuit 1326
DXNBKY – Bucket3 epc solenoid hot short circuit 1326
DXNCKY – Boom3 epc solenoid hot short circuit 1326
DXNLKY – Stick3 epc solenoid hot short circuit 1326
DXNKKY – Travel3 right epc solenoid hot short circuit 1326
DXNMKY – Slew4 epc solenoid hot short circuit 1326
Details of above 6-digit failure codes (FSA & BHA) 1327
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 – 61K623 1328
Wiring Diagram for EPC 61K624 – 61K625 1329
Wiring Diagram for EPC 61K626 – 61K627 – 61K628 – 61K629 1330
Wiring Diagram for EPC 61K630 – 61K631 – 61K632 1331
DWACKA – Service arm check valve sol open circuit 1332
Wiring Diagram and monitoring screen for message DWACKA 1333
DWACKB – Service arm check valve sol short circuit 1334
Wiring Diagram and monitoring screen for message DWACKB 1335
DWACKY – Service arm check valveSol hotShortCircuit 1336
Wiring Diagram and monitoring screen for message DWACKY 1337
DWADKA – Ladder speed control solenoid open circuit 1338
Wiring Diagram and monitoring screen for message DWADKA 1339
DWADKB – Ladder speed control sol short circuit 1340
Wiring Diagram and monitoring screen for message DWADKB 1341
DWADKY – Ladder speed control sol hot short circuit 1342
Wiring Diagram – Ladder speed control sol hot short circuit (DWADKY) 1343
DBW5MA – 5V sensor1 power abnormality 1344
DBW6MA – 5V sensor2 power abnormality 1344
Wiring Diagram – 5V power supply and GND output at VALVE0 1348
DBW9KQ – Model Selection Abnormality 1350
Monitoring screen and Wiring Diagram – model selection abnormality (DBW9KQ) 1351
DBWZKQ – Lever control selection abnormality 1352
Monitoring screen & Wiring Diagram – Lever control selection abnormality (DBWZKQ) 1353
DBWYKQ – Attachment selection abnormality 1354
Monitoring screen & Wiring Diagram – Attachment selection abnormality (DBWYKQ) 1355
DBW2KK – Solenoid Power Low Error(VALVE/M Con) 1356
Wiring Diagram 1 for message DBW2KK 1358
Wiring Diagram 2 for message DBW2KK 1359
DBW0KQ – VALVE/M Con Selection Abnormality 1360
Monitoring screen and Wiring Diagram for message DBW0KQ 1361
DBW0MA – VALVE/M Con Error 1362
DDDWMC – Ladder operation switch abnormality 1364
Wiring Diagram and monitoring screen for message DDDWMC 1365
DKWHMA – R lever right-left redu pot abnorm(VLV/S1) 1366
Wiring Diagram – right lever redundant right-left potentiometer input (DKWHMA) 1367
DKWFL4 – R lever right-left sig mismatch(VALVE/S1) 1368
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1 1369
DKWLMA – R lever front-back redu pot abnorm(VLV/S1) 1370
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA) 1371
DKWJL4 – R lever front-back sig mismatch(VALVE/S1) 1372
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1 1373
DKWPMA – L lever right-left redu pot abnorm(VLV/S1) 1374
Wiring Diagram – left lever redundant right-left potentiometer input (DKWPMA) 1375
DKWML4 – L lever right-left sig mismatch(VALVE/S1) 1376
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1 1377
DKWSMA – L lever front-back redu pot abnorm(VLV/S1) 1378
Wiring Diagram – L lever front-back redu pot abnorm(VLV/S1) for DKWSMA 1379
DKWQL4 – L lever front-back sig mismatch(VALVE/S1) 1380
Wiring Diagram – L lever front-back sig mismatch(VALVE/S1) for DKWQL4 1381
DKWVMA – R pedal red pot abnormality(VALVE/S1) 1382
Wiring Diagram – R pedal red pot abnormality(VALVE/S1) for DKWVMA 1383
DKWTL4 – R pedal signal mismatch(VALVE/S1 Con) 1384
Wiring Diagram – R pedal signal mismatch(VALVE/S1 Con) for DKWTL4 1385
DKWYMA – L pedal red pot abnormality(VALVE/S1) 1386
Wiring Diagram – L pedal red pot abnormality(VALVE/S1) for DKWYMA 1387
DKWWL4 – L pedal signal mismatch(VALVE/S1 Con) 1388
Wiring Diagram – L pedal signal mismatch(VALVE/S1 Con) for DKWWL4 1389
DKX2MA – Clam open redu pot abnormality(VALVE/S1) 1390
Wiring Diagram – Clam open redu pot abnormality(VALVE/S1) for DKX2MA 1391
DKX0L4 – Clam open signal mismatch(VALVE/S1 Con) 1392
Wiring Diagram – Clam open signal mismatch(VALVE/S1 Con) for DKX0L4 1393
DKX5MA – Clam close redu pot abnormality(VALVE/S1) 1394
Wiring Diagram – Clam close redu pot abnormality(VALVE/S1) for DKX5MA 1395
DKX3L4 – Clam close signal mismatch(VALVE/S1 Con) 1396
Wiring Diagram – Clam close signal mismatch(VALVE/S1 Con) for DKX3L4 1397
DKX8MA – Hyd slew brake redu pot abnorm(VALVE/S1) 1398
Wiring Diagram – Hyd slew brake redu pot abnorm(VALVE/S1) for DKX8MA 1399
DKX6L4 – Hyd slew brake signal mismatch(VALVE/S1) 1400
Wiring Diagram – Hyd slew brake signal mismatch(VALVE/S1) for DKX6L4 1401
DBXLKA – Operating Lamp Open Circuit(VALVE/S1 Con) 1402
Wiring Diagram – Operating Lamp Open Circuit((VALVE/S1 Con) 1403
DBXLKB – Operating Lamp Short Circuit(VALVE/S1 Con) 1404
Wiring Diagram – Operating Lamp Short Circuit(VALVE/S1 Con) 1405
DWNRKB – Ladder up solenoid short circuit 1406
Wiring Diagram and monitoring screen for message DWNRKB 1407
DWNRKY – Ladder up solenoid hot short circuit 1408
Wiring Diagram – Ladder up solenoid hot short circuit (DWNRKY) 1409
DWNRMA – Ladder up solenoid circuit abnormality 1410
Wiring Diagram and monitoring screen for DWNRMA 1411
DW7RKA – Hydraulic slew brake solenoid open circuit 1412
Wiring Diagram and monitoring screen for message DW7RKA 1413
DW7RKB – Hydraulic slew brake sol short circuit 1414
Wiring Diagram and monitoring screen for message DW7RKB 1415
DW7RKY – Hyd slew brake sol hot short circuit 1416
Wiring Diagram – Hyd slew brake sol hot short circuit (DW7RKY) 1417
DWASKA – Bucket1 fill solenoid open circuit 1418
Wiring Diagram and monitoring screen for message DWASKA 1419
DWASKB – Bucket1 fill solenoid short circuit 1420
Wiring Diagram and monitoring screen for message DWASKB 1421
DWASKY – Bucket1 fill solenoid hot short circuit 1422
Wiring Diagram and monitoring screen for message DWASKY 1423
DWAWKA – Bucket1 dump solenoid open circuit 1424
Wiring Diagram and monitoring screen for message DWAWKA 1425
DWAWKB – Bucket1 dump solenoid short circuit 1426
Wiring Diagram and monitoring screen for message DWAWKB 1427
DWAWKY – Bucket1 dump solenoid hot short circuit 1428
Wiring Diagram and monitoring screen for message DWAWKY 1429
DWKAKA – Travel1 left forward sol open circuit 1430
Wiring Diagram and monitoring screen for message DWKAKA 1431
DWKAKB – Travel1 left forward sol short circuit 1432
Wiring Diagram and monitoring screen for message DWKAKB 1433
DWKAKY – Travel1 left forward sol hot short circuit 1434
Wiring Diagram and monitoring screen for message DWKAKY 1435
DWKEKA – Travel1 left backward sol open circuit 1436
Wiring Diagram and monitoring screen for message DWKEKA 1437
DWKEKB – Travel1 left backward sol short circuit 1438
Wiring Diagram and monitoring screen for message DWKEKB 1439
DWKEKY – Travel1 left backward sol hot short circuit 1440
Wiring Diagram and monitoring screen for message DWKEKY 1441
DWBEKA – Boom1 down solenoid open circuit 1442
Wiring Diagram and monitoring screen for message DWBEKA 1443
DWBEKB – Boom1 down solenoid short circuit 1444
Wiring Diagram and monitoring screen for message DWBEKB 1445
DWBEKY – Boom1 down solenoid hot short circuit 1446
Wiring Diagram and monitoring screen for message DWBEKY 1447
DWBAKA – Boom1 up solenoid open circuit 1448
Wiring Diagram and monitoring screen for message DWBAKA 1449
DWBAKB – Boom1 up solenoid short circuit 1450
Wiring Diagram and monitoring screen for message DWBAKB 1451
DWBAKY – Boom1 up solenoid hot short circuit 1452
Wiring Diagram and monitoring screen for message DWBAKY 1453
DWBJKA – Stick1 out solenoid open circuit 1454
Wiring Diagram and monitoring screen for message DWBJKA 1455
DWBJKB – Stick1 out solenoid short circuit 1456
Wiring Diagram and monitoring screen for message DWBJKB 1457
DWBJKY – Stick1 out solenoid hot short circuit 1458
Wiring Diagram and monitoring screen for message DWBJKY 1459
DWBNKA – Stick1 in solenoid open circuit 1460
Wiring Diagram and monitoring screen for message DWBNKA 1461
DWBNKB – Stick1 in solenoid short circuit 1462
Wiring Diagram and monitoring screen for message DWBNKB 1463
DWBNKY – Stick1 in solenoid hot short circuit 1464
Wiring Diagram and monitoring screen for message DWBNKY 1465
DWBBKA – Boom2 up solenoid open circuit 1466
Wiring Diagram (BHA) and monitoring screen for message DWBBKA 1467
Wiring Diagram (FSA) and monitoring screen for message DWBBKA 1468
DWBBKB – Boom2 up solenoid short circuit 1469
Wiring Diagram (BHA) and monitoring screen for message DWBBKB 1470
Wiring Diagram (FSA) and monitoring screen for message DWBBKA 1471
DWBBKY – Boom2 up solenoid hot short circuit 1472
Wiring Diagram for message DWBBKY 1473
DWBFKA – Boom2 down solenoid open circuit 1474
Wiring Diagram (BHA) and monitoring screen for message DWBFKA 1475
Wiring Diagram (FSA) and monitoring screen for message DWBFKA 1476
DWBFKB – Boom2 down solenoid short circuit 1477
Wiring Diagram (BHA) and monitoring screen for message DWBFKB 1478
Wiring Diagram (FSA) and monitoring screen for message DWBFKB 1479
DWBFKY – Boom2 down solenoid hot short circuit 1480
Wiring Diagram for message DWBFKY 1481
DWBXKA – Clam2 close solenoid open circuit 1482
Wiring Diagram and monitoring screen for message DWBXKA 1483
DWBXKB – Clam2 close solenoid short circuit 1484
Wiring Diagram and monitoring screen for message DWBXKB 1485
DWBXKY – Clam2 close solenoid hot short circuit 1486
Wiring Diagram and monitoring screen for message DWBXKY 1487
DWBKKA – Stick2 out solenoid open circuit 1488
Wiring Diagram and monitoring screen for message DWBKKA 1489
DWBKKB – Stick2 out solenoid short circuit 1490
Wiring Diagram and monitoring screen for message DWBKKB 1491
DWBKKY – Stick2 out solenoid hot short circuit 1492
Wiring Diagram and monitoring screen for message DWBKKY 1493
DWBTKA – Clam2 open solenoid open circuit 1494
Wiring Diagram and monitoring screen for message DWBTKA 1495
DWBTKB – Clam2 open solenoid short circuit 1496
Wiring Diagram and monitoring screen for message DWBTKB 1497
DWBTKY – Clam2 open solenoid hot short circuit 1498
Wiring Diagram and monitoring screen for message DWBTKY 1499
DWBPKA – Stick2 in solenoid open circuit 1500
Wiring Diagram and monitoring screen for message DWBPKA 1501
DWBPKB – Stick2 in solenoid short circuit 1502
Wiring Diagram and monitoring screen for message DWBPKB 1503
DWBPKY – Stick2 in solenoid hot short circuit 1504
Wiring Diagram and monitoring screen for message DWBPKY 1505
DWATKA – Bucket2 fill solenoid open circuit 1506
Wiring Diagram (BHA) and monitoring screen for message DWATKA 1507
Wiring Diagram (FSA) and monitoring screen for message DWATKA 1508
DWATKB – Bucket2 fill solenoid short circuit 1509
Wiring Diagram (BHA) and monitoring screen for message DWATKB 1510
Wiring Diagram (FSA) and monitoring screen for message DWATKB 1511
DWATKY – Bucket2 fill solenoid hot short circuit 1512
Wiring Diagram for message DWATKY 1513
DWAXKA – Bucket2 dump solenoid open circuit 1514
Wiring Diagram (BHA) and monitoring screen for message DWAXKA 1515
Wiring Diagram (FSA) and monitoring screen for message DWAXKA 1516
DWAXKB – Bucket2 dump solenoid short circuit 1517
Wiring Diagram (BHA) and monitoring screen for message DWAXKB 1518
Wiring Diagram (FSA) and monitoring screen for message DWAXKB 1519
DWAXKY – Bucket2 dump solenoid hot short circuit 1520
Wiring Diagram and monitoring screen for message DWAXKY 1521
D5ZWKB – Travel hour meter short circuit 1522
Wiring Diagram and monitoring screen for message D5ZWKB 1523
D1EUKB – Travel alarm relay short circuit 1524
Wiring Diagram and monitoring screen for message D1EUKB 1525
DBX9KQ – Model Selection Abnormality 1526
Wiring Diagram and monitoring screen for message DBX9KQ 1527
DBXZKQ – Lever Control Selection Abnormality 1528
Wiring Diagram and monitoring screen for message DBXZKQ 1529
DBXYKQ – Attachment selection abnormality 1530
Wiring Diagram – Attachment selection abnormality (DBXYKQ) 1531
D561MA – Lock lever sol power cut abnorm(VALVE/S1) 1532
Wiring Diagram 1 for message D561MA 1534
Monitoring screens and Wiring Diagram 2 for message D561MA 1535
D563MA – Ladder up sensor sol cut abnorm(VLV/S1) 1536
Wiring Diagram 1 for message D563MA 1538
Monitoring screens and Wiring Diagram 2 for message D563MA 1539
D565MA – Service arm (up) sensor sol cut abnorm(VLV/S1) 1540
Wiring Diagram 1 for message D565MA 1542
Wiring Diagram 2 and monitoring screens for message D565MA 1543
DBX2KK – Solenoid Power Low Error(VALVE/S1 Con) 1544
Monitoring screen and Wiring Diagram 1 for message DBX2KK 1545
Wiring Diagram 2 for message DBX2KK – PPC safety circuit 1546
DBX0KQ – VALVE/S1 Con Selection Abnormality 1547
Wiring Diagram and monitoring screen for message DBX0KQ 1548
DBX0MA – VALVE/S1 Con Error 1549
DBYLKA – Operating Lamp Open Circuit(VALVE/S2 Con) 1550
Wiring Diagram – Operating Lamp Open Circuit(VALVE/S2 Con) 1551
DBYLKB – Operating Lamp Short Circuit(VALVE/S2 Con) 1552
Wiring Diagram – Operating Lamp Short Circuit(VALVE/S2 Con) 1553
DWAUKA – Bucket3 fill solenoid open circuit 1554
Wiring Diagram and monitoring screen for message DWAUKA 1555
DWAUKB – Bucket3 fill solenoid short circuit 1556
Wiring Diagram and monitoring screen for message DWAUKB 1557
DWAUKY – Bucket3 fill solenoid hot short circuit 1558
Wiring Diagram and monitoring screen for message DWAUKY 1559
DWAYKA – Bucket3 dump solenoid open circuit 1560
Wiring Diagram and monitoring screen for message DWAYKA 1561
DWAYKB – Bucket3 dump solenoid short circuit 1562
Wiring Diagram and monitoring screen for message DWAYKB 1563
DWAYKY – Bucket3 dump solenoid hot short circuit 1564
Wiring Diagram and monitoring screen for message DWAYKY 1565
DWBCKA – Boom3 up solenoid open circuit 1566
Wiring Diagram and monitoring screen for message DWBCKA 1567
DWBCKB – Boom3 up solenoid short circuit 1568
Wiring Diagram and monitoring screen for message DWBCKB 1569
DWBCKY – Boom3 up solenoid hot short circuit 1570
Wiring Diagram and monitoring screen for message DWBCKY 1571
DWBGKA – Boom3 down solenoid open circuit 1572
Wiring Diagram and monitoring screen for message DWBGKA 1573
DWBGKB – Boom3 down solenoid short circuit 1574
Wiring Diagram and monitoring screen for message DWBGKB 1575
DWBGKY – Boom3 down solenoid hot short circuit 1576
Wiring Diagram and monitoring screen for message DWBGKY 1577
DWBLKA – Stick3 out solenoid open circuit 1578
Wiring Diagram (BHA) and monitoring screen for message DWBLKA 1579
Wiring Diagram (FSA) and monitoring screen for message DWBLKA 1580
DWBLKB – Stick3 out solenoid short circuit 1581
Wiring Diagram (BHA) and monitoring screen for message DWBLKB 1582
Wiring Diagram (FSA) and monitoring screen for message DWBLKB 1583
DWBLKY – Stick3 out solenoid hot short circuit 1584
Wiring Diagram and monitoring screen for message DWBLKY 1585
DWBQKA – Stick3 in solenoid open circuit 1586
Wiring Diagram (BHA) and monitoring screen for message DWBQKA 1587
Wiring Diagram (FSA) and monitoring screen for message DWBQKA 1588
DWBQKB – Stick3 in solenoid short circuit 1589
Wiring Diagram (BHA) and monitoring screen for message DWBQKB 1590
Wiring Diagram (FSA) and monitoring screen for message DWBQKB 1591
DWBQKY – Stick3 in solenoid hot short circuit 1592
Wiring Diagram and monitoring screen for message DWBQKY 1593
DWKQKA – Travel3 right backward sol open circuit 1594
Wiring Diagram and monitoring screen for message DWKQKA 1595
DWKQKB – Travel3 right backward sol short circuit 1596
Wiring Diagram and monitoring screen for message DWKQKB 1597
DWKQKY – Travel3 right backward sol hot short 1598
Wiring Diagram and monitoring screen for message DWKQKY 1599
DWKLKA – Travel3 right forward sol open circuit 1600
Wiring Diagram and monitoring screen for message DWKLKA 1601
DWKLKB – Travel3 right forward sol short circuit 1602
Wiring Diagram and monitoring screen for message DWKLKB 1603
DWKLKY – Travel3 right forward sol hot short 1604
Wiring Diagram and monitoring screen for message DWKLKY 1605
DWARKA – Slew4 right solenoid open circuit 1606
Wiring Diagram and monitoring screen for message DWARKA 1607
DWARKB – Slew4 right solenoid short circuit 1608
Wiring Diagram and monitoring screen for message DWARKB 1609
DWARKY – Slew4 right solenoid hot short circuit 1610
Wiring Diagram and monitoring screen for message DWARKY 1611
DWAMKA – Slew4 left solenoid open circuit 1612
Wiring Diagram and monitoring screen for message DWAMKA 1613
DWAMKB – Slew4 left solenoid short circuit 1614
Wiring Diagram and monitoring screen for message DWAMKB 1615
DWAMKY – Slew4 left solenoid hot short circuit 1616
Wiring Diagram and monitoring screen for message DWAMKY 1617
DXEDKA – Hydraulic slew brake epc sol open circuit 1618
Wiring Diagram and monitoring screen for message DXEDKA 1619
DXEDKB – Hyd slew brake epc sol short circuit 1620
Wiring Diagram and monitoring screen for message DXEDKB 1621
DXEDKY – Hyd slew brake epc sol hot short circuit 1622
Wiring Diagram and monitoring screen for message DXEDKY 1623
DBY9KQ – Model Selection Abnormality 1624
Wiring Diagram and monitoring screen for message DBY9KQ 1625
DBYZKQ – Lever Control Selection Abnormality 1626
Wiring Diagram and monitoring screen for message DBYZKQ 1627
DBYYKQ – Attachment selection abnormality 1628
Wiring Diagram – Attachment selection abnormality (DBYYKQ) 1629
D562MA – Lock lever sol power cut abnorm(VALVE/S2) 1630
Wiring Diagram 1 for message D562MA 1632
Monitoring screens and Wiring Diagram 2 for message D562MA 1633
D564MA – Ladder up sensor sol cut abnorm(VLV/S2) 1634
Wiring Diagram 1 for message D564MA 1636
Monitoring screens and Wiring Diagram 2 for message D564MA 1637
D566MA – Service arm sensor sol cut abnorm(VALV/S2) 1638
Wiring Diagram 1 for message D566MA 1640
Monitoring screens and Wiring Diagram 2 for message D566MA 1641
DBY2KK – Solenoid Power Low Error(VALVE/S2 Con) 1642
Monitoring screen and Wiring Diagram 1 for message DBY2KK 1643
Wiring Diagram 2 for message DBY2KK – PPC safety circuit 1644
DBY0KQ – VALVE/S2 Con Selection Abnormality 1645
Wiring Diagram and monitoring screen for message DBY0KQ 1646
DBY0MA – VALVE/S2 Con Error 1647
DJH2KX – Hydraulic oil level sensor abnormality 1648
Wiring Diagram and monitoring screen for message DJH2KX 1649
DJE3KX – Remote engine oil level1 sens abnormality 1650
DJE4KX – Remote engine oil level2 sens abnormality 1650
Wiring Diagram and monitoring screen for message DJE3KX & DJE4KX 1651
B@NHKX – Hydraulic oil tank air filter sensor abnormality 1652
Wiring Diagram and monitoring screen for message B@NHKX 1653
DH2GKX – Suction tank pressure sensor abnormality 1654
Wiring Diagram and monitoring screen for message DH2GKX 1655
DH2HKX – Oil cooler pressure sensor abnormality 1656
Wiring Diagram and monitoring screen for message DH2HKX 1657
DH2JKX – Preload valve return oil press abnormality 1658
Wiring Diagram and monitoring screen for message DH2JKX 1659
DHSUKX – X2 pressure sensor abnormality 1660
Wiring Diagram and monitoring screen for message DHSUKX 1661
DJF1KX – Fuel level sensor abnormality 1662
Wiring Diagram and monitoring screen for message DJF1KX 1663
DH2KKX – Return oil chamber press sensor abnormal 1664
Wiring Diagram and monitoring screen for message DH2KKX 1665
DH2LKX – Leak oil chamber press sensor abnormality 1666
Wiring Diagram and monitoring screen for message DH2LKX 1667
DJE5L4 – SLS sensor system abnormality 1668
Wiring Diagram and monitoring screen for message DJE5L4 1669
DJE6L4 – CLS sensor system abnormality 1670
Wiring Diagram and monitoring screen for message DJE6L4 1671
DBVLKA – Operating Lamp Open Circuit(KOMTRAX) 1672
Wiring Diagram for message DBVLKA 1673
DBVLKB – Operating Lamp Short Circuit(KOMTRAX) 1674
Wiring Diagram for message DBVLKB 1675
DBV1KK – KOMTRAX Plus source voltage Error 1676
Wiring Diagram for message DBV1KK 1677
DBV5KB – 5V sensor1 power abnormality 1678
Wiring Diagram 1 and monitoring screens for message DBV5KB 1679
DBV6KB – 24V Sensor Power Abnormality 1680
Wiring Diagram 1 and monitoring screens for message DBV6KB 1681
DAFGMC – GPS Module Error 1682
Wiring Diagram for message DAFGMC 1683
D862KA – GPS Antenna Open Circuit 1684
DBVVKR – Ethernet 1 Disconnection 1685
DBVWKR – Ethernet 2 Disconnection 1686
DA2RKR – CAN1 Discon (Pump Con) 1688
CAN1 overview for message DA2RKR 1689
DBZRKR – CAN1 Discon (Pump2 Con) 1690
CAN1 overview for message DBZRKR 1691
DBWRKR – CAN1 Discon (Valve/M Con) 1692
CAN1 overview for message DBWRKR 1693
DBXRKR – CAN1 Discon (Valve/S1 Con) 1694
CAN1 overview for message DBXRKR 1695
DBYRKR – CAN1 Discon (Valve/S2 Con) 1696
CAN1 overview for message DBYRKR 1697
DB2QKR – CAN2 Discon (Engine Con) 1698
CAN2 overview for message DB2QKR 1699
Wiring Diagram for PWR supply at 52K014-1 (DB2QKR) 1700
F72QKR – CAN2 Discon (Engine2 Con) 1701
CAN2 overview for message F72QKR 1702
Wiring Diagram for PWR supply at 52K014-2 (F72QKR) 1703
DA2QKR – CAN2 Discon (Pump Con) 1704
CAN2 overview for message DA2QKR 1705
DBZQKR – CAN2 Discon (Pump2 Con) 1706
CAN2 overview for message DBZQKR 1707
DBWQKR – CAN2 Discon (Valve/M Con) 1708
CAN2 overview for message DBWQKR 1709
DBXQKR – CAN2 Discon (Valve/S1 Con) 1710
CAN2 overview for message DBXQKR 1711
DBYQKR – CAN2 Discon (Valve/S2 Con) 1712
CAN2 overview for message DBYQKR 1713
DBVRKR – CAN1 Discon (KOMTRAX Plus) 1714
CAN1 overview for message DBVRKR 1715
DBVQKR – CAN2 Discon (KOMTRAX Plus) 1716
CAN2 overview for message DBVQKR 1717
DBPRKR – CAN1 Discon (KomVision) 1718
Wiring Diagram for DBPRKR 1719
DBPQKR – CAN2 Discon (KomVision) 1720
Wiring Diagram for DBPQKR 1721
DAFLKA – Operating Lamp Open Circuit(Monitor) 1722
Wiring Diagram for message DAFLKA 1723
DAFLKB – Operating Lamp Short Circuit(Monitor) 1724
Wiring Diagram for message DAFLKB 1725
D5XLMA – Fuel Filter Failure 1726
D19YKB – Emergency Lighting Ladder Relay Short Circuit 1728
Wiring Diagram and monitoring screen for message D19YKB 1729
DV00KB – Shutdown Buzzer Short Circuit 1730
Wiring Diagram and monitoring screen for message DV00KB 1731
DAF0KM – Inconsistency of KomVision Setting 1732
DBP5KP – Camera Power Output Voltage Low 1734
Wiring Diagram for message DBP5KP 1735
DBP0NR – KomVision Controller High Temperature Error 1736
DBPVKR – CAN5 Discon (KomVision) 1737
DBPUKR – CAN4 Discon (KomVision) 1737
DPQ4KB – Short Circuit of KomVision Monitor ON/OFF Signal 1738
Wiring Diagram for message DPQ4KB 1739
DBP0KT – KomVision Controller Internal Error 1740
DBP0KM – KomVision Controller Setting Error 1741
DR10KA – Disconnection of Camera 1 NTSC Input 1742
DR20KA – Disconnection of Camera 2 NTSC Input 1742
DR30KA – Disconnection of Camera 3 NTSC Input 1742
DR40KA – Disconnection of Camera 4 NTSC Input 1742
DR50KA – Disconnection of Camera 5 NTSC Input 1742
DR60KA – Disconnection of Camera 6 NTSC Input 1742
DR90KA – Disconnection of Camera 7 NTSC Input 1742
Wiring Diagram for message DR10KA DR90KA 1743
DPQ4KT – KomVision Monitor Internal Error 1744
DBPLKA – Operating Lamp Open Circuit (KomVision) 1746
Wiring Diagram for message DBPLKA 1747
DBPLKB – Operating Lamp Short Circuit (KomVision) 1748
Wiring Diagram for message DBPLKB 1749
DBPWKR – Ethernet 1 Discon (KomVision) 1750
DBPXKR – Ethernet 2 Discon (KomVision) 1750
7 Troubleshooting by Symptoms 1751
7 1 Symptoms of engines and related electrical systems 1752
SEL001 – Engine does not start (engine does not rotate) 1752
Wiring Diagram 1 (batteries) for symptom code SEL001 1754
Wiring Diagram 2 (20S030 & 20S105a/b) for symptom code SEL001 1755
Wiring Diagram 3 (engine enable) for symptom code SEL001 1756
Wiring Diagram 4 (starter motors) for symptom code SEL001 (engine 1 as example) 1757
SEL002 – Engine stops while in operation 1758
View onto the fuel system water separator (SEL002) 1759
SEL003 – Engine speed is hunting during boom-up movement 1760
SEL004 – Engine does not stop 1762
SEL005 – Engine lacks output (no power) 1763
Judgment Table for SEL005 1764
SEL006 – Engine does not start (Pre-lube does not stop) 1765
SEL007 – Oil consumption is excessive 1766
Judgment Table for SEL007 1767
SEL008 – Oil becomes contaminated quickly 1768
Judgment Table for SEL008 1769
SEL009 – Fuel consumption is excessive 1770
Judgment Table for SEL009 1771
SEL010 – Oil is in engine coolant 1772
Judgment Table for SEL010 1773
SEL011 – Oil level rises 1774
Judgment Table for SEL011 1775
SEL012 – Coolant temperature becomes too high (overheating) 1776
Judgment Table for SEL012 1777
7 2 Symptoms of Hydraulic System 1778
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function) 1778
SHY002 – Engine speed sharply drops or engine stalls too much 1780
SHY003 – No work equipment, travel, or slew movement 1781
SHY004 – Work equipment has too much hydraulic drift 1782
SHY005 – Work equipment has big time lag 1783
SHY006 – Excavator deviates during travel movement 1784
SHY007 – Hydraulic system has lack of power 1785
SHY008 – Excavator does not slew 1786
Slew brake block (SHY008) 1787
SHY009 – Slew acceleration is poor 1788
SHY010 – Excessive overrun when stopping slew movement 1790
SHY011 – Floating system without function (FSA only) 1792
SHY012 – Abnormal noise coming from SRV or MRV 1793
SHY013 – Track tensioning system without function 1794
Track tensioning – overview (SHY013) 1795
SHY014 – Stairway does not move, or slow movement 1796
SHY015 – Refilling arm does not move, or slow movement 1798
SHY016 – Hydraulic driven grease pump does not move 1800
SHY017 – Abnormal track chain movement during digging 1802
SHY018 – Slew parking brake without function 1803
SHY019 – Travel parking brake without function 1804
7 3 Symptoms of Mechanical System 1806
SME001 – Abnormal noise is made 1806
Judgment Table for SME001 1807
SME002 – Abnormal noise around PTOs / hydraulic pumps 1808
SME003 – Vibration is excessive (engine mountings) 1810
Judgment Table for SME003 1811
SME004 – Vibration is excessive (engine torsion) 1812
SME005 – There is a big shock when stopping slew movement 1813
SME006 – There is a big abnormal noise when moving/stopping slew movement 1814
SME007 – Fan blades make abnormal noise 1816
SME008 – Abnormal noise coming from a travel gearbox 1818
SME009 – Abnormal noise coming from work equipment (lack of grease) 1820
SME010 – Abnormal idler movement 1822
SME011 – Leak at PTO drive shaft seal 1824
7 4 Symptoms of Additional Systems 1826
SAD001 – Air conditioner for cabin does not work 1826
View onto A/C unit (SAD001) 1827
SAD002 – Air conditioner compressor clutch is burnt 1828
View onto A/C compressor and its mounting (SAD002) 1829
SAD003 – Air conditioning system defective (pipes and hoses full of moisture) 1830
View onto A/C filling and service station 1831
50 DISASSEMBLY & ASSEMBLY 1833
TOC 1835
1 Introduction 1843
1 1 Foreword 1844
1 2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 1845
1 3 Diagrams and illustrations in this manual 1845
1 4 Procedures for disassembling and assembling in this manual 1846
2 Safety 1847
2 1 Overview 1848
2 1 1 Method of using this manual 1848
2 2 General precautions 1850
2 2 1 General 1850
2 2 2 Personal protective clothing 1850
2 2 3 When using a hammer 1851
2 2 4 Proper tools 1851
2 2 5 Personnel 1851
2 2 6 Fire prevention 1852
2 2 7 Unauthorized modification 1852
2 3 Precautions for maintenance and repair 1853
2 3 1 General precautions 1853
2 3 2 Keep work place clean and tidy 1853
2 3 3 Precautions when welding 1854
2 3 4 Precaution with high pressure fluids 1854
2 3 4 1 Handling high pressure hoses and pipes 1854
2 3 5 Compressed air 1854
2 3 6 Waste materials 1855
2 3 7 Isolate the excavator using the transfer pump 1856
2 3 8 Isolate the excavator 1856
2 3 9 De-isolate the excavator 1857
3 Superstructure 1859
3 1 Superstructure overview 1860
3 2 Machinery house 1862
3 2 1 Disconnection plates 1864
3 2 1 1 R H -side disconnection plate [56XH01] – port allocations 1864
3 2 1 2 L H -side disconnection plate [50XH01] – port allocations 1865
3 2 2 Machinery house roof 1866
3 2 2 1 Disassembling of the machinery house roof cover plates 1868
3 2 2 2 Assembling of the machinery house roof cover plates 1873
3 2 3 Air intake system 1878
3 2 3 1 Disassembling of the air intake system 1878
3 2 3 2 Assembling of the air intake system 1882
3 2 4 Exhaust system 1887
3 2 4 1 Disassembling of the exhaust system 1887
3 2 4 2 Assembling of the exhaust system 1891
3 2 5 Lubrication pump station 1894
3 2 5 1 Disassembling of the lubrication pump station 1894
3 2 5 2 Assembling of the lubricating pump station 1896
3 2 6 Diesel engines 1898
3 2 6 1 Disassembling of the Diesel engine (engine 1 or 2) 1898
3 2 6 2 Assembling of the Diesel engine (engine 1 or 2) 1905
3 2 6 3 Disassembling of the alternator 1912
3 2 6 4 Assembling of the alternator 1913
3 2 6 5 Disassembling of the starter motor 1914
3 2 6 6 Assembling of the starter motor 1915
3 2 7 Batteries 1916
3 2 7 1 Disassembling of the batteries 1916
3 2 7 2 Assembling of the batteries 1918
3 2 8 Engine cooling system 1920
3 2 8 1 Disassembling of the radiator assembly 1921
3 2 8 2 Assembling of the radiator assembly 1924
3 2 8 3 Disassembling of the radiator fan assembly 1927
3 2 8 4 Assembling of the radiator fan assembly 1930
3 2 9 Flexible drive coupling 1934
3 2 9 1 Disassembling of the Geislinger coupling 1934
3 2 9 2 Assembling of the Geislinger coupling 1936
3 2 9 3 Disassembling of the CentaFlex coupling assembly 1938
3 2 9 4 Assembling of the CentaFlex coupling assembly 1941
3 2 9 5 Replacing the rubber rollers of the CentaFlex coupling 1943
3 2 10 Main pump assemblies 1946
3 2 10 1 Disassembling of the main pump assemblies 1947
3 2 10 2 Assembling of the main pump assemblies 1951
3 2 11 Universal pump distributor gear box (PTO) 1954
3 2 11 1 Disassembling of the universal pump distributor gear box (PTO) 1955
3 2 11 2 Assembling of the universal pump distributor gear box (PTO) 1959
3 2 11 3 Disassembling of the control and filter plate assemblies 1964
3 2 11 4 Assembling of the control and filter plate assemblies 1973
3 2 11 5 Disassembling of the PTO gear oil pump 1982
3 2 11 6 Assembling of the PTO gear oil pump 1985
3 3 Hydraulic system 1988
3 3 1 Hydraulic oil cooler assembly 1988
3 3 1 1 Disassembling of hydraulic cooler fan 1989
3 3 1 2 Assembling of hydraulic cooler fan 1990
3 3 1 3 Disassembling of hydraulic cooler fan motor 1991
3 3 1 4 Assembling of hydraulic cooler fan motor 1993
3 3 1 5 Disassembling of the hydraulic oil coolers 1995
3 3 1 6 Assembling of the hydraulic oil coolers 1998
3 3 1 7 Disassembling of the hydraulic oil cooler assembly 2001
3 3 1 8 Assembling of the hydraulic oil cooler assembly 2006
3 3 2 Hydraulic oil tank 2012
3 3 2 1 Disassembling of the main shut-off valve 2014
3 3 2 2 Assembling of the main shut-off valve 2016
3 3 2 3 Disassembling of the hydraulic oil tank 2018
3 3 2 4 Assembling of the hydraulic oil tank 2028
3 3 3 Control frame assembly 2040
3 3 3 1 Disassembling of the main control valve blocks I, II and III 2041
3 3 3 2 Assembling of the main control valve blocks I, II and III 2045
3 3 3 3 Disassembling of the main control valve block IV (Slewing) 2049
3 3 3 4 Assembling of the main control valve block IV (Slewing) 2051
3 3 3 5 Disassembling of the high pressure filters at the main control valve blocks 2053
3 3 3 6 Assembling of the high pressure filters at the main control valve blocks 2056
3 3 3 7 Disassembling of the MRV at the main control valve blocks 2059
3 3 3 8 Assembling of the MRV at the main control valve blocks 2060
3 3 3 9 Disassembling of SRV on main control valve block 2061
3 3 3 10 Assembling of SRV on main control valve blocks 2063
3 3 3 11 Disassembling of ACV-/SRV-block on main control valve blocks 2064
3 3 3 12 Assembling of ACV-/SRV-block on main control valve blocks 2066
3 3 4 Distributor manifold 2068
3 3 4 1 Disassembling of throttle check valves at the distributor manifold 2069
3 3 4 2 Assembling of throttle check valves at the distributor manifold 2071
3 3 4 3 Disassembling of anti cavitation valves at the distributor manifold 2073
3 3 4 4 Assembling of anti cavitation valves at the distributor manifold 2076
3 3 4 5 Disassembling of the distributor manifold 2079
3 3 4 6 Assembling of the distributor manifold 2082
3 4 Slew system 2084
3 4 1 Slew gears 2084
3 4 1 1 Disassembling of the slew gear 2085
3 4 1 2 Assembling of the slew gear 2089
3 4 2 Slew brake valve block 2093
3 4 2 1 Disassembling of the slew brake valve block 2093
3 4 2 2 Assembling of the slew brake valve block 2095
3 4 3 Hydraulic slew motors 2098
3 4 3 1 Disassembling of the slew motor 2098
3 4 3 2 Assembling of the slew motor 2100
3 4 4 Slew parking brake 2102
3 4 4 1 Disassembly of the slew parking brake of slew gear type 2063 2103
3 4 4 2 Assembly of the slew parking brake of slew gear type 2063 2106
3 4 4 3 Disassembling of the slew parking brake of slew gear type 632770 2109
3 4 4 4 Assembling of the slew parking brake of slew gear type 632770 2113
3 4 5 Slew circle 2116
3 4 5 1 Disassembling of the slew circle 2116
3 4 5 2 Assembling of the slew circle 2120
3 4 6 Slew circle lubrication pinion (dummy wheel) 2121
3 4 6 1 Disassembling of the lubrication pinion assembly 2122
3 4 6 2 Assembling of the lubrication pinion assembly 2123
3 5 Operator’s cab 2124
3 5 1 Disassembling of the operator’s cab 2125
3 5 2 Assembling of the operator’s cab 2129
3 5 3 Disassembling of the operator’s cab together with the cab support frame 2133
3 5 4 Assembling of the operator’s cab together with the cab support frame 2137
3 5 5 Cab-mounts 2141
3 5 5 1 Disassembling of the cab-mounts 2141
3 5 5 2 Assembling of the cab-mounts 2143
3 5 6 Front window 2146
3 5 6 1 Disassembling of the front window 2146
3 5 6 2 Assembling of the front window 2147
3 5 7 Operator’s seat 2148
3 5 7 1 Disassembling of the operator’s seat 2148
3 5 7 2 Assembling of the operator’s seat 2149
3 6 Cab base 2150
3 6 1 Disassembling of the cab support frame 2151
3 6 2 Assembling of the cab support frame 2153
3 6 3 Disassembling of the cab base 2155
3 6 4 Assembling of the cab base 2158
3 7 Stairways, ladders and platforms 2162
3 7 1 Hydraulic access stairway 2162
3 7 1 1 Disassembling of the hydraulic access stairway 2162
3 7 1 2 Assembling of the hydraulic access stairway 2164
3 7 1 3 Disassembling of the access stairway cylinder 2166
3 7 1 4 Assembling of the access stairway cylinder 2168
3 7 2 Fuel tank step 2169
3 7 2 1 Disassembling of the fuel tank step 2169
3 7 2 2 Assembling of the fuel tank step 2171
3 7 3 Access stairway platform 2172
3 7 3 1 Disassembling of the access stairway platform 2172
3 7 3 2 Assembling of the access stairway platform 2175
3 7 4 Emergency escape ladders 2178
3 7 4 1 Disassembling of the emergency escape ladder assembly at the cab base 2178
3 7 4 2 Assembling of the emergency escape ladder assembly at the cab base 2180
3 7 4 3 Disassembling of the emergency escape ladder assembly at the machinery house 2181
3 7 4 4 Assembling of the emergency escape ladder assembly at the machinery house 2183
3 8 Counterweight 2184
3 8 1 Disassembling of the counterweight 2184
3 8 2 Assembling of the counterweight 2187
3 9 Fuel tank 2192
3 9 1 General information regarding disassembling and assembling 2192
3 9 2 Disassembling of the fuel tank 2194
3 9 3 Assembling of the fuel tank 2203
3 10 Superstructure lifting 2214
3 10 1 Disassembling the superstructure from the undercarriage 2214
3 10 2 Assembling the superstructure onto the undercarriage 2217
4 Undercarriage 2221
4 1 Undercarriage overview 2222
4 2 Travel system 2224
4 2 1 Crawler track 2224
4 2 1 1 Changing of the crawler track 2224
4 2 1 2 Disassembling of the sprocket assembly 2230
4 2 1 3 Assembling of the sprocket assembly 2236
4 2 2 Guide wheel assembly 2239
4 2 2 1 Disassembling of the guide wheel assembly 2239
4 2 2 2 Assembling of the guide wheel assembly 2242
4 2 3 Track tensioning accumulators 2245
4 2 3 1 Disassembling of the low pressure accumulators 2245
4 2 3 2 Assembling of the low pressure accumulators 2247
4 2 3 3 Disassembling of the high pressure accumulators 2249
4 2 3 4 Assembling of the high pressure accumulators 2250
4 2 4 Track tensioning valve block 2251
4 2 4 1 Disassembling of the track tensioning valve block 2251
4 2 4 2 Assembling of the track tensioning valve block 2253
4 2 5 Track tensioning cylinders 2254
4 2 5 1 Disassembling of the track tensioning cylinders 2254
4 2 5 2 Assembling of the track tensioning cylinders 2256
4 2 6 Replace the Hydraulic hoses of the track tensioning system 2258
4 2 6 1 Precursory work 2258
4 2 6 2 Replace the hydraulic hoses inside the undercarriage center body 2260
4 2 6 3 Replace the hydraulic hose between undercarriage center body and crawler frame 2260
4 2 6 4 Replace the hydraulic hoses inside the crawler frame 2263
4 2 6 5 Subsequent work 2263
4 2 7 Travel brake valve block (overspeed valve) 2264
4 2 7 1 Disassembling of the travel brake valve block 2264
4 2 7 2 Assembling of the travel brake valve block 2265
4 2 8 Travel motor 2267
4 2 8 1 Disassembling of the travel motors 2267
4 2 8 2 Assembling of the travel motors 2269
4 2 9 Travel parking brake 2272
4 2 9 1 Disassembling of the travel parking brake of type 631053 and 2063 2273
4 2 9 2 Assembling of the travel parking brake of type 631053 and type 2063 2277
4 2 10 Travel gearbox 2282
4 2 10 1 Disassembling of the travel gearbox 2283
4 2 10 2 Assembling of the travel gearbox 2285
4 2 11 Carrier rollers 2288
4 2 11 1 Disassembling of the carrier roller assembly 2288
4 2 11 2 Assembling of the carrier roller assembly 2290
4 2 12 Track rollers 2292
4 2 12 1 Disassembling of the track roller assembly 2292
4 2 12 2 Assembling of the track roller assembly 2294
4 2 13 Replace the hydraulic hoses of the traveling system 2298
4 3 Undercarriage Center body 2302
4 3 1 Disassembling of the undercarriage center body and the crawler carriers 2302
4 3 2 Assembling of the undercarriage center body and the crawler carriers 2307
4 3 2 1 Install crawler carrier mounting bolts 2312
4 3 3 Rotary joint 2313
4 3 3 1 Disassembling of the rotary joint 2313
4 3 3 2 Assembling of the rotary joint 2316
5 Attachment 2321
5 1 Attachment bearings at superstructure 2322
5 1 1 Boom foot bearings with full floating pins 2322
5 1 1 1 Disassembling of the boom foot bearings 2323
5 1 1 2 Assembling of the boom foot bearings 2325
5 1 2 Boom cylinder foot bearings with full floating pins 2328
5 1 2 1 Disassembling of the boom cylinder foot bearings – BHA arrangement 2330
5 1 2 2 Assembling of the boom cylinder foot bearings – BHA arrangement 2332
5 1 2 3 Disassembling of the boom cylinder foot bearings – FSA arrangement 2334
5 1 2 4 Assembling of the boom cylinder foot bearings – FSA arrangement 2336
5 2 Repair procedures 2338
5 2 1 Replacement of bushings at the attachment 2338
5 2 1 1 Removal of the bushings 2338
5 2 1 2 Installation of the bushings 2339
5 2 2 General installation instructions for attachment pins 2340
5 3 Backhoe (BHA) 2342
5 3 1 Overview 2342
5 3 2 Pin Sealing bucket – steering rod – bucket link rod 2344
5 3 3 Boom assembly 2346
5 3 3 1 Disassembling of the boom 2346
5 3 3 2 Assembling of the boom 2348
5 3 3 3 Disassembling of the boom cylinders 2350
5 3 3 4 Assembling of the boom cylinders 2354
5 3 4 Stick assembly 2359
5 3 4 1 Disassembling of the stick 2359
5 3 4 2 Assembling of the stick 2364
5 3 4 3 Disassembling of the stick cylinders 2369
5 3 4 4 Assembling of the stick cylinders 2374
5 3 5 Bucket and steering 2379
5 3 5 1 Disassembling of the bucket 2379
5 3 5 2 Assembling of the bucket 2383
5 3 5 3 Disassembling of the bucket cylinders 2386
5 3 5 4 Assembling of the bucket cylinders 2393
5 3 5 5 Disassembling of the bucket link rod 2400
5 3 5 6 Assembling of the bucket link rod 2403
5 3 5 7 Disassembling of the steering rods 2406
5 3 5 8 Assembling of the steering rods 2412
5 3 6 Hydraulic hoses at the backhoe attachment 2416
5 3 6 1 Replace the boom arc hoses 2416
5 3 6 2 Replace the boom cylinder hoses 2420
5 3 6 3 Replace the stick cylinder hoses 2422
5 3 6 4 Replace the bucket cylinder hoses 2424
5 4 Front shovel (FSA) 2426
5 4 1 Overview 2426
5 4 2 Using the cylinder mounting device for front shovel attachments (PN 967 000 40) 2428
5 4 2 1 Designated usage 2429
5 4 2 2 Non-designated usage 2429
5 4 3 Boom assembly 2430
5 4 3 1 Disassembling of the boom 2430
5 4 3 2 Assembling of the boom 2432
5 4 3 3 Disassembling of the boom cylinders 2434
5 4 3 4 Assembling of the boom cylinders 2438
5 4 4 Stick assembly 2444
5 4 4 1 Disassembling of the stick 2444
5 4 4 2 Assembling of the stick 2449
5 4 4 3 Disassembling of the stick cylinders 2454
5 4 4 4 Assembling of the stick cylinders 2458
5 4 5 Bull clam bucket 2462
5 4 5 1 Disassembling of the bull clam bucket 2462
5 4 5 2 Assembling of the bull clam bucket 2466
5 4 5 3 Disassembling of the bucket cylinders 2470
5 4 5 4 Assembling of the bucket cylinders 2476
5 4 5 5 Disassembling of the clam cylinders 2482
5 4 5 6 Assembling of the clam cylinders 2487
5 4 6 Hydraulic hoses at the front shovel attachment 2492
5 4 6 1 Replace the boom arc hoses 2492
5 4 6 2 Replace the boom cylinder hoses 2496
5 4 6 3 Replace the stick arc hoses 2498
5 4 6 4 Replace the stick cylinder hoses 2500
5 4 6 5 Replace the bucket cylinder hoses 2502
5 4 6 6 Replace the clam cylinder hoses 2504
5 4 6 7 Disassembling of the clam 2509
5 4 6 8 Assembling of the clamp 2510
5 5 Metering valves (grease injectors) at the attachment 2511
5 5 1 Disassembling of the metering valves (grease injectors) 2511
5 5 2 Assembling of the metering valves (grease injectors) 2513
5 6 Ground engaging tools (GET) 2514
5 6 1 Replacement of the GET 2514
5 7 Cylinder bypass test 2515
6 Service Information 2517
6 1 Fluids and lubricants 2518
6 2 Lifting Gears 2518
6 3 Safety hints for sling accessory 2520
6 4 Weight tables 2521
6 4 1 Superstructure 2521
6 4 2 Undercarriage 2523
6 4 3 Backhoe attachment (BHA) 2524
6 4 4 Face shovel attachment (FSA) 2525
6 5 Torque charts according to KOMATSU company standard 2526
6 5 1 Metric standard thread 2526
6 5 2 Metric fine thread 2527
6 5 3 Cummins motor torques – metric 2528
6 5 4 Cummins motor torques – U S customary 2528
6 5 5 Torque Charts for flange joints 2530
6 5 6 Tightening torque for hydraulic hose connecting nut 2532
6 6 Blind plugs 2533
6 6 1 Dummy plates for hydraulic–flanges 2533
6 6 2 Classification of threads to the nominal width 2535
6 6 3 Plugs and fittings according to DIN 2353 2536
6 7 Conversion table 2537
6 7 1 Method of using the conversion table 2537
6 7 2 Millimeter – inch & kilogram – pound 2538
6 7 3 Liter – U S gallon & liter – U K gallon 2539
6 7 4 Nm- ft lb 2540
6 7 5 Bar – PSI – kPa – MPa 2541
6 7 6 Temperature 2542
6 8 Tools 2543
6 8 1 Standard tool case 2543
6 8 2 Used special tools (Overview) 2545
6 9 Work instructions 2548
6 9 1 Bleeding the track tensioning system 2548
6 9 2 General installation procedures for hydraulic hose lines 2550
6 9 3 Remove / install the crawler carrier 2553
6 9 4 Repair procedure for the radiator assembly 2554
7 Parts & Service News 2555
7 1 List of the PARTS AND SERVICE NEWS 2556

DESCRIPTION:

Komatsu PC7000-11 T2 Hydraulic Mining Excavator 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