Komatsu PC7000-6 T2 Hydraulic Mining Shovel Shop Manual 35001-xD-GB-4 – PDF DOWNLOAD

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Komatsu PC7000-6 T2 Hydraulic Mining Shovel Shop Manual 35001-xD-GB-4 – PDF DOWNLOAD

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Komatsu PC7000-6 T2 Hydraulic Mining Shovel Shop Manual 35001-xD-GB-4 – PDF DOWNLOAD

SERIAL NUMBER 35001 and up

BEFORE READING THIS MANUAL:

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

TABLE OF CONTENTS:

Komatsu PC7000-6 T2 Hydraulic Mining Shovel Shop Manual 35001-xD-GB-4 – PDF DOWNLOAD

SHOP 35001-xD-GB-4 PC7000-6 T2 TOC – 1
Table of Contents
1 INTRODUCTION 1-1
1 1 FOREWORD 1-2
1 2 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND
MAINTENANCE OF HYDRAULIC MINING SHOVELS 1-3
1 3 EXPLANATION OF ABBREVIATIONS 1-4
1 4 DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL 1-5
2 SPECIFICATIONS 2-1
2 1 LIFTING GEARS 2-2
2 2 SAFETY HINTS FOR SLING ACCESSORY 2-4
2 3 STANDARD TIGHTENING TORQUE CHART 2-5
2 4 CONVERSION TABLE 2-6
2 5 BLIND PLUGS 2-12
2 6 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH 2-14
2 7 PLUGS AND FITTINGS ACCORDING TO ISO 8434-1 / DIN 2353 2-15
3 MAIN ASSEMBLY GROUPS 3-1
3 1 GENERAL LAYOUT 3-2
3 2 SUPERSTRUCTURE 3-4
3 2 1 SUPERSTRUCTURE SIDE VIEW 3-4
3 2 2 SUPERSTRUCTURE TOP VIEW 3-6
3 3 MACHINE HOUSE 3-8
3 4 HYDRAULIC OIL TANK 3-10
3 5 HYDRAULIC OIL COOLER 3-12
3 6 FUEL TANK 3-14
3 7 CAB SUPPORT 3-16
3 8 OPERATOR’S CAB 3-18
3 9 MAIN CONTROL BLOCKS (FSA) 3-20
3 10 SLEW MACHINERY 3-22
3 10 1 SLEW GEAR TYPE 2063 / SLEW MOTOR TYPE A6VLM 3-22
3 10 2 SLEW GEAR TYPE 632770 / SLEW MOTOR TYPE A6VLM 3-24
3 11 UNDERCARRIAGE 3-26
3 12 SLEW RING 3-28
3 13 ATTACHMENT 3-30
3 13 1 FRONT SHOVEL ATTACHMENT (FSA) 3-30
3 13 2 BACK HOE ATTACHMENT (BHA) 3-32
3 14 COUNTERWEIGHT 3-34
3 15 PPC SAFETY CIRCUIT 3-36
4 DRIVE 4-1
4 1 PRIME DRIVE ASSEMBLY 4-2
4 2 ENGINE AND PTO MOUNTS 4-4
TOC – 2 PC7000-6 T2 SHOP 35001-xD-GB-4
4 2 1 ENGINE MOUNTS 4-4
4 2 2 CHECKS AND ADJUSTMENTS 4-5
4 2 3 TORQUE SUPPORT 4-5
4 3 FLEXIBLE COUPLING (TYPE A) 4-6
4 4 FLEXIBLE COUPLING (TYPE B) 4-8
4 4 1 INFORMATION FOR MAINTENANCE 4-10
4 4 2 COUPLING ELEMENTS 4-11
4 4 3 SEPARATION AND ASSEMBLY OF THE COUPLING INNER AND OUTER PART 4-12
4 4 4 OPERATION TROUBLES, CAUSES, AND RECTIFICATION 4-13
4 5 FAN DRIVE AND RADIATOR ASSEMBLY 4-14
4 5 1 RADIATOR ASSEMBLY 4-14
4 5 2 FAN MOTOR 4-16
4 5 3 EXPANSION TANKS 4-17
4 5 4 RADIATOR FAN DRIVE 4-18
4 5 4 1 FLOW CHART OF RADIATOR FAN CONTROL 4-20
4 5 4 2 HYDRAULIC SCHEMATIC OF RADIATOR FAN DRIVE 4-21
4 5 5 FAN PUMP TYPE HPV190 4-22
4 5 6 RADIATOR FAN SPEED TESTING & ADJUSTMENT 4-24
4 5 6 1 TESTING & READJUSTMENT PROCEDURE 4-26
4 5 6 2 BASIC ADJUSTMENT PROCEDURE 4-27
4 6 PUMP DISTRIBUTOR GEARBOX (PTO) 4-28
4 6 1 PTO OIL FILLING, OIL LEVEL, AND VENTILATION 4-30
4 6 2 PUMP SPLINE LUBRICATION 4-32
4 6 2 1 OIL LEVEL IN THE MAIN PUMP & GEAR OIL PUMP DRIVE SHAFT
HOUSING 4-33
4 6 3 PTO LUBRICATION AND COOLING 4-34
4 6 3 1 HYDRAULIC COMPONENTS AND SCHEMATIC OF COOLING CIRCUIT-1 4-34
4 6 3 2 SCHEMATIC OVERVIEW – PTO GEAR OIL COOLING CIRCUIT-1 4-36
4 6 3 3 CHECKS AND ADJUSTMENTS 4-38
4 7 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES 4-40
4 8 AIR CLEANER 4-44
5 HYDRAULIC OIL TANK 5-1
5 1 GENERAL LAYOUT 5-2
5 2 HYDRAULIC OIL TANK, LOCATION OF THE ELECTRIC EQUIPMENT 5-4
5 3 SUCTION OIL TANK WITH STRAINERS 5-6
5 4 RETURN OIL COLLECTOR PIPE WITH STRAINER 5-8
5 5 BACK PRESSURE VALVE 5-10
5 6 TRANSFER PUMP 5-12
5 7 RETURN AND LEAK OIL FILTER 5-14
5 8 BREATHER FILTER 5-16
6 HYDRAULIC OIL COOLING 6-1
6 1 OVERALL VIEW ON THE HYDRAULIC OIL COOLING 6-2
6 2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT 6-4
6 3 ADJUSTMENT OF THE BACK PRESSURE VALVE 6-6
SHOP 35001-xD-GB-4 PC7000-6 T2 TOC – 3
6 4 STEPLESS COOLER FAN RPM CONTROL 6-8
6 4 1 PRESSURE LIMITING VALVES 6-10
6 4 2 COMPONENTS OF THE FAN DRIVE CIRCUITS 6-12
6 4 3 FAN PUMP TYPE HPV190 6-14
6 5 OIL COOLER FAN SPEED TESTING/ADJUSTMENT 6-16
6 5 1 TESTING & READJUSTMENT PROCEDURE 6-18
6 5 2 BASIC ADJUSTMENT PROCEDURE 6-19
6 6 OC FAN RESONANCE SPEED ADJUSTMENT 6-20
6 6 1 HYDRAULIC OIL TEMPERATURE CHARTS 6-22
7 CONTROLLING 7-1
7 1 GENERAL LAYOUT 7-2
7 2 CONTROL AND FILTER PANELS – LOCATION OF COMPONENTS 7-4
7 2 1 CONTROL AND FILTER PANEL ENGINE 1 (REAR) 7-4
7 2 2 VALVE CARTRIDGE BLOCK ENGINE 1 (REAR) 7-6
7 2 3 CONTROL AND FILTER PANEL ENGINE 2 (FRONT) 7-8
7 3 PILOT PRESSURE SUPPLY AND ADJUSTMENTS 7-10
7 3 1 PILOT PRESSURE CONTROL (PPC) CIRCUIT 7-10
7 3 2 PILOT PRESSURE OPERATING THE MAIN BLOCK SPOOLS 7-12
7 3 3 CHECKS AND ADJUSTMENT OF PILOT PRESSURE 7-14
7 3 4 REMOTE CONTROL VALVES ARRANGEMENT 7-16
7 4 FUNCTION OF THE ELECTRO HYDRAULIC CONTROL SYSTEM 7-18
7 4 1 ILLUSTRATION OF THE JOYSTICK SIGNAL FLOW (EXAMPLE) 7-20
7 5 HAND LEVER (JOYSTICK) CONTROL 7-22
7 5 1 VOLTAGE SUPPLY OF HAND LEVER 20S020 7-23
7 5 2 DIRECTION SIGNAL COURSE FROM HAND LEVER TO CONTROLLERS 7-24
7 5 3 DOUBLE RATIOMETRIC* OUTPUT DIAGRAM 7-25
7 6 FOOT PEDAL CONTROL 7-26
7 6 1 VOLTAGE SUPPLY OF FOOT LEVER 20S021A 7-28
7 6 2 DIRECTION SIGNAL COURSE FROM FOOT PEDAL TO CONTROLLERS 7-29
7 6 3 DOUBLE RATIOMETRIC* OUTPUT DIAGRAM FOR 2 DIRECTION PEDAL 7-30
7 6 4 SINGLE RATIOMETRIC* OUTPUT DIAGRAM FOR 1 DIRECTION PEDAL 7-31
7 7 HAND LEVER & FOOT PEDAL MONITORING 7-32
7 7 1 LEVER MONITORING SCREENS (EXAMPLE) 7-34
7 7 2 VALVE MONITORING SCREEN (EXAMPLE) 7-36
7 8 VALVE SOLENOID ADJUSTMENT 7-38
7 8 1 OVERVIEW SOL MIN/MAX CURRENT & ADJUSTMENT RANGE 7-39
7 9 ACCEL & DECEL TIME ADJUSTMENT 7-40
7 9 1 ACCEL & DECEL TIMES 7-40
8 COMPONENTS 8-1
8 1 MAIN CONTROL BLOCKS AND HIGH PRESSURE SCREENS (FSA) 8-2
8 2 MAIN CONTROL BLOCKS WITH VALVES AND HP SCREENS (FSA) 8-4
8 3 MAIN CONTROL BLOCKS WITH VALVES AND HP SCREENS (BHA) 8-6
8 4 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS
AND ANTI CAVITATION VALVES (FSA) 8-8
TOC – 4 PC7000-6 T2 SHOP 35001-xD-GB-4
8 5 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS
AND ANTI CAVITATION VALVES (BHA) 8-10
8 6 RESTRICTOR BLOCK WITH SECONDARY RELIEF VALVE 8-12
8 7 ANTI-CAVITATION VALVE (ACV) BLOCK 8-14
8 7 1 SINGLE ACV BLOCK ON THE MANIFOLD 8-14
8 7 2 DOUBLE ACV BLOCK ON THE MANIFOLD 8-16
8 8 REMOTE CONTROL VALVES 8-18
8 9 4/3 DIRECTIONAL SOLENOID VALVES 8-20
8 10 PROPORTIONAL SOLENOID VALVES 8-22
8 11 HIGH-PRESSURE SCREEN 8-24
8 12 CONTROL BLOCKS AND VALVES 8-26
8 12 1 MAIN CONTROL BLOCKS I, II, III (4 SPOOL BLOCKS) 8-26
8 12 1 1 SPIN LOCK FOR VALVE BLOCKS (ND52) 8-27
8 12 2 HYDRAULIC DIAGRAM OF A 4-SPOOL VALVE BLOCK 8-28
8 12 3 SPOOL TYPES 8-29
8 12 4 SPOOL POSITIONS (CONTROL BLOCK) 8-32
8 12 5 MRV, SRV, AND ACV 8-34
8 12 6 LOAD HOLDING VALVE 8-36
8 12 7 MAIN CONTROL BLOCK IV (SLEW) 8-38
8 13 TRAVEL BRAKE VALVE 8-40
8 14 PRESSURE REDUCING VALVE 8-42
8 15 4/2 DIRECTIONAL VALVES 8-44
8 16 PRESSURE DOUBLE STAGE VALVE 8-46
8 17 HYDRAULIC CYLINDER 8-48
8 17 1 HYDRAULIC CYLINDER – CHEVRON® SEALING 8-48
8 17 2 HYDRAULIC CYLINDER – CHESTERTON® 11KE SEALING 8-50
8 17 3 CYLINDER DATA MARKINGS 8-52
9 MAIN HYDRAULIC PUMPS, PUMP REGULATION, VALVE CONTROL
& MONITORING SYSTEM 9-1
9 1 GENERAL 9-2
9 1 1 PUMP DATA 9-4
9 2 MAIN PUMPS 9-8
9 2 1 HYDRAULIC PUMP TYPE HPV375+375 9-8
9 2 1 1 MAIN PUMP SECTIONAL DRAWINGS 9-10
9 2 2 SERVO VALVE 9-12
9 2 2 1 VC VALVE ⇔ SERVO PISTON 9-13
9 2 3 EPC VALVE 9-18
9 3 ELECTRONIC PUMP REGULATION SYSTEM 9-20
9 3 1 CUT-OFF FUNCTION 9-22
9 3 2 SLEW CONTROL 9-23
9 3 3 TEMPERATURE CONTROL 9-23
9 3 4 DIAGNOSTICS AND MONITORING 9-23
9 3 5 HYDRAULIC OIL TEMPERATURE CHARTS 9-24
9 3 6 PTO GEAR OIL TEMPERATURE CHARTS 9-24
9 4 PUMP & VALVE CONTROLLERS 9-26
SHOP 35001-xD-GB-4 PC7000-6 T2 TOC – 5
9 5 MULTIMONITOR 9-28
9 5 1 SERVICE MENU SCREEN 9-31
9 6 SERVICE MENU – 01 MONITORING 9-31
9 6 1 MONITORING PUMP 1 CONTROLLER 9-32
9 6 2 MONITORING PUMP 2 CONTROLLER 9-33
9 6 3 MONITORING VALVE 0 CONTROLLER 9-34
9 6 4 MONITORING VALVE 1 CONTROLLER 9-36
9 6 5 MONITORING VALVE 2 CONTROLLER 9-37
9 6 6 MONITORING ALL CONTROLLERS 9-37
9 7 USING MULTIMONITOR FUNCTIONS FOR MONITORING 9-38
9 7 1 HOLD FUNCTION 9-38
9 8 SERVICE MENU – 02 ABNORMALITY RECORD 9-39
9 8 1 TO DELETE ANY FAILURE RECORD FROM THE DISPLAY 9-40
9 8 2 TROUBLESHOOTING PROCEDURES 9-40
9 8 3 FAILURE CODES FOR PUMPS & VALVE CONTROLLERS &
SYSTEM CONNECTIONS 9-41
9 9 SERVICE MENU – 03 DEFAULT 9-49
9 10 SERVICE MENU – 04 ADJUSTMENT 9-50
9 10 1 ADJUSTMENTS FOR PUMP 1 CONTROLLER 9-50
9 10 2 ADJUSTMENTS FOR PUMP 2 CONTROLLER 9-52
9 10 3 ADJUSTMENTS FOR VALVE 0 CONTROLLER 9-54
9 10 4 ADJUSTMENTS FOR VALVE 2 CONTROLLER 9-55
9 10 5 DETAILS ON THE ADJUSTABLE PARAMETERS 9-56
9 10 5 1 PUMP 1 CONTROLLER 9-56
9 10 5 2 PUMP 2 CONTROLLER 9-58
9 10 5 3 VALVE 0 CONTROLLER 9-60
9 10 5 4 VALVE 1 & 2 CONTROLLER 9-62
9 10 6 DESCRIPTION OF THE PRIMARY P-FACTOR 9-63
9 10 7 PUMP1 6F/R SOLENOID MIN CURRENT ADJUSTMENT 9-64
9 10 8 PUMP1 6F/R SOLENOID MAX CURRENT ADJUSTMENT 9-65
9 11 ACCEL & DECEL TIME ADJUSTMENT 9-66
9 11 1 ACCEL & DECEL TIMES 9-66
9 12 SERVICE MENU – 05 CONTROLLER SETTING 9-68
9 13 CONTROLLER REPLACEMENT PROCEDURE 9-68
9 13 1 CONTROLLER SETTING → WIRING INPUT CHECK 9-68
9 13 2 CONTROLLER SETTING → MEMORY 9-72
9 13 3 CONFIRMATION 9-74
9 14 SERVICE MENU – 06 DISPLAY SETUP 9-75
9 15 CHECKS AND ADJUSTMENTS 9-76
9 15 1 ENGINE POWER CHECK 9-76
9 15 2 CUT-OFF FUNCTION CHECK 9-78
9 15 2 1 CUT-OFF FOR CLAM CLOSE (FSA ONLY) 9-79
9 16 ENGINE SPEED SENSORS (PICK-UP) 9-80
9 16 1 GENERAL 9-81
9 16 2 ENGINE SPEED SENSOR (PICK-UP) ADJUSTMENT 9-81
10 OPERATING HYDRAULICS 10-1
TOC – 6 PC7000-6 T2 SHOP 35001-xD-GB-4
10 1 GENERAL 10-2
10 1 1 ALLOCATION OF PUMPS AND MAIN VALVE BLOCKS 10-4
10 2 SPOOL FUNCTIONS (FSA) 10-6
10 2 1 FLOATING FUNCTION FOR BOOM AND STICK CYLINDERS 10-6
10 2 2 SPOOL FUNCTIONS (BHA) 10-8
10 3 HYDRAULICS FOR THE ATTACHMENT CYLINDERS 10-10
10 3 1 ELECTRIC / HYDRAULIC FLOWCHART “BOOM UP” (FSA) 10-10
10 3 2 ELECTRIC / HYDRAULIC FLOWCHART “BOOM UP” (BHA) 10-12
10 3 3 ELECTRIC / HYDRAULIC FLOWCHART “BOOM DOWN” (FSA),
SINGLE MOVEMENT AND AUTO-FLOAT ON 10-14
10 3 4 ELECTRIC / HYDRAULIC FLOWCHART “BOOM DOWN” (FSA), AUTO-FLOAT OFF –
BUTTON 20S095 PRESSED AND SINGLE MOVEMENT 10-16
10 3 5 ELECTRIC / HYDRAULIC FLOWCHART “BOOM DOWN” (BHA) 10-18
10 3 6 ELECTRIC / HYDRAULIC FLOWCHART “STICK OUT” (FSA) 10-20
10 3 7 ELECTRIC / HYDRAULIC FLOWCHART “STICK OUT” (BHA) 10-22
10 3 8 ELECTRIC / HYDRAULIC FLOWCHART “STICK IN” (FSA), AUTO-FLOAT ON
AND SINGLE MOVEMENT 10-24
10 3 9 ELECTRIC / HYDRAULIC FLOWCHART “STICK IN” (FSA), AUTO-FLOAT OFF –
20S098 PRESSED & SINGLE MOVEMENT 10-26
10 3 10 ELECTRIC / HYDRAULIC FLOWCHART “STICK IN” (BHA) 10-28
10 3 11 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET FILL” (FSA) 10-30
10 3 12 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET FILL” (BHA) 10-32
10 3 13 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET DUMP” (FSA) 10-34
10 3 14 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET DUMP” (BHA) 10-36
10 3 15 ELECTRIC / HYDRAULIC FLOWCHART “CLAM OPEN” (FSA) 10-38
10 3 16 ELECTRIC / HYDRAULIC FLOWCHART “CLAM CLOSE” (FSA) 10-40
10 3 17 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVE (MRV) 10-42
10 3 18 CHECKS AND ADJUSTMENTS OF THE SECONDARY RELIEF VALVES (SRV) 10-44
10 3 18 1 BOOM CYLINDERS, PISTON SIDE (BHA & FSA), BOOM UP 10-44
10 3 18 2 BOOM CYLINDER, PISTON ROD SIDE (BHA & FSA), BOOM DOWN 10-48
10 3 18 3 STICK CYLINDERS, PISTON SIDE (FSA), STICK OUT 10-52
10 3 18 4 STICK CYLINDERS, PISTON SIDE (BHA), STICK IN 10-56
10 3 18 5 STICK CYLINDERS, PISTON ROD SIDE (FSA), STICK IN 10-60
10 3 18 6 STICK CYLINDERS, PISTON ROD SIDE (BHA), STICK OUT 10-64
10 3 18 7 BUCKET CYLINDERS, PISTON SIDE (FSA), BUCKET FILL 10-68
10 3 18 8 BUCKET CYLINDERS, PISTON SIDE (BHA), BUCKET FILL 10-72
10 3 18 9 BUCKET CYLINDERS, PISTON ROD SIDE (FSA), BUCKET DUMP 10-76
10 3 18 10BUCKET CYLINDERS, PISTON ROD SIDE (BHA), BUCKET DUMP 10-80
10 3 18 11CLAM CYLINDERS, PISTON ROD SIDE (FSA), CLAM OPEN 10-84
10 3 18 12CLAM CYLINDERS, PISTON SIDE (FSA), CLAM CLOSE 10-88
10 3 19 CHECKS AND ADJUSTMENTS OF CYCLE TIMES 10-92
10 3 19 1 CHECKS AND ADJUSTMENTS OF BOOM LOWERING SPEED (FSA) 10-92
10 3 19 2 CHECKS AND ADJUSTMENTS OF BOOM LOWERING SPEED (BHA) 10-96
10 3 19 3 CHECKS AND ADJUSTMENTS OF STICK RETRACT SPEED (FSA) 10-100
10 3 19 4 CHECKS AND ADJUSTMENTS OF STICK RETRACT SPEED (BHA) 10-104
10 3 19 5 CHECKS AND ADJUSTMENTS OF BUCKET DUMP SPEED (FSA) 10-108
10 3 19 6 CHECKS AND ADJUSTMENTS OF BUCKET DUMP SPEED (BHA) 10-112
10 3 19 7 CHECKS AND ADJUSTMENT OF BUCKET CURL SPEED (BHA) 10-116
10 3 19 8 CHECKS AND ADJUSTMENTS OF CLAM CLOSE SPEED (FSA) 10-120
10 4 HYDRAULICS FOR THE SLEW CIRCUIT 10-122
SHOP 35001-xD-GB-4 PC7000-6 T2 TOC – 7
10 4 1 SLEW CIRCUIT WITH VARIABLE SLEW MOTORS 10-122
10 4 2 SLEW MOTOR (VARIABLE DISPLACEMENT) 10-126
10 4 2 1 HYDRAULIC SLEW MOTOR – DISPLACEMENT CONTROL 10-128
10 4 3 SLEW GEARBOX TYPE 2063 10-130
10 4 4 SLEW GEARBOX TYPE 632770 10-132
10 4 5 SLEW PARKING BRAKE (ON SLEW GEAR TYPE 2063) 10-134
10 4 6 SLEW PARKING BRAKE (ON SLEW GEAR TYPE 632770) 10-136
10 4 7 SLEW BRAKE VALVE 10-138
10 4 8 FLUSHING CIRCUIT 10-142
10 4 9 ELECTRIC / HYDRAULIC FLOWCHART “SLEW LEFT” FSA 10-144
10 4 10 ELECTRIC / HYDRAULIC FLOWCHART “SLEW LEFT” BHA 10-146
10 4 11 ELECTRIC / HYDRAULIC FLOWCHART “SLEW RIGHT” FSA 10-148
10 4 12 ELECTRIC / HYDRAULIC FLOWCHART “SLEW RIGHT” BHA 10-150
10 4 13 CHECKS AND ADJUSTMENTS FOR THE SLEW CIRCUIT 10-152
10 4 13 1 PRESSURE CHECKS & ADJUSTMENTS – DOUBLE STAGE VALVE
(DSV) 10-153
10 4 13 2 CHECKS & ADJUSTMENTS – BRAKE PILOT PRESSURE 10-155
10 4 13 3 CHECKS & ADJUSTMENTS – SLEW SPEED 10-157
10 4 14 FUNCTION CHECK FOR THE HYDRAULIC SLEW BRAKE 10-158
10 4 15 FUNCTION CHECK FOR THE SLEW PARKING BRAKE 10-160
10 4 15 1 PARKING BRAKE RELEASE PRESSURE CHECK 10-160
10 4 15 2 FUNCTION CHECK OF RELAYS 56K250A & B 10-161
10 5 HYDRAULICS FOR THE TRAVEL CIRCUIT 10-162
10 5 1 TRAVEL CIRCUIT 10-162
10 5 2 TRAVEL MOTOR 10-166
10 5 3 ROTARY JOINT 10-168
10 5 4 TRAVEL GEARBOX 10-170
10 5 4 1 TRAVEL GEARBOX TYPE 2063 10-170
10 5 4 2 TRAVEL GEARBOX TYPE 631053 10-172
10 5 5 TRAVEL PARKING BRAKE 10-174
10 5 5 1 TRAVEL PARKING BRAKE ON TRAVEL GEAR TYPE 2063 10-174
10 5 5 2 TRAVEL PARKING BRAKE ON TRAVEL GEAR TYPE 631053 10-175
10 5 5 3 TRAVEL BRAKE VALVE 10-176
10 5 6 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL FORWARD” 10-178
10 5 7 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL BACKWARDS” 10-180
10 5 8 CHECKS AND ADJUSTMENTS 10-182
10 5 8 1 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT 10-182
10 5 8 2 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE 10-185
11 HYDRAULIC TRACK TENSIONING SYSTEM 11-1
11 1 GENERAL 11-2
11 2 FUNCTIONAL DESCRIPTION 11-4
11 2 1 HYDRAULIC SCHEMATIC FOR TRACK TENSIONING 11-5
11 3 DOUBLE STAGE VALVE 11-6
11 4 TENSIONING CYLINDER 11-8
11 5 ADJUSTMENTS / CHECKS 11-10
12 ACCESS LADDER, HYDRAULICALLY OPERATED 12-1
12 1 OVERVIEW 12-2
TOC – 8 PC7000-6 T2 SHOP 35001-xD-GB-4
12 2 FUNCTION OF THE HYDRAULICALLY OPERATED ACCESS LADDER 12-4
12 3 ADJUSTMENTS / CHECKS 12-10
13 CENTRAL REFILLING SYSTEM (SERVICE ARM) 13-1
13 1 REFILLING ARM LOCATION 13-2
13 2 FUNCTION 13-4
14 HINTS FOR READING THE HYDRAULIC DIAGRAM 14-1
14 1 GENERAL 14-2
14 2 HYDRAULIC SYMBOLS 14-4
14 2 1 LINES, UNIONS 14-5
14 2 2 COMPONENTS, VALVES 14-7
14 2 3 SENSORS 14-7
14 2 4 VALVES, VALVE COMPONENTS 14-8
14 2 5 PUMP, MOTOR, CYLINDER 14-12
15 HINTS FOR READING THE ELECTRIC WIRING DIAGRAM 15-1
15 1 GENERAL 15-2
15 2 REFERENCE CODE OF THE ELECTRICAL COMPONENTS 15-3
15 2 1 AREA CODE 15-3
15 2 2 COMPONENT IDENTIFYING LETTER 15-5
15 3 GRAPHICAL SYMBOLS 15-6
15 4 DRAWING CONCEPT 15-10
15 5 CABLE AND CONNECTOR MARKING 15-20
16 KOMTRAX PLUS & MTC CONTROL SYSTEM 16-1
16 1 GENERAL 16-2
16 2 SPECIFICATIONS FOR OPERATORS 16-4
16 2 1 OPENING SCREEN 16-5
16 2 2 MAIN GAUGE SCREENS 1 TO 4 16-6
16 2 3 FUEL CONSUMPTION SCREEN 16-10
16 2 4 FAILURE MESSAGES FOR THE OPERATOR 16-12
16 2 5 MAIN GAUGE SCREENS – CHANGING OF TIME / SMR / DATE 16-14
16 2 6 MAINTENANCE MONITOR 16-16
16 2 7 SETTINGS FOR OPERATOR 16-18
16 2 8 AUTOMATIC MESSAGES 16-24
16 3 TABLES OF ALL PROVIDED MESSAGES 16-26
16 3 1 TABLE OF ERROR CODES & MESSAGES 16-27
16 3 2 TABLE OF 7-SEGMENT ERROR CODES 16-32
16 3 3 TABLE OF AVAILABLE INSTRUCTION MESSAGES 16-33
16 4 FLOW CHARTS (1-4) OF K+ MAIN SCREENS 16-36
16 5 KOMTRAX PLUS SERVICE LEVEL 16-40
16 5 1 EXPLANATION OF THE BUTTON SYMBOLS (SERVICE LEVEL) 16-42
16 5 2 SERVICE MENU SELECT SCREEN 16-43
16 5 3 REAL TIME MENU SELECT SCREEN 16-44
16 5 3 1 REAL TIME MENU, OPTION: 01 ENGINE 1 16-45
SHOP 35001-xD-GB-4 PC7000-6 T2 TOC – 9
16 5 3 2 REAL TIME MENU, OPTION: 02 ENGINE 2 16-46
16 5 3 3 REAL TIME MENU, OPTION: 03 PTO 1 16-46
16 5 3 4 REAL TIME MENU, OPTION: 04 PTO 2 16-46
16 5 3 5 REAL TIME MENU, OPTION: 05 HYDRAULIC 16-47
16 5 3 6 REAL TIME MENU, OPTION: 06 SLEW 16-48
16 5 3 7 REAL TIME MENU, OPTION: 07 ELECTRICAL EQUIPMENT 16-49
16 5 3 8 REAL TIME MENU, OPTION: 08 EMERGENCY STOP 16-50
16 5 3 9 REAL TIME MENU, OPTION: 09 MANUAL SWITCH 16-51
16 5 3 10 REAL TIME MENU, OPTION: 10 CENTRAL LUBE SYSTEM 1 16-52
16 5 3 11 REAL TIME MENU, OPTION: 11 SLEW RING GEAR LUBE SYSTEM 16-53
16 5 3 12 REAL TIME MENU, OPTION: 12 CENTRAL LUBE SYSTEM 2 16-54
16 5 3 13 REAL TIME MENU, OPTION: 13 WINDSCREEN WIPER 16-55
16 5 3 14 REAL TIME MENU, OPTION: 14 LADDER 16-56
16 5 3 15 REAL TIME MENU, OPTION: 15 SERVICE ARM 16-57
16 5 3 16 REAL TIME MENU, OPTION: 16 PILOT CONTROL 16-58
16 5 3 17 REAL TIME MENU, OPTION: 17 OTHER ITEMS 16-59
16 5 3 18 REAL TIME MENU, OPTION: 18 OUTPUT SIGNALS 16-60
16 5 3 19 OUTPUT SIGNALS WITH DEACTIVATED MTC EVALUATION 16-63
16 5 4 PM-CLINIC 16-64
16 5 4 1 GENERAL 16-64
16 5 4 2 POWER CHECK 16-65
16 5 5 SERIAL/GCC NO SETTING 16-66
16 5 6 MEMORY CLEAR 16-67
16 5 6 1 INPUT MEMORY CLEAR ID 16-67
16 5 6 2 MEMORY CLEAR SCREEN 16-68
16 5 7 FAILURE HISTORY 16-69
16 5 8 MAINTENANCE MONITOR 16-70
16 5 9 SNAPSHOT 16-71
16 5 10 SETTINGS 16-72
16 5 10 1 CENTRAL LUBRICATION SYSTEM (CLS 1), SCREEN 1/10 16-72
16 5 10 2 SLEW RING GEAR LUBRICATION SYSTEM (SLS), SCREEN 2/10 16-73
16 5 10 3 CENTRAL LUBRICATION SYSTEM (CLS 2), SCREEN 3/10 16-74
16 5 10 4 QMIN – QMAX SETTING, SCREEN 4/10 16-75
16 5 10 5 OTHER SETTINGS 1/2, SCREEN 5/10 16-75
16 5 10 6 HYDRAULIC OIL & PTO GEAR OIL DEFINITION TABLE 16-76
16 5 10 7 HYDRAULIC OIL TEMPERATURE CHARTS 16-76
16 5 10 8 PTO GEAR OIL TEMPERATURE CHARTS 16-76
16 5 10 9 OTHER SETTINGS 2/2, SCREEN 6/10 16-77
16 5 10 10PLC-EVALUATION ON/OFF 16-79
16 5 10 11SHUTDOWN BYPASS ON/OFF 16-80
16 6 INTERFACE-CONNECTION KOMTRAX PLUS CONTROLLER & MTC 16-84
16 6 1 KOMTRAX PLUS CONTROLLER 16-85
16 7 7-SEGMENT ERROR CODE INDICATION 16-86
16 8 WIRING OF KOMTRAX PLUS CONTROLLER 16-88
16 9 MTC CONTROL SYSTEM – GLOBAL LAYOUT 16-92
16 9 1 MTC (MASTER TURBO CONTROLLER) 16-94
16 9 1 1 MTC FLOWCHART 16-94
16 9 1 2 MTC FEATURES 16-94
16 9 1 3 MTC FIRMWARE AND SOFTWARE 16-95
16 9 1 4 CONNECTOR & COMPONENT LOCATION IN THE CONTROL SYSTEM 16-95
TOC – 10 PC7000-6 T2 SHOP 35001-xD-GB-4
16 9 1 5 VIEW ONTO THE MTC UNIT AND ITS CONNECTORS 16-96
16 9 1 6 LED INDICATIONS AT THE MTC 16-97
16 10 GLOBAL LAYOUT OF THE INTERNAL CAN BUS 16-98
16 10 1 GENERAL INFORMATION ON A CAN BUS SYSTEM 16-98
16 10 1 1 GENERAL CAN BUS DESCRIPTION 16-99
16 10 1 2 CAN BUS TROUBLESHOOTING 16-99
16 10 1 3 CAN BUS WIRING 16-100
16 10 1 4 CAN BUS END RESISTOR 16-102
16 11 THE NODES IN THE CAN BUS SYSTEM 16-104
16 11 1 GLOBAL LAYOUT 16-104
16 11 2 INTRODUCTION 16-106
16 11 2 1 ICN-V FEATURES 16-106
16 11 2 2 VIEW ONTO AN OPEN ICN-V NODE WITH DIP SWITCHES
& STATUS LED 16-108
16 11 2 3 GENERAL INFORMATION ON THE LED CONTROL 16-109
16 11 2 4 ICN-D FEATURES 16-110
16 11 2 5 VIEW ONTO AN ICN-D NODE WITHOUT WIRING 16-111
16 11 2 6 VIEW ONTO THE STATUS LEDS AT THE ICN-D NODE 16-112
16 11 2 7 GENERAL INFORMATION ON THE LED CONTROL 16-112
16 11 2 8 NODE DIP-SWITCHES 16-114
16 11 2 9 DETAILED VIEW ONTO THE DIP SWITCHES 16-115
16 11 3 NODE BOX 16-116
16 11 4 NODE LOCATIONS ON THE MACHINE 16-118
16 11 4 1 NODE & LOCATION CHART 16-119
16 11 4 2 VIEW ONTO THE CONTROL COMPONENTS IN A CAB BASE 16-120
17 LUBRICATION SYSTEM 17-1
17 1 GENERAL OVERVIEW – SLS & CLS1/2 17-2
17 1 1 GENERAL DESCRIPTION 17-3
17 2 BASIC FUNCTION OF THE LUBRICATION SYSTEMS 17-4
17 3 LUBRICATION SYSTEMS (SLS & CLS1/2) 17-6
17 3 1 LUBRICATION PUMP STATION 17-6
17 3 2 GENERAL INFORMATION ON CLS1/2 17-8
17 3 3 GENERAL INFORMATION ON SLS 17-8
17 3 4 MANUAL LUBE ACTIVATION 17-8
17 4 LUBRICATION CYCLE 17-9
17 4 1 OPERATION AND CONTROL 17-9
17 4 2 LUBRICATION CYCLE – PROCESSING 17-10
17 4 3 TIME SEGMENTS & SWITCH POINTS OF A LUBRICATION CYCLE 17-11
17 4 4 LUBRICATION MODES 17-12
17 4 4 1 AUTOMATIC LUBRICATION MODE 17-12
17 4 4 2 MANUAL LUBRICATION MODE 17-12
17 4 4 3 REDUCED PAUSE TIME FOR SERVICE 17-12
17 5 HYDRAULICALLY DRIVEN LUBE PUMP 17-14
17 5 1 ADJUSTMENT OF LUBE PUMP SPEED 17-16
17 5 1 1 STROKE SPEED ADJUSTMENT 17-17
17 5 1 2 WORKING PRESSURE 17-17
17 6 LUBRICANT INJECTORS 17-18
17 6 1 TIGHTENING TORQUES FOR FITTINGS AT GREASE INJECTORS 17-19
SHOP 35001-xD-GB-4 PC7000-6 T2 TOC – 11
17 6 2 DESCRIPTION 17-19
17 6 3 ADJUSTMENT OF LUBRICANT OUTPUT 17-20
17 6 4 OPERATION PRINCIPLE OF LUBRICANT INJECTORS 17-22
17 6 4 1 FUNCTION DESCRIPTION 17-23
17 6 5 CONNECTION OF ONE OR MORE INJECTORS 17-24
17 7 VENT VALVE AND GREASE OUTLET FILTER 17-26
17 7 1 VENT VALVE DESCRIPTION 17-27
17 8 END-LINE SWITCH 17-28
17 8 1 DESCRIPTION 17-29
17 8 2 CLS1/2 END-LINE SWITCH ADJUSTMENT 17-30
17 8 3 SLS END-LINE SWITCH ADJUSTMENT 17-32
17 9 LUBRICANT LEVEL SENSORS 17-34
17 9 1 DESCRIPTION 17-35
17 9 1 1 CHECKS 17-35
17 10 COMMISSIONING 17-36
17 10 1 COMMISSIONING OF THE CLS1/2 LUBRICATION SYSTEM 17-36
17 10 2 FINE ADJUSTMENT 17-37
17 10 3 COMMISSIONING OF THE SLS LUBRICATION SYSTEM 17-38
18 DEEP TEMPERATURE EQUIPMENT (OPTION) 18-1
18 1 GENERAL INFORMATION 18-2
18 1 1 INTRODUCTION 18-2
18 1 2 DEEP TEMPERATURE COMPONENTS OVERVIEW 18-2
18 1 3 POWER SUPPLY PRECONDITIONS FOR PREHEATING 18-3
18 1 4 POWER REQUIREMENTS FOR PREHEATING SYSTEMS 18-4
18 2 PREHEATING PROCEDURE 18-5
18 2 1 GLOBAL FLOW CHART OF THE PREHEATING PROCEDURE 18-5
18 2 2 STARTING THE PREHEATING PROCEDURE 18-6
18 2 3 PREHEATING OF OPERATOR’S CAB AND DIESEL ENGINE
[COOLANT SYSTEM] 18-7
18 2 4 PREHEATING OF LUBRICANTS AND SUPERSTRUCTURE (DIESEL)
[ELECTRIC SYSTEM] 18-8
18 3 CONSTANT HEATING OF TRAVEL MOTORS (TTT EQUIPMENT BELOW-40°C ONLY) 18-9
18 4 COMPONENT LOCATION 18-10
18 4 1 ELECTRIC HEATING ELEMENTS FOR HYDRAULIC & BATTERIES
[ELECTRIC MACHINE] 18-10
18 4 2 ELECTRIC HEATING ELEMENTS FOR HYDRAULICS [DIESEL MACHINE] 18-12
18 4 3 ELECTRIC HEATING ELEMENTS FOR ENGINES & BATTERIES
[DIESEL MACHINE] 18-14
18 5 COMPONENTS OF TT EQUIPMENT 18-16
18 5 1 PREHEATING COMPONENTS ON A DIESEL MACHINE 18-16
18 5 2 PREHEATING COMPONENTS ON AN ELECTRIC MACHINE 18-17
18 5 3 WIRING DIAGRAMS FOR PREHEATING SYSTEMS 18-18
18 5 3 1 WIRING DIAGRAM “HYDRAULIC OIL TANK PREHEATING” PART 1 OF 3 18-18
18 5 3 2 WIRING DIAGRAM “HYDRAULIC OIL TANK PREHEATING” PART 2 OF 3 18-19
18 5 3 3 WIRING DIAGRAM “HYDRAULIC OIL TANK PREHEATING” PART 3 OF 3 18-20
18 5 3 4 WIRING DIAGRAM “SUCTION OIL MANIFOLD PREHEATING” 18-21
18 5 3 5 WIRING DIAGRAM “PTO PREHEATING” 18-22
18 5 3 6 WIRING DIAGRAM “BATTERY HEATER PADS” 18-23

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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